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Oldsmobile Aurora 2001-2003 Factory Service Workshop Repair Manual

Complete Factory service manual for the Olds Aurora 2001-3

Uploaded by

James Doolittle

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100% found this document useful (3 votes)

6K views3,942 pages

Oldsmobile Aurora 2001-2003 Factory Service Workshop Repair Manual

Complete Factory service manual for the Olds Aurora 2001-3

Uploaded by

James Doolittle

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 3942

Document ID: 465623 Page 1 of 1

Fastener Tightening Specifications

Specification
Application Metric English
BPMV Bracket to Frame Mounting Bolts 10 N·m 89 lb in
BPMV Brake Pipes 15 N·m 11 lb ft
BPMV to Bracket Mounting Nuts 10 N·m 89 lb in
Brake Pressure Modulator Valve (BPMV) Bracket Mounting Bolts 12 N·m 106 lb in
Electronic Brake Control Module (EBCM) to BPMV Mounting Screws 3.2 N·m 28 lb in
Lateral Accelerometer Mounting Screws 2.4 N·m 21 lb in
Yaw Rate Sensor Mounting Nuts 6 N·m 53 lb in

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Indicators and Traction Control Switch

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Power, Ground, Stoplamp Switch, Solenoid Valves, and

Pump Motor

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Traction Control (w/NW9) and Variable Effort Steering

(w/NV8)

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Vehicle Stability Enhancement System (w/JL4)

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Wheel Speed Sensors

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Antilock Brake System Connector End Views

Table 1: Electronic Brake Control Module (EBCM)
Table 2: Lateral Accelerometer Sensor (w/JL4)
Table 3: Steering Wheel Position Sensor (w/JL4)
Table 4: Traction Control Switch (w/NW9)
Table 5: Wheel Speed Sensor (WSS) -- LF
Table 6: Wheel Speed Sensor (WSS) -- LR
Table 7: Wheel Speed Sensor (WSS) -- RF
Table 8: Wheel Speed Sensor (WSS) --RR
Table 9: Yaw Rate Sensor (w/JL4)

Electronic Brake Control Module (EBCM)

• C1 - 15318099
Connector Part • 7 Way F Metri-Pack 480 Series (BLK)
Information • C2 - 15356700
• 29 Way F Micro-Pack 100 Series (GRY)
Circuit
Pin Wire Color No. Function
A RED 442 Battery Positive Voltage
B BRN 241 Ignition 3 Voltage
Variable Effort Steering Actuator High Effort Control
C GRY 1787
(w/NV8)
Variable Effort Steering Actuator Low Effort Control
D WHT 345
(w/NV8)
E -- -- Vent Tube
F BLK/WHT 1651 Ground
G BLK 1650 Ground
1 -- -- Not Used
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2 TAN/BLK 464 Delivered Torque Signal (w/NW9)

3 LT GRN 1763 Steering Wheel Position Signal A (w/JL4)
4 -- -- Not Used
5 LT BLU 715 Lateral Accelerometer Signal (w/JL4)
6 WHT 17 Stoplamp Switch Signal (w/NW9)
7 PPL 1807 Class 2 Serial Data
8 RED 885 Left Rear Wheel Speed Sensor Low Reference
9 BRN 882 Right Rear Wheel Speed Sensor Signal
10 DK GRN 872 Right Front Wheel Speed Sensor Signal
11 DK BLU 830 Left Front Wheel Speed Sensor Signal
12 ORN/BLK 463 Requested Torque Signal (w/NW9)
13 LT GRN 1338 Low Reference (w/JL4)
14-17 -- -- Not Used
18 LT BLU 1764 Steering Wheel Position Signal B (w/JL4)
19 DK BLU 716 Yaw Rate Sensor Signal (w/JL4)
20 -- -- Not Used
21 PPL 1807 Class 2 Serial Data
22 BLK 884 Left Rear Wheel Speed Sensor Signal
23 WHT 883 Right Rear Wheel Speed Sensor Low Reference
24 TAN 833 Right Front Wheel Speed Sensor Low Reference
25 YEL 873 Left Front Wheel Speed Sensor Low Reference
26 DK BLU 1537 ABS Indicator Signal
27 GRY 1337 5 V Reference (w/JL4)
28-29 -- -- Not Used

Lateral Accelerometer Sensor (w/JL4)

• 12146121
Connector Part Information
• 3 Way F Metri-Pack 150 Series (BRN)
Pin Wire Color Circuit No. Function

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A GRY/BLK 1337 5 Volt Reference

B LT BLU 715 Lateral Accelerometer Signal
C LT GRN/BLK 1338 Low Reference

Steering Wheel Position Sensor (w/JL4)

• 12064978
Connector Part Information
• 6 Way F Micro-Pack 100 Series (GRY)
Pin Wire Color Circuit No. Function
1 DK GRN 1337 5 Volt Reference
2 LT BLU 1338 Low Reference
3-4 -- -- Not Used
5 LT GRN 1763 Steering Wheel Position Signal A
6 LT BLU 1764 Steering Wheel Position Signal B

Traction Control Switch (w/NW9)

• 12065872
Connector Part Information
• 7 Way F Micro-Pack 100 Series (GRY)

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Pin Wire Color Circuit No. Function

1 YEL 1491 Backlight Lamps Control
2 LT BLU 1788 Traction Control Switch Signal
3 BLK 450 Ground
4-7 -- -- Not Used

Wheel Speed Sensor (WSS) -- LF

• 12052638
Connector Part Information
• 2 Way F Metri-Pack 150 Series Sealed (LT GRY)
Pin Wire Color Circuit No. Function
A WHT 830 Left Front Wheel Speed Sensor Signal
B BLK 873 Left Front Wheel Speed Sensor Low Reference

Wheel Speed Sensor (WSS) -- LR

• 12052638
Connector Part Information
• 2 Way F Metri-Pack 150 Series Sealed (LT GRY)
Pin Wire Color Circuit No. Function

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A BLK 884 Left Rear Wheel Speed Sensor Signal

B WHT 885 Left Rear Wheel Speed Sensor Low Reference

Wheel Speed Sensor (WSS) -- RF

• 12052638
Connector Part Information
• 2 Way F Metri-Pack 150 Series Sealed (LT GRY)
Pin Wire Color Circuit No. Function
A WHT 872 Right Front Wheel Speed Sensor Signal
B BLK 833 Right Front Wheel Speed Sensor Low Reference

Wheel Speed Sensor (WSS) --RR

• 12052638
Connector Part Information
• 2 Way F Metri-Pack 150 Series Sealed (LT GRY)
Pin Wire Color Circuit No. Function
A BLK 882 Right Rear Wheel Speed Sensor Signal
B WHT 883 Right Rear Wheel Speed Sensor Low Reference

Yaw Rate Sensor (w/JL4)

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• 12064758
Connector Part Information
• 3 Way Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A GRY/BLK 1337 5 Volt Reference
B LT GRN/BLK 1338 Low Reference
C DK BLU 716 Yaw Rate Sensor Signal

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Below the Left of the Instrument Panel

(1) Steering Column

(2) Steering Wheel Position Sensor

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EBCM/BPMV, Left Front Corner of the Engine

Compartment, on the Frame Rail

(1) Secondary Air Injection Air Pump

(2) Electronic Brake Control Module (EBCM)
(3) Brake Pressure Modulator Valve (BPMV)

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Fuse Block - Rear

(1) Lateral Accelerometer Sensor

(2) Fuse Block - Rear

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Traction Control and Heated Seat Switches

(1) Traction Control Switch (w/NW9)

(2) Console Trim Plate
(3) Heated Seat Switch - Front Passenger (w/KA1)
(4) Heated Seat Switch - Driver (w/KA1)

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Wheel Speed Sensor (WSS) -- LF

(1) Wheel Speed Sensor (WSS) -- LF (RF Similar)

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Wheel Speed Sensor (WSS) -- RR

(1) Wheel Speed Sensor (WSS) -- RR (LR Similar)

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Yaw Rate Sensor, Left Corner of the Rear Compartment,

In the Rear Shelf

(1) Yaw Rate Sensor

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Antilock Brake System Automated Bleed Procedure

Bleeding the ABS/TCS System
Perform a manual or pressure bleeding procedure. Refer to Hydraulic Brake System Bleeding in
Hydraulic Brakes. If the desired brake pedal height results are not achieved, perform the auto
bleed procedure below.

The procedure cycles the system valves and runs the pump in order to purge the air from the
secondary circuits normally closed off during non ABS/TCS mode operation and bleeding. The auto
bleed procedure is recommended when air ingestion is suspected in the secondary circuits, or when
the BPMV has been replaced.

Auto Bleed Procedure

Notice: The Auto Bleed Procedure may be terminated at any time during the process by
pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed
procedure will be given. After exiting the bleed procedure, relieve bleed pressure and
disconnect bleed equipment per manufacturers instructions. Failure to properly relieve
pressure may result in spilled brake fluid causing damage to components and painted
surfaces.

1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.
3. Inspect the brake system for leaks and visual damage. Refer to Brake Fluid Leak or
Symptoms - Hydraulic Brakes in Hydraulic Brakes. Repair or replace as needed.
4. Inspect the battery state of charge. Refer to Battery Inspection/Test in Engine Electrical.
5. Install a scan tool.
6. Turn ON the ignition, with the engine OFF.
7. With the scan tool, establish communications with the ABS/TCS system. Select Special
Functions from the ABS/TCS menu. Select Automated Bleed from the Special Functions
menu.
8. Bleed the base brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
9. Follow the scan tool directions until the desired brake pedal height is achieved.
10. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before
resuming the bleed procedure:
• If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List and diagnose the
appropriate DTC.
• If the brake pedal feels spongy, perform the conventional brake bleed procedure again.
Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
11. When the desired pedal height is achieved, press the brake pedal in order to inspect for
firmness.
12. Remove the scan tool.
13. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
14. Inspect the brake fluid level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
15. Road test the vehicle while inspecting that the pedal remains high and firm.
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Brake Pressure Modulator Valve Bracket Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
4. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Remove the 2 brake pressure modulator valve (BPMV) bracket nuts (2).

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6. Remove the 3 BPMV bracket to frame bolts (2).

7. Remove the BPMV bracket (1) from the frame (3).

Installation Procedure

1. Install the brake pressure modulator valve (BPMV) bracket (1) to the frame (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the 3 BPMV bracket to frame bolts (2).

Tighten
Tighten the 3 bolts to 9 N·m (80 lb in).

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3. Install the electronic brake control module (EBCM)/BPMV assembly (1) to the BPMV
bracket (3).
4. Install the 2 BPMV bracket nuts (2).

Tighten
Tighten the 2 nuts to 10 N·m (89 lb in).

5. Install the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
6. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
7. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tire and
Wheels.
8. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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Brake Pressure Modulator Valve Replacement

Removal Procedure
Caution: For safety reasons, the brake pressure modulator valve assembly must not be repaired,
the complete unit must be replaced. With the exception of the EBCM, no screws on the brake
pressure modulator valve assembly may be loosened. If screws are loosened, it will not be possible
to get the brake circuits leak-tight and personal injury may result.

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Remove the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
6. Remove the EBCM connector position assurance (2) from the EBCM electrical connector (1).
7. Rotate the electronic brake control module (EBCM) connector tab up to the unlocked position.

Notice: To prevent equipment damage, never connect or disconnect the wiring harness
connection from the EBCM with the ignition switch in the ON position.

8. Disconnect the EBCM electrical connector (1) from the EBCM (4).

Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact--rinse thoroughly with water.
• Skin contact--wash with soap and water.
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• If ingested--consult a physician immediately.

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.

Notice: Excessive bending of brake pipes during BPMV removal or installation may cause
permanent damage that will require replacement.

Important: Record the location of all brake pipes to the brake pressure modulator valve
(BPMV) for use as an aid during installation.

9. Remove the 2 master cylinder brake pipes (1) from the BPMV (2).

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10. Remove the 4 wheel brake pipes (1) from the BPMV (2).

11. Clean any brake fluid spillage from the BPMV (1).
12. Remove the 2 BPMV bracket nuts (2).
13. Remove the EBCM/BPMV assembly (1) from the BPMV bracket (3).

14. Disconnect the BPMV electrical connector (2) from the EBCM (3).

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15. Remove the 6 EBCM to BPMV screws (2).

16. Clean the surface of the EBCM/BPMV assembly.

Important: The EBCM cannot be repaired. If faulty, the unit must be replaced.

17. Separate the EBCM (2) from the BPMV (1).

Installation Procedure

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1. Clean the seal surface of the brake pressure modulator valve (BPMV).
2. Install the electronic brake control module (EBCM) (2) to the BPMV (1).

3. Install the 6 EBCM to BPMV screws (2).

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Tighten
Tighten the 6 screws to 3.2 N·m (28 lb in).

4. Connect the BPMV electrical connector (2) to the EBCM (3).

Important: Make sure that all 3 rubber isolators are installed on the BPMV. The isolators
protect the EBCM/BPMV assembly from vehicle vibrations.

5. Install the EBCM/BPMV assembly (1) to the BPMV bracket (3).

6. Install the 2 BPMV bracket nuts (2).

Tighten

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Tighten the 2 nuts to 10 N·m (89 lb in).

Caution: Make sure brake pipes are correctly connected to BPMV. If brake pipes are
switched by mistake Inlet vs. Outlet, wheel lockup will occur and personal injury may result.

Important: If a new BPMV is being installed, remove the shipping plugs from the valve
openings.

7. Install the 4 wheel brake pipes (1) to the BPMV (2) using the locations recorded during the
removal procedure.

Tighten
Tighten the 4 brake pipes to 15 N·m (11 lb ft).

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8. Install the 2 master cylinder brake pipes (1) to the BPMV (2) using the locations recorded
during the removal procedure.

Tighten
Tighten the 2 brake pipes to 15 N·m (11 lb ft).

Notice: To prevent equipment damage, never connect or disconnect the wiring harness
connection from the EBCM with the ignition switch in the ON position.

9. Connect the EBCM electrical connector (1) to the EBCM (4).

10. Rotate the EBCM connector tab (1) down to the locked position.

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11. Install the EBCM connector position assurance (2) to the EBCM electrical connector (1).
12. Install the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
13. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
14. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tire and
Wheels.
15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
16. Fill and bleed the hydraulic brake system. Refer to Master Cylinder Reservoir Filling and
Hydraulic Brake System Bleeding in Hydraulic Brakes.
17. Perform the Auto Bleed Procedure. Refer to Antilock Brake System Automated Bleed
Procedure .
18. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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Electronic Brake Control Module Replacement

Removal Procedure

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Remove the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
5. Remove the EBCM connector position assurance (2) from the EBCM electrical connector (1).
6. Rotate the electronic brake control module (EBCM) connector tab up to the unlocked position.

Notice: To prevent equipment damage, never connect or disconnect the wiring harness
connection from the EBCM with the ignition switch in the ON position.

7. Disconnect the EBCM electrical connector (1) from the EBCM (4).

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8. Disconnect the brake pressure modulator valve (BPMV) electrical connector (2) from the
EBCM (3).

9. Remove the 6 EBCM to BPMV screws (2).

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10. Clean the surface of the EBCM/BPMV assembly.

Important: The EBCM cannot be repaired. If faulty, the unit must be replaced.

11. Separate the EBCM (2) from the BPMV (1).

Installation Procedure

1. Clean the seal surface of the brake pressure modulator valve (BPMV).
2. Install the electronic brake control module (EBCM) (2) to the BPMV (1).

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3. Install the 6 EBCM to BPMV screws (2).

Tighten
Tighten the 6 screws to 3.2 N·m (28 lb in).

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4. Connect the BPMV electrical connector (2) to the EBCM (3).

Notice: To prevent equipment damage, never connect or disconnect the wiring harness
connection from the EBCM with the ignition switch in the ON position.

5. Connect the EBCM electrical connector (1) to the EBCM (4).

6. Rotate the EBCM connector tab (2) down to the locked position.
7. Install the EBCM connector position assurance (4) to the EBCM electrical connector (2).
8. Install the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
9. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tire and

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Wheels.
10. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Important: An unprogrammed EBCM will result in the following conditions:

• Inoperative or poorly functioning DRP/ABS/TCS/VSES/TIM/VES (if equipped)
• Turn on the Red Brake Warning Indicator On
• The EBCM will Malfunction Internally

11. If a replacement EBCM is being installed, it must be programmed using the latest software
matching the vehicle. Refer to the Techline Terminal/Equipment user's instructions.
12. Use the scan tool in order to clear the DTCs.
13. Perform the Auto Bleed Procedure. Refer to Antilock Brake System Automated Bleed
Procedure .
14. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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Electronic Traction Control Switch Replacement

(w/NW9)
Removal Procedure

1. Remove the center console trim plate (2). Refer to Console Trim Plate Replacement in
Instrument Panel, Gages and Console.
2. Disconnect the traction control switch electrical connector.
3. Remove the traction control switch (5).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the traction control switch (5).

2. Connect the traction control switch electrical connector.
3. Install the center console trim plate (2). Refer to Console Trim Plate Replacement in
Instrument Panel, Gages and Console.

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Front Wheel Speed Sensor Wiring Harness Replacement

(Left)
Removal Procedure

Important: The wheel speed sensor wiring is included in the engine harness. The wiring
between the wheel speed sensor and the heat shrink sealed splices is high-flex cable and
must not be repaired or spliced. This procedure replaces the high-flex cable with a jumper
harness from a supplied repair kit.

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
4. Disconnect the wheel speed sensor connector (7) from the wheel speed sensor (6).
5. Disconnect the harness grommet (3) from the strut bracket (5).
6. Disconnect the harness grommet (1) from the rail bracket (2).
7. Disconnect the harness clip (4) from the rail bracket (2).
8. Route the wheel speed sensor wiring (8) through the top of the engine compartment.
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

© 2014 General Motors Corporation. All rights reserved.

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10. Remove the ground wire from the top of the transmission near the shift lever.
11. If equipped with a 4.0L remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct
Replacement in Engine Controls - 4.0L.
12. Pull the harness out above the air cleaner assembly for access.
13. Strip back the conduit to gain access to the 2 heat shrink sealed splices.

Installation Procedure

1. Replace the wheel speed sensor jumper harness. Refer to Wiring Repairs in Wiring Repair.
2. Route the wheel speed sensor jumper (1) through the engine compartment to the wheel well.
3. If equipped with a 4.0L install the ground wire and bolt to the top of the transmission near
the shift lever. Refer to Transmission Replacement in Automatic Transaxle or Transmission

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Replacement in Automatic Transaxle.

4. If equipped with a 4.0L install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct
Replacement in Engine Controls - 4.0L.

5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Connect the wheel speed sensor connector (7) to the wheel speed sensor (6).
7. Connect the harness grommet (3) to the strut bracket (5).
8. Connect the harness grommet (1) to the rail bracket (2).
9. Connect the harness clip (4) the rail bracket (2).
10. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
11. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
12. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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Front Wheel Speed Sensor Wiring Harness Replacement

(Right)
Removal Procedure

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
4. Disconnect the wheel speed sensor connector (7) from the wheel speed sensor (6).
5. Disconnect the harness grommet (3) from the strut bracket (5).
6. Disconnect the harness grommet (1) from the rail bracket (2).
7. Disconnect the harness clip (4) from the rail bracket (2).
8. Complete the following depending on engine RPO:

© 2014 General Motors Corporation. All rights reserved.

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• If equipped with LX5 complete the following:

1. Disconnect the vehicle speed sensor electrical connector.
2. Cut the engine harness conduit (1) at the shown location.
• If equipped with L47 complete the following:
1. Disconnect the vehicle speed sensor electrical connector.
2. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the engine harness from the engine harness retainer clip and carefully pull
the harness upward to access the wheel speed sensor harness.
4. Cut the engine harness conduit to locate the 2 heat shrink sealed splices.

Installation Procedure

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1. Replace the wheel speed sensor jumper harness. Refer to Wiring Repairs in Wiring Repair.
2. Complete the following depending on engine RPO:

2.1. If equipped with LX5 complete the following:

2.2. Connect the vehicle speed sensor electrical connector.
2.3. If equipped with L47 complete the following:
2.3.1. Route the wheel speed sensor jumper through the engine compartment to the
wheel well.
2.3.2. Connect the engine harness to the engine harness retainer.
2.3.3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2.3.4. Connect the vehicle speed sensor electrical connector.

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3. Connect the wheel speed sensor connector (7) to the wheel speed sensor (6).
4. Connect the harness grommet (3) to the strut bracket (5).
5. Connect the harness grommet (1) to the rail bracket (2).
6. Connect the harness clip (4) to the rail bracket (2).
7. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
8. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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Lateral Accelerometer Replacement (w/JL4)

Removal Procedure

1. Turn OFF the ignition.

2. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
3. Disconnect the lateral accelerometer sensor electrical connector (2).
4. Remove the 2 lateral accelerometer sensor mounting screws (3).
5. Remove the lateral accelerometer sensor (1).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the lateral accelerometer sensor (1).

2. Install the 2 lateral accelerometer sensor mounting screws (3).

Tighten
Tighten the 2 lateral accelerometer sensor mounting screws to 2.4 N·m (21 lb in).

3. Connect the lateral accelerometer sensor electrical connector (2).

4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
5. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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Vehicle Yaw Sensor Replacement

Removal Procedure

1. Turn OFF the ignition.

2. Remove the 2 yaw rate sensor mounting nuts (1).
3. Remove the yaw rate sensor (2).
4. Disconnect the yaw rate sensor electrical connector (3).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the yaw rate sensor electrical connector (3).

2. Install the yaw rate sensor (2).

Tighten
Tighten the 2 yaw rate sensor mounting nuts (1) to 6 N·m (53 lb in).

3. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

2000-01 AUTOMATIC TRANSMISSIONS

Servicing - Lumina

APPLICATION

TRANSAXLE APPLICATION
Application Transaxle Model (RPO Code)
Lumina 4T65-E (M15)

IDENTIFICATION
OIL PAN GASKET

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 1: Identifying Oil Pan Gasket (Hydra-Matic 4T65-E)

LUBRICATION
SERVICE INTERVALS

Change the ATF and filter every 50,000 miles if the vehicle is mainly driven under one or more
of these conditions:

In heavy traffic where the outside temperature regularly reaches 90°F or higher.
In hilly or mountainous terrain.
Uses such as high performance operation.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

If the vehicle is not used under any of these conditions, change the fluid and filter every 100,000
miles.

CHECKING FLUID LEVEL & CONDITION

1. Start the engine and allow the engine to idle until the transaxle has reached 180-200°F.
Depress the brake pedal and move the shift lever through the gear ranges, pausing a few
seconds in each gear. Is the fluid Red or Light Brown? If so, go to step 4 . If not, go to next
step.
2. Does the fluid have a burnt odor or a Dark Brown color? If so, go to step 11 . If not, go to
next step.
3. Does the fluid have a cloudy or milky appearance? If so, go to step 10 . If not, go to next
step.
4. Check the fluid level. The vehicle must be level, with the engine running and the shift lever
in the Park range. Check both sides of the fluid level indicator, and read the lower level.
The proper fluid level should be in the middle of the cross-hatch. Is the fluid level too high?
If so, go to step 9 . If not, go to next step.
5. Is the fluid level low? If not, system is okay. If so, go to next step.
6. Add DEXRON-III(R) ATF in increments of 0.5L until the fluid is in the middle of the
cross-hatch. Check both sides of the fluid level indicator, and read the lower level. Did you
add more than 1.5L to the transaxle? If not, go to step 9 . If so, go to next step.
7. Check for external leaks. Did you find any leaks? If not, go to step 15 . If so, go to next
step.
8. Correct the leak condition. Did you correct the leak condition? If so, go to step 15 .
9. Remove any excess fluid to the proper level, the middle of the cross-hatch. Is the fluid level
satisfactory? If so, system is okay.
10. The transaxle is contaminated with engine coolant. Replace the cooler. Is the replacement
complete? If so, go to step 13 .

NOTE: Transmission fluid may turn dark with normal use. This does
not always indicate oxidation or contamination. Drain the fluid
to determine if the fluid is contaminated.

11. A very small amount of material in the bottom pan is a normal condition, but large pieces of
metal or other material in the bottom pan require a transaxle overhaul. Was the fluid
contaminated? If not, go to step 13 . If so, go to next step.
12. Overhaul the transaxle. See appropriate OVERHAUL article in AUTOMATIC
TRANSMISSIONS. Is the overhaul complete? If so, go to next step.
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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

13. Flush the cooler. See OIL COOLER FLUSHING . Has the cooler been flushed? If so, go
to next step.
14. Change the fluid and the filter. See DRAINING & REFILLING . Is the procedure
complete? If so, go to next step.
15. Add new fluid to the proper level, in the middle of the cross-hatch. Is the procedure
complete? If so, system is okay.

RECOMMENDED FLUIDS

Manufacturer recommends DEXRON-III(R) ATF. Fill transaxle with appropriate quantity. See
FLUID CAPACITIES .

FLUID CAPACITIES

TRANSAXLE FLUID CAPACITY (1)

Bottom Pan Removal -
Application Qts. (L) Overhaul - Qts. (L) Dry - Qts. (L)
4T65-E 7.4 (7.0) 10.0 (9.5) 13.4 (12.7)
(1) Fluid capacities listed are approximate. Always fill to specified area on dipstick (if
equipped). See CHECKING FLUID LEVEL & CONDITION .

DRAINING & REFILLING

CAUTION: DO NOT use any type of grease to retain parts during the
assembly of this unit. Using greases other than the
recommended assembly lube changes the transaxle fluid
characteristics. Using greases other than the recommended
assembly lube causes undesirable shift conditions and/or
filter clogging. Use TRANSJEL(tm) (J-36850) or equivalent
during the assembly of this unit.

1. Raise and support the vehicle. Place a drain pan under the transaxle bottom oil pan. Remove
the oil pan bolts (23) from the front. See Fig. 2 . Remove the oil pan bolts (23) from the
sides. Loosen the rear oil pan bolts (23) approximately 4 turns.

NOTE: Ensure care is taken NOT to damage the mating surfaces of the
oil pan and of the case or oil leaks may occur.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

2. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose.
Allow the fluid to drain. Remove the remaining oil pan bolts (23).
3. Remove the oil pan (24). Remove the oil pan gasket (25). Remove the filter (100). Remove
the lip ring seal (101) pressed into the case only if replacement is necessary. Inspect the oil
pan and the filter screen for the following foreign material:
Inspect for metal particles.

Inspect for clutch facing material.

Inspect for rubber particles.

Inspect for engine coolant.

4. Determine the source of the contamination if foreign material is evident. Correct the source
of the contamination. Use solvent to clean the screen and blow-dry if reusing. Install a new
seal (101). See Fig. 3 . Install the filter (100). See Fig. 2 .
5. Inspect the oil pan flange (1) for distortion. See Fig. 4 . Replace the oil pan (1) if bent or
distorted. Do not attempt to straighten. Inspect the washers on the bolts when service
requires the removal of the bottom oil pan. Install a new bolt and washer assembly if the
washer is inverted. See Fig. 5 .

NOTE: Ensure the oil pan and the case flanges are dry and are free of
any oil film or leakage may result.

6. Use solvent to clean the case. Air dry the case. Use solvent to clean the oil pan gasket
surfaces. Air dry the oil pan gasket surfaces. Ensure all traces of the old gasket material are
removed.
7. Install the oil pan gasket (25). See Fig. 2 . Install the oil pan (24). Install the oil pan bolts
(23). See Fig. 5 . Tighten the oil pan bolts (23) to specification. See TORQUE
SPECIFICATIONS .
8. Lower the vehicle. Fill the transaxle with the proper quantity of DEXRON-III(R) ATF.
Place the gear selector in the Park position. Start the engine.

CAUTION: Do not overfill the transaxle. Overfilling of the transaxle

causes foaming, loss of fluid, shift complaints, and
possible damage to the transaxle.

9. Run the engine at a slow idle. Do not race the engine. Adjust the fluid level. See
CHECKING FLUID LEVEL & CONDITION . Inspect for proper completion of the
repairs. Inspect for fluid leaks.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 2: Removing & Installing Oil Pan & Filter

Courtesy of GENERAL MOTORS CORP.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 3: Installing Oil Filter Seal

Courtesy of GENERAL MOTORS CORP.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 4: Inspecting Oil Pan Flange

Courtesy of GENERAL MOTORS CORP.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 5: Identifying Conical Washers

Courtesy of GENERAL MOTORS CORP.

OIL COOLER FLUSHING

Preparation

1. After the repair or replacement transaxle is installed in the vehicle, do not reconnect the oil
cooler pipes.
2. Remove the fill cap (9) on the Oil Cooler and Line Flusher (J-35944-A) and fill the flusher
tank (4) with 20-21 oz. (0.6L) of Flushing Solution (J-35944-22) using the measuring cup
(6). See Fig. 6 . Do not overfill. Install the fill cap (9) on the oil cooler and line flusher and
pressurize the flusher tank (4) to 80-100 psi (550-700 kPa), using the shop air supply at the
tank air valve (9).
3. Connect the oil cooler and line flusher discharge hose (5) to the oil cooler return pipe (top
connector). This may require (J 35944-600). Clip the discharge hose (5) onto the oil drain
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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

container. Attach the oil cooler and line flusher to the undercarriage of the vehicle with the
hook provided, and connect the flushing system feed supply hose (3) from the oil cooler and
line flusher to the oil cooler feed pipe (bottom connector). This may require (J 35944-600).
See Fig. 7 .
4. With the water supply valve (1) on the oil cooler and line flusher in the off position, connect
the water supply hose (7) from the oil cooler and line flusher to the water supply at the
faucet. See Fig. 6 and Fig. 7 . Turn ON the water supply at the faucet.

Fig. 6: Identifying Flushing Equipment

Courtesy of GENERAL MOTORS CORP.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 7: Connecting Flushing Equipment

Courtesy of GENERAL MOTORS CORP.
Initial Flush

1. Turn the oil cooler and line flusher water supply valve (1) to the ON position and allow
water to flow through the oil cooler and pipes for 10 seconds to remove any remaining
transmission fluid. See Fig. 8 . If water does not flow through the oil cooler and pipes, the
cause of the blockage must be diagnosed and the plugged component must be repaired or
replaced. Continue with the cooler flushing and flow check procedure once the blockage is
corrected.
2. Turn the oil cooler and line flusher water supply valve (1) to the off position and clip the
discharge hose (5) onto an appropriate container with a lid, to avoid splashback. See Fig.
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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

9.
3. Turn the oil cooler and line flusher water supply valve (1) to the ON position and depress
the trigger (8) to mix cooler flushing solution into the water flow. See Fig. 6 . Use the clip
provided on the handle to hold the trigger (8) down. The discharge will foam vigorously
when the solution is introduced into the water stream.
4. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush,
attach the air supply to the air valve located on the oil cooler and line flusher for 3 to 5
seconds at the end of every 15 to 20 second interval to create a surge action.
5. Release the trigger and turn the water valve on the oil cooler and line flusher to the off
position.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 8: Flushing Oil Cooling System

Courtesy of GENERAL MOTORS CORP.

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 9: Capturing Fluid Discharge

Courtesy of GENERAL MOTORS CORP.
Back Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil
cooler pipe. This will allow the oil cooler and pipes to be back flushed.
2. Repeat steps 3 and 4 on the INITIAL FLUSH procedure. Release the trigger (8) of the oil
cooler and line flusher and allow water only to rinse the oil cooler and pipes for one minute.
See Fig. 8 .
3. Turn the oil cooler and line flusher water supply valve (1) to the off position and turn off the
water supply at the faucet. Attach the shop air supply to the flushing system feed air valve
(2) on the (J-35944-A), and blow out the water from the oil cooler and pipes. Continue until
no water comes out of the discharge hose (5). See Fig. 9 .

OIL COOLER FLOW TEST

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe to the
transaxle and the return pipe to the discharge hose (5). See Fig. 9 . Clip the discharge hose
(5) onto the empty oil drain container.
2. Confirm the transaxle is filled with ATF. See CHECKING FLUID LEVEL &
CONDITION .
3. Start the engine with the transaxle in Park range and run for 30 seconds. A minimum of 2
qts. (1.9L) must be discharged during this 30-second run time. If fluid flow is greater than 2
qts. (1.9L) in 30 seconds, go to step 4 . If fluid flow is less than 2 qts. (1.9L) in 30 seconds,
perform the following diagnosis:
Disconnect the oil cooler feed line at the radiator.

Connect the discharge hose to the cooler feed line. Clip the discharge hose onto the
empty oil drain container.
Start the engine with the transaxle in Park and run for 30 seconds. A minimum of 2 qts.
(1.9L) must discharge during the 30-second run time. Do the following according to
flow rate. For insufficient feed flow, inspect the transaxle. For sufficient feed flow,
inspect the cooler return pipe and the cooler.
4. Remove the discharge hose, reconnect the cooler feed and return pipes to the transaxle and
refill the unit to the proper fluid level. See CHECKING FLUID LEVEL &
CONDITION .

ON-VEHICLE REPAIRS
Various components may be serviced without transaxle removal. For servicing of these
components, see appropriate component under ADJUSTMENTS and/or REMOVAL &
INSTALLATION . For additional information on servicing electrical components, see
appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

ADJUSTMENTS

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint

(SIR) system. When servicing vehicle, use care to avoid
accidental air bag deployment. SIR system-related
components are located in various locations throughout
interior and exterior of vehicle, depending on application. Do
not use electrical test equipment on or near these circuits. If
necessary, deactivate SIR system before servicing
components. See AIR BAG DEACTIVATION PROCEDURES
article in GENERAL INFORMATION.
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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

PARK/NEUTRAL POSITION SWITCH

1. If a new Park/Neutral Position (PNP) switch has been rotated and the pin is broken or if
using an old PNP switch, adjust the PNP switch. Place the shift shaft in the Neutral position.
2. Use the Park/Neutral Switch Alignment Tool (J-41545) to align the slots of the PNP switch
to the Neutral position. Align the flats of the shift shaft to the flats in the PNP switch.

NOTE: If the PNP switch bolt holes do not align with the mounting
boss on the transaxle, verify that the shaft is in the Neutral
position.

3. Install the PNP switch to the mounting boss. See Fig. 10 .

4. Assemble the PNP switch mounting bolts loosely. Use the (J-41545) to align the PNP
switch. See Fig. 11 . Install the PNP switch mounting bolts. Tighten the PNP switch
mounting bolts to specification. See TORQUE SPECIFICATIONS .

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 10: Removing & Installing Park Neutral Position Switch

Courtesy of GENERAL MOTORS CORP.

Fig. 11: Identifying Park/Neutral Switch Alignment Tool

Courtesy of GENERAL MOTORS CORP.

SHIFT CABLE

NOTE: Adjust the automatic transaxle range selector cable while the
transaxle and the gear selector are in the Neutral position only.
Failure to do so may cause misadjustment.
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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

1. Set the parking brake. Block the wheels. Disconnect the shift cables at both ends with the
system in Neutral.

NOTE: Do not attempt to separate the metal couplings. Replace both

cable pieces if the metal couplings are separated. Both of the
cable sections will be damaged if the 2 metal couplings are
disconnected.

2. Push up to the adjustment position to release the adjuster until the cable housings separate.
See Fig. 12 . Depress the adjuster clip once.
3. This mobilizes the adjuster housing toward the transaxle end fitting. Line up the end fittings
so they slide together until you feel the parts cam together and lock.
4. Depress the adjuster clip completely. This locks the cable into its adjusted service position.
Pull the conduit in the opposite direction to assure full system adjustment of the shift cable.
5. The horseshoe clip with the tab is flush when fully engaged. See Fig. 13 .
6. Ensure the conduit is fully engaged. The horseshoe clip with the tab is not flush when not
fully engaged. Install the shift cable retainer and the wiring harness clip or wiring harness
strap.

Fig. 12: Identifying Shift Cable Adjuster (1 Of 2)

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2001 Chevrolet Lumina
2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Courtesy of GENERAL MOTORS CORP.

Fig. 13: Identifying Shift Cable Adjuster (2 Of 2)

Courtesy of GENERAL MOTORS CORP.

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint

CAUTION: When battery is disconnected, vehicle computer and memory

systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle.
See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION before disconnecting battery.

NOTE: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
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thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These
coatings affect fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening sequence and
specifications when installing fasteners in order to avoid damage to
parts and systems.

ACCUMULATOR & 2-1 MANUAL SERVO

Removal

1. Raise and support the vehicle. Remove the oil pan and filter. See DRAINING &
REFILLING under LUBRICATION. Remove the accumulator attaching bolts (131). See
Fig. 14 . Remove the manual 2-1 band servo cover bolts (103).
2. Remove the accumulator (132). Remove the manual 2-1 band servo cover (104). Remove
the manual 2-1 band servo. See Fig. 15 . To disassemble, inspect and service, see
appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.

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Fig. 14: Identifying Accumulator & Manual Servo Bolts

Courtesy of GENERAL MOTORS CORP.

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Fig. 15: Removing & Installing 2-1 Manual Band Servo & Seal
Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the manual 2-1 band servo. See Fig. 15 . Install the manual 2-1 band servo cover
(104). See Fig. 14 . Install the manual 2-1 band servo cover bolts (103).
2. Tighten the manual 2-1 band servo cover bolts (103) to specification. See TORQUE
SPECIFICATIONS . Install the accumulator (132). Install the accumulator attaching bolts
(131).
3. Tighten the accumulator attaching bolts (131) to specification. See TORQUE
SPECIFICATIONS . If removed, install the new filter seal. Install the oil filter. Install the
oil pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle.

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AIR CLEANER ASSEMBLY

Removal

Disconnect the retainer clips in the air cleaner cover. See Fig. 16 . Remove the air filter element.
Inspect the air filter element for dust, dirt, and water, replace if required. Disconnect the MAF
sensor connector. Remove the air intake duct. Remove the air cleaner assembly retainer screws.
Remove the air cleaner assembly.

Fig. 16: Removing & Installing Air Cleaner Assembly

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Courtesy of GENERAL MOTORS CORP.

Installation

Install the air cleaner assembly. Install the air cleaner assembly retainer screws. See Fig. 16 .
Tighten the air cleaner retainer screws to specification. See TORQUE SPECIFICATIONS .
Install the air filter element. Install the air intake duct. Connect the MAF sensor connector. Install
the air cleaner cover assembly, and latch the cover assembly.

AUXILIARY OIL COOLER

Removal

CAUTION: Allow sufficient clearance around the transaxle oil cooler

pipes and around the hoses to prevent damage or wear which
may cause fluid loss.

Remove the auxiliary transaxle oil cooler hose and pipe fittings from the auxiliary transaxle oil
cooler. See AUXILIARY OIL COOLER HOSE . Remove the auxiliary transaxle oil cooler
nuts from the lower radiator support. See Fig. 17 . Remove the auxiliary transaxle oil cooler
bolts from the upper radiator support. Remove the auxiliary transaxle oil cooler.

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Fig. 17: Removing & Installing Auxiliary Oil Cooler

Courtesy of GENERAL MOTORS CORP.
Installation

Install the auxiliary transaxle oil cooler. Install the auxiliary transaxle oil cooler bolts to the
upper radiator support. See Fig. 17 . Tighten the auxiliary transaxle oil cooler bolts to
specification. Install the auxiliary transaxle oil cooler nuts to the lower radiator support. Tighten
the auxiliary transaxle oil cooler nuts to specification. See TORQUE SPECIFICATIONS . The
correct thread engagement is critical. Crossthreaded fittings can achieve proper tightness value
and still leak. Install the auxiliary transaxle oil cooler hose and pipe fittings to the auxiliary
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transaxle oil cooler. See AUXILIARY OIL COOLER HOSE .

AUXILIARY OIL COOLER HOSE

Removal

CAUTION: Allow sufficient clearance around the transaxle oil cooler

pipes and around the hoses to prevent damage or wear which
may cause fluid loss.

1. Raise and support the vehicle. Remove the auxiliary transaxle oil cooler hose clamps.
2. Remove the auxiliary transaxle oil cooler hose and pipe from the transaxle oil cooler hose
and pipe. Remove the auxiliary transaxle oil cooler hose and pipe bracket from the lower
radiator support. See Fig. 18 .
3. Remove the auxiliary transaxle oil cooler hose and pipe fittings from the auxiliary transaxle
oil cooler hose and pipe. See Fig. 19 .

Fig. 18: Removing & Installing Oil Cooler Hose & Pipe Bracket
Courtesy of GENERAL MOTORS CORP.

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Fig. 19: Removing & Installing Oil Cooler Pipe Fittings

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Courtesy of GENERAL MOTORS CORP.

Installation

CAUTION: The correct thread engagement is critical. Crossthreaded

fittings can achieve proper tightness and still leak.

1. Install the auxiliary transaxle oil cooler hose and pipe. Install the auxiliary transaxle oil
cooler hose and pipe fittings to the auxiliary transaxle oil cooler. See Fig. 19 .
2. Tighten the auxiliary transaxle oil cooler hose and pipe fittings to specification. See
TORQUE SPECIFICATIONS . Install the auxiliary transaxle oil cooler hose and pipe to
the transaxle oil cooler hose and pipe.

CAUTION: Do not overfill the transaxle. The overfilling of the

transaxle causes foaming, loss of fluid, shift complaints,
and possible damage to the transaxle.

3. Install the auxiliary transaxle oil cooler hose clamps. Lower the vehicle. Adjust the fluid
level. See CHECKING FLUID LEVEL & CONDITION under LUBRICATION.
Inspect for proper completion of the repairs. Inspect for fluid leaks.

CASE EXTENSION HOUSING

Removal

1. Disconnect the negative battery cable. Raise and support the vehicle.
2. Disconnect the right drive axle from the transaxle. See appropriate article in DRIVE
AXLES. Remove the transaxle brace. See TRANSAXLE BRACE . Remove the vehicle
speed sensor. See VEHICLE SPEED SENSOR . Remove the case extension housing bolts
(5). See Fig. 20 .
3. Remove the case extension housing (6) with axle seal and the O-ring (8). Inspect the case
extension (6) for the following conditions:
A damaged or porous sealing surface for the case extension seal.

A damaged or porous sealing surface for the vehicle speed sensor.

A damaged or porous sealing surface for the right drive axle oil seal.

A damaged or porous sealing surface for the case extension housing.

A damaged or worn differential carrier bushing or output shaft bearing.

Damaged bolt holes.

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Inspect the drive axle seal and replace if necessary.

Fig. 20: Removing & Installing Case Extension Housing

Courtesy of GENERAL MOTORS CORP.
Installation

1. If removed, install the drive axle seal. Install the case extension housing (6) with the axle
seal and the O-ring (8). See Fig. 20 .
2. Install the case extension housing bolts (5). Tighten the case extension housing bolts (5) to
specification. See TORQUE SPECIFICATIONS . Install the vehicle speed sensor. See
VEHICLE SPEED SENSOR .

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3. Install the transaxle brace. See TRANSAXLE BRACE . Connect the right drive axle to the
transaxle. Lower the vehicle. Connect the negative battery cable.
4. Adjust the fluid level. Do not overfill the transaxle. Overfilling of the transaxle causes
foaming, loss of fluid, shift complaints, and possible damage to the transaxle. See
CHECKING FLUID LEVEL & CONDITION under LUBRICATION. Inspect for
completion of the repairs. Inspect for fluid leaks.

CASE SIDE COVER

Removal

1. Disconnect the negative battery cable. Remove the throttle body air inlet duct. See AIR
CLEANER ASSEMBLY . Install the Engine Support Fixture (J-28467-A). Install the
Engine Support Adapter (J-28467-90). Install the Engine Support Adapter Leg Set (J-
36462). See appropriate REMOVAL & INSTALLATION article.
2. Remove the left engine mount strut by removing the bolt and the nut from the engine mount
strut at the engine mount strut bracket on the engine. See Fig. 24 . Remove the bolt and the
nut from the engine mount strut at the engine mount strut bracket on the upper radiator
support. Remove the engine mount strut.
3. Remove the right engine mount strut by removing the bolt, the nut and the "P" clip from the
engine mount strut at the right engine mount strut bracket on the engine. See Fig. 25 .
Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket
on the upper radiator support. Remove the engine mount strut.
4. Raise and support the vehicle. Remove the left front wheel. Remove the left engine splash
shield. Remove the stabilizer shaft brackets from the lower control arms. See appropriate
FRONT article in SUSPENSION. Remove the left tie rod end from the steering knuckle.
See appropriate POWER RACK & PINION article in STEERING.
5. Remove the wheel speed sensor harness connector. See appropriate ANTI-LOCK/TCS
article in BRAKES. Remove the left lower ball joint from the left lower control arm. See
appropriate FRONT article in SUSPENSION. Disconnect the left drive axle from the
transaxle. See appropriate article in DRIVE AXLES.

WARNING: Failure to disconnect the intermediate shaft from the

rack and pinion stub shaft can result in damage to the
steering gear and/or damage to the intermediate shaft.
This damage may cause loss of steering control which
could result in personal injury.

6. Secure the drive axle to the steering knuckle/strut. Disconnect the intermediate shaft from
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the steering gear. See appropriate POWER RACK & PINION article in STEERING.
Disconnect the 3-way catalytic converter pipe to the right (rear) exhaust manifold.
7. Support the right side of the frame with jackstands. Support the left side of the frame with
jackstands. Remove the transaxle mount bracket. Remove the transaxle mount. See
TRANSAXLE MOUNT & BRACKET .
8. Remove the engine mount lower nuts. See Fig. 21 . Adjust the jackstand to the lower left
side of the frame. Loosen the right side frame-to-body bolts. Remove the left side frame-to-
body bolts.
9. Position the drain pan under the transaxle. Remove the wiring harness connector. Remove
the case side cover bolts (56-58). See Fig. 22 .
10. Remove the case side cover pan (53). See Fig. 23 . Remove the case side cover gasket (54).
Clean the case. Clean the side cover gasket surfaces.

Fig. 21: Removing & Installing Engine Mount

Courtesy of GENERAL MOTORS CORP.
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Fig. 22: Identifying Case Side Cover Bolts

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Courtesy of GENERAL MOTORS CORP.

Fig. 23: Removing & Installing Case Side Cover Pan

Courtesy of GENERAL MOTORS CORP.

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Fig. 24: Removing & Installing Left Engine Mount Strut

Courtesy of GENERAL MOTORS CORP.

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Fig. 25: Removing & Installing Right Engine Mount Strut

Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the case side cover gasket (54). See Fig. 23 . Install the case side cover pan (53).
Install the case side cover bolts (56-58). See Fig. 22 . Tighten the case side cover bolts (56-
58) to 18 ft. lbs. (25 N.m).
2. Remove the drain pan from under the transaxle. Install the wiring harness connector. Adjust
the jackstand to raise the left side of the frame. Install the left side frame-to-body bolts.
3. Install the right side frame-to-body bolts. Install the engine mount lower nuts. See Fig. 21 .
Install the transaxle mount. Install the transaxle mount bracket. Remove the jackstand
support from the right side of the frame. Remove the jackstand support from the left side of
the frame.
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CAUTION: When installing the intermediate shaft make sure that the
shaft is seated prior to pinch bolt installation. If the pinch
bolt is inserted into the coupling before shaft installation,
the 2 mating shafts may disengage. Disengagement of the
2 mating shafts will cause loss of steering control which
could result in personal injury.

4. Connect the 3-way catalytic converter pipe to the right (rear) exhaust manifold. Install the
intermediate shaft to the steering gear. See appropriate POWER RACK & PINION article
in STEERING. Install the left drive axle to the transaxle. Install the left lower ball joint to
the left lower control arm. See appropriate FRONT article in SUSPENSION.
5. Install the wheel speed sensor harness connector. See appropriate ANTI-LOCK/TCS article
in BRAKES. Install the left tie rod end to the steering knuckle. See appropriate POWER
RACK & PINION article in STEERING. Install the stabilizer shaft brackets to the lower
control arms. See appropriate FRONT article in SUSPENSION. Install the left engine
splash shield. Install the left front wheel. Lower the vehicle.
6. Install the left and right engine mount struts. See Fig. 24 and Fig. 25 . Tighten the engine
mount strut bolts to specification. See TORQUE SPECIFICATIONS .

CAUTION: Do not overfill the transaxle. Overfilling of the transaxle

causes foaming, loss of fluid, shift complaints, and
possible damage to the transaxle.

7. Remove the engine support adapter leg set, engine support adapter and the engine support
fixture. See appropriate REMOVAL & INSTALLATION article. Install the throttle body
air inlet duct. Connect the negative battery cable. Adjust the fluid level. See CHECKING
FLUID LEVEL & CONDITION under LUBRICATION. Inspect for proper completion
of the repairs. Inspect for fluid leaks.

CONTROL VALVE BODY

Removal

1. Remove the case side cover. See CASE SIDE COVER . Remove the oil pump. See OIL
PUMP .
2. Remove the valve body bolts (374-381 and 384). See Fig. 26 . Remove the valve body
(300) while keeping the spacer plate (370) with the transaxle. See Fig. 27 . Remove the ball
check valves (372 and 373) from the valve body. See Fig. 28 .
3. Remove the spacer plate (370) and gasket. See Fig. 29 . Remove the ball check valves
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(372) from the case cover. See Fig. 30 . Inspect each check valve seat in the spacer plate
(370) for excessive peening. See Fig. 31 .
4. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible
light between the valve and the seat. See Fig. 31 . Inspect all components removed from the
transaxle. See appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.

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Fig. 26: Identifying Valve Body Bolts

Courtesy of GENERAL MOTORS CORP.

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Fig. 27: Removing & Installing Control Valve Body Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 28: Locating Check Balls In Valve Body

Courtesy of GENERAL MOTORS CORP.

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Fig. 29: Identifying Spacer Plate

Courtesy of GENERAL MOTORS CORP.

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Fig. 30: Locating Check Balls In Case Cover

Courtesy of GENERAL MOTORS CORP.

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Fig. 31: Inspecting Check Valve Seats In Spacer Plate

Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the ball check valves (372) into the case cover. See Fig. 30 . Use the (J-36850)
TRANSJEL(tm) to retain the ball check valves in their proper locations. Install the gasket
and the spacer plate (370). See Fig. 29 .
2. Install the ball check valves (372 and 373) into the valve body. See Fig. 28 . Use the (J-
36850) TRANSJEL(tm) to retain the ball check valves in their proper locations.
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NOTE: Do not use impact type tools on the valve body or on the oil
pump.

3. Install the gasket (371) and the valve body (300). See Fig. 27 . Install the valve body bolts
(374-381 and 384). See Fig. 26 .
4. Tighten the bolts as follows:
M6 X 1.0 X 20 - 70 INCH lbs. (8 N.m)

M6 X 1.0 X 30 - 106 INCH lbs. (12 N.m)

M6 X 1.0 X 45 - 106 INCH lbs. (12 N.m)

M6 X 1.0 X 55 - 97 INCH lbs. (11 N.m)

M6 X 1.0 X 60 - 106 INCH lbs. (12 N.m)

M6 X 1.0 X 65 - 106 INCH lbs. (12 N.m)

M6 X 1.0 X 85 - 97 INCH lbs. (11 N.m)

M6 X 1.0 X 90 - 97 INCH lbs. (11 N.m)

M8 X 1.0 X 90 - 18 ft. lbs. (25 N.m)

5. Do not use impact type tools on the valve body or on the oil pump. Install the oil pump. See
OIL PUMP . Install the case side cover. See CASE SIDE COVER .

FLUID FILLER TUBE

Removal

Remove the indicator. Raise and support the vehicle. Disconnect the 3-way catalytic converter
pipe. Remove the fluid filler tube bracket bolt from the fluid filler tube bracket. See Fig. 32 .
Remove the fluid filler tube.

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Fig. 32: Removing & Installing Fluid Filler Tube

Courtesy of GENERAL MOTORS CORP.
Installation

Install the fluid filler tube seal in the transaxle. Position the fluid filler tube. Install the fluid filler
tube bracket bolt through the fluid filler tube bracket. Tighten the fluid filler tube bracket bolt to
specification. See TORQUE SPECIFICATIONS . Connect the 3-way catalytic converter pipe.
Lower the vehicle. Install the indicator. Adjust the fluid level. See CHECKING FLUID
LEVEL & CONDITION under LUBRICATION. Inspect for proper completion of the repairs.
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Inspect for proper fluid level. Inspect for fluid leaks

INPUT SPEED SENSOR

Removal

1. Remove the case side cover. See CASE SIDE COVER .

2. Disconnect the transaxle wiring harness. Remove the input speed sensor clip (441) from the
case cover. See Fig. 33 . Remove the input speed sensor (440) from the case cover.
3. Inspect the input speed sensor (440) for the following conditions:
Damaged or missing magnet.

Damaged housing.

Bent or missing electrical terminals.

Damaged speed sensor clip (441).

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Fig. 33: Removing & Installing Input Sensor

Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the input speed sensor (440) into the case cover. See Fig. 33 .
2. Install the input speed sensor clip (441) into the case cover.
3. Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE
COVER .

MANUAL CONTROL LEVER

Removal
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Remove the throttle body air inlet duct. See AIR CLEANER ASSEMBLY . Remove the shift
cable from the manual control lever. See Fig. 63 . Remove the manual control lever nut. Remove
the manual control lever. See Fig. 34 .

Fig. 34: Removing & Installing Manual Control Lever Nut

Courtesy of GENERAL MOTORS CORP.
Installation

Install the manual control lever. Install the manual control lever nut. Tighten the nut to
specification. See TORQUE SPECIFICATIONS . Install the shift cable to the manual control
lever. Adjust the shift cable if necessary. See SHIFT CABLE under ADJUSTMENTS. Install
the throttle body air inlet duct. See AIR CLEANER ASSEMBLY .

OIL COOLER HOSE

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Removal

Raise and support the vehicle. Position the drain pan. Remove the transaxle oil cooler hoses from
the transaxle oil cooler fittings in the transaxle. See Fig. 35 . Remove the transaxle oil cooler
clamps from the transaxle oil cooler hoses at the transaxle oil cooler and/or auxiliary transaxle oil
cooler pipes at the radiator. Remove the transaxle oil cooler hoses from the transaxle oil cooler
and/or auxiliary transaxle oil cooler pipes at the radiator. See AUXILIARY OIL COOLER
HOSE . Remove the transaxle oil cooler hose clip bolt. Remove the transaxle oil cooler hoses.

Fig. 35: Removing & Installing Oil Cooler Lines From Transaxle
Courtesy of GENERAL MOTORS CORP.
Installation

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CAUTION: Do not overfill the transaxle. The overfilling of the transaxle

causes foaming, loss of fluid, shift complaints, and possible
damage to the transaxle.

NOTE: The correct thread engagement is critical. The crossthreaded

fittings can achieve proper tightness value and still leak.

Install the transaxle oil cooler hoses. Install the transaxle oil cooler hose clip bolt. Tighten the
transaxle oil cooler hose clip bolt to specification. Install the transaxle oil cooler hoses to the
transaxle oil cooler and/or auxiliary transaxle oil cooler pipes at the radiator. See Fig. 35 . Install
the transaxle oil cooler clamps to the transaxle oil cooler hoses at the transaxle oil cooler and/or
auxiliary transaxle oil cooler pipes at the radiator. Install the transaxle oil cooler hoses to the
transaxle oil cooler fittings in the transaxle. Tighten the transaxle oil cooler hose fittings to
specification. See TORQUE SPECIFICATIONS . Lower the vehicle. Adjust the fluid level.
See CHECKING FLUID LEVEL & CONDITION under LUBRICATION. Inspect for proper
completion of the repairs. Inspect for fluid leaks

OIL COOLER PIPES (WITH QUICK CONNECT FITTINGS)

NOTE: Use only double-wrapped and use only brazed steel pipe meeting
the GM specification 123M or equivalent if replacement of the
transaxle oil cooler pipes are required. Ensure the pipe is double-
flared, as required.

Removal

CAUTION: Allow sufficient clearance around the transaxle oil cooler

pipes and around the hoses to prevent damage or wear which
may cause fluid loss.

1. Raise and support the vehicle. Position the drain pan. Remove the transaxle oil cooler hoses
from the pipes. Disconnect the transaxle oil cooler pipes from the fittings at the radiator.
See Fig. 47 .

NOTE: Perform the following procedures when removing the retaining

ring and transaxle oil cooler pipe from the quick connect fitting
on the transaxle.

2. Pull the plastic cap back from the quick connect fitting and down along the transaxle oil

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cooler pipe about 2".

3. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to
rotate the retaining ring around the quick connect fitting until the retaining ring is out of
position and can be completely removed.
4. Remove the retaining ring from the quick connect fitting. See Fig. 36 . Discard the retaining
ring. Pull the transaxle oil cooler pipe straight out from the quick connect fitting. See Fig.
37 .
5. Remove the retaining ring "E" clip securing the transaxle oil cooler pipe to the quick
connect in order to remove the remaining transaxle oil cooler pipes from the remaining
quick connect fittings.
6. Remove the transaxle oil cooler pipe clip bolt. Remove the transaxle oil cooler pipes from
the vehicle.

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Fig. 36: Removing Retaining Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 37: Removing & Installing Cooler Line From Quick Connect Fitting
Courtesy of GENERAL MOTORS CORP.
Installation

NOTE: Do not reuse any of the existing retaining rings that were removed
from the existing quick connect fittings. All retaining rings being
installed must be new.

1. Install the transaxle oil cooler pipes. Ensure the following procedures are performed when
installing the new retaining rings onto the fittings.
2. Install a new retaining ring "E" clip into the quick connect fitting using the following
procedure. Hook one of the open ends of retaining ring in one of the slots in the quick
connect fitting. See Fig. 38 . Rotate the retaining ring around the fitting until the retaining
ring is positioned with all 3 ears through the 3 slots on the fitting. See Fig. 39 .
3. Do not install the new retaining ring onto the fitting by pushing the retaining ring. See Fig.
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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

40 . Ensure that the 3 retaining ring ears are seen from inside the fitting and that the
retaining ring moves freely in the fitting slots. See Fig. 41 . Install the new retaining ring
"E" clip into the remaining quick connect fittings.

NOTE: Ensure that the cooler line being installed has a plastic cap on
each end that connects to a quick connect fitting. If no plastic
cap exists, or the plastic cap is damaged, obtain a new plastic
cap and position on to the cooler line prior to the cooler line
installation.

4. Install the transaxle oil cooler pipes to the vehicle. Install the transaxle oil cooler pipe into
the quick connect fitting. Insert the transaxle oil cooler pipe end into the quick connect
fitting until a click is either heard or felt. See Fig. 42 . Do not use the plastic cap on the
transaxle oil cooler pipe in order to install the transaxle oil cooler pipe into the fitting. See
Fig. 43 .
5. Pull back sharply on the transaxle oil cooler pipe in order to ensure that the transaxle oil
cooler pipe is fastened into the quick connect fitting. Position (snap) the plastic cap onto the
fitting. See Fig. 44 . Do not manually depress the retaining ring when installing the plastic
cap onto the quick connect fitting.
6. Ensure that the plastic cap is fully seated against the fitting. See Fig. 45 . Ensure that no gap
is present between the cap and the fitting. Ensure that the yellow identification band on the
tube is hidden within the quick connect fitting. A hidden yellow identification band
indicates proper joint seating. See Fig. 46 .
7. Do not install the transaxle oil cooler pipe end into the fitting incorrectly. If you cannot
position the plastic cap against the fitting, remove the retaining ring from the quick connect
fitting per step 4 of the transaxle oil cooler pipe removal procedure. Check the retaining
ring and the transaxle oil cooler pipe end in order to ensure neither is bent.
8. Replace the transaxle oil cooler pipe or the retaining ring if necessary, and install per step 2
of the transaxle oil cooler pipe installation procedure. Install the transaxle oil cooler pipe
clip bolt. Tighten the transaxle oil cooler pipe clip bolt to specification. See TORQUE
SPECIFICATIONS . Install the transaxle oil cooler hoses to the pipes.
9. Lower the vehicle. Adjust the fluid level. Do not overfill the transaxle. Overfilling of the
transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the
transaxle. See CHECKING FLUID LEVEL & CONDITION under LUBRICATION.
Inspect for proper completion of the repairs. Inspect for fluid leaks.

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Fig. 38: Starting Retaining Ring Onto Quick Connect Fitting

Courtesy of GENERAL MOTORS CORP.

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Fig. 39: Installing Retaining Ring On Quick Connect Fitting

Courtesy of GENERAL MOTORS CORP.

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Fig. 40: View Of Incorrect Method Of Installing Retainer Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 41: View Of Correctly Installed Retainer Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 42: Installing Cooler Lines To Quick Connect Fitting

Courtesy of GENERAL MOTORS CORP.

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Fig. 43: Incorrect Installation Method Using Plastic Cap To Install

Courtesy of GENERAL MOTORS CORP.

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Fig. 44: Installed View Of Quick Connect Fitting

Courtesy of GENERAL MOTORS CORP.

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Fig. 45: Checking For Improper Gap

Courtesy of GENERAL MOTORS CORP.

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Fig. 46: Checking For Identification Band

Courtesy of GENERAL MOTORS CORP.

OIL COOLER PIPES (WITH THREADED FITTINGS)

Removal

CAUTION: Allow sufficient clearance around the transaxle oil cooler

pipes and around the hoses to prevent damage or wear which
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may cause fluid loss.

Raise and support the vehicle. Position the drain pan. Remove the transaxle oil cooler hoses from
the pipes. Remove the transaxle oil cooler pipe fittings at the radiator. See Fig. 47 . Remove the
transaxle oil cooler pipe clip bolt. Remove the transaxle oil cooler pipes.

Fig. 47: Removing & Installing Oil Cooler Pipes

Courtesy of GENERAL MOTORS CORP.
Installation
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CAUTION: Do not overfill the transaxle. The overfilling of the transaxle

causes foaming, loss of fluid, shift complaints, and possible
damage to the transaxle.

NOTE: The correct thread engagement is critical. Crossthreaded fittings

can achieve proper tightness value and still leak. Install the
transaxle oil cooler pipes.

Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to 27
INCH lbs. (4 N.m). Install the transaxle oil cooler pipe fittings at the radiator. See Fig. 47 .
Tighten the transaxle oil cooler pipe fittings to specification. See TORQUE
SPECIFICATIONS . Install the transaxle oil cooler hoses to the pipes. See AUXILIARY OIL
COOLER HOSE or OIL COOLER HOSE . Lower the vehicle. Adjust the fluid level. See
CHECKING FLUID LEVEL & CONDITION under LUBRICATION. Inspect for proper
completion of the repairs. Inspect for fluid leaks.

OIL PRESSURE TEST PLUG

Removal

Remove the throttle body air inlet duct. See AIR CLEANER ASSEMBLY . Remove the line
the pressure pipe plug (38). See Fig. 48 .

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Fig. 48: Removing & Installing Oil Pressure Test Plug

Courtesy of GENERAL MOTORS CORP.
Installation

Install the line pressure pipe plug (38). See Fig. 48 . Tighten the line pressure pipe plug (38) to
specification. See TORQUE SPECIFICATIONS . Install the throttle body air inlet duct. See
AIR CLEANER ASSEMBLY .

OIL PUMP

Removal

Remove the case side cover. See CASE SIDE COVER . Do not remove the 3 bolts which hold
the pump together. Remove the oil pump bolts (205-207). See Fig. 49 . Remove the oil pump
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(200) from the valve body (300). See Fig. 50 . Inspect the oil pump.

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Fig. 49: Identifying Oil Pump Bolts

Courtesy of GENERAL MOTORS CORP.

Fig. 50: Identifying Oil Pump

Courtesy of GENERAL MOTORS CORP.
Installation

Install the oil pump (200) to the valve body (300). See Fig. 50 . Install the oil pump bolts (205-
207). Tighten the bolts as follows:

M6 X 1.0 X 20 - 70 INCH lbs. (8 N.m)

M6 X 1.0 X 85 - 106 INCH lbs. (12 N.m)
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M6 X 1.0 X 95 - 106 INCH lbs. (12 N.m).

Install the case side cover. See CASE SIDE COVER .

OUTPUT SHAFT

Removal

1. Remove the case extension housing. See CASE EXTENSION HOUSING . Disconnect the
left drive axle from the transaxle. See appropriate article in DRIVE AXLES.
2. Rotate the differential carrier until the end of the output shaft can be seen and the
differential pinion shaft (701) is in a horizontal position. See Fig. 51 .
3. Place the (J-42562) Snap Ring Tool between the end of the output shaft and the differential
pinion shaft. Using a hammer, hit the end of the axle removal tool in order to compress the
output shaft compression ring (512) and push the output shaft through the differential side
gear.
4. Remove the differential carrier (700). See Fig. 52 . Using snap ring pliers remove the
compression ring (512) from the output shaft.
5. Remove the output shaft through the left wheel opening. Inspect the output shaft (510) for
the following: stripped splines or a damaged retainer ring groove. See Fig. 53 .

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Fig. 51: Identifying Differential Pinion Shaft

Courtesy of GENERAL MOTORS CORP.

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Fig. 52: Removing & Installing Differential Carrier

Courtesy of GENERAL MOTORS CORP.

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Fig. 53: Inspecting Output Shaft

Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the drive axle retainer ring (509) and the output shaft differential inboard snap ring
(512) onto the output shaft (510). See Fig. 51 and Fig. 52 .
2. Hold the front differential carrier (700) in place and carefully install the output shaft (510)
into the transaxle through the left wheel opening.
3. Extend the output shaft through the differential side gear. Install the case extension housing.
See CASE EXTENSION HOUSING . Connect the left drive axle to the transaxle. See
appropriate article in DRIVE AXLES.

PARK/NEUTRAL POSITION SWITCH

Removal

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1. Apply the parking brake.

2. Block the wheels.
3. Place the vehicle is the Neutral position.
4. Remove the air cleaner intake duct.
5. Remove the range selector cable from the PNP switch.
6. Disconnect the PNP switch electrical connectors. See Fig. 54 .
7. Remove the range selector lever nut.
8. Remove the range selector lever.
9. Remove the PNP switch bolts. See Fig. 55 .
10. Remove the PNP switch.
Installation

CAUTION: Do not rotate a NEW PNP switch. A NEW PNP switch is pinned
in the Neutral position. If the bolt holes do not align with the
mounting boss on the transaxle, verify that the shaft is in the
Neutral position. Adjust the PNP switch if the new switch has
been rotated and the pin is broken or if using an old PNP
switch. See PARK/NEUTRAL POSITION SWITCH under
ADJUSTMENTS.

1. Verify that the shift shaft in the Neutral position.

2. Align the flats of the shift shaft to the flats in the PNP switch.
3. Install the PNP switch to the mounting boss. See Fig. 55 .
4. Install the PNP switch bolts. Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
5. Install the range selector lever.
6. Install the range selector lever nut. Tighten the nut to specification. See TORQUE
SPECIFICATIONS .
7. Connect the PNP switch electrical connectors. See Fig. 54 .
8. Install the automatic transaxle range selector cable to the PNP switch. Verify that the engine
starts only in the Park or Neutral position once the PNP switch is installed. Readjust the
PNP switch and/or inspect the shifter and the range selector lever if the engine starts in any
other position. See PARK/NEUTRAL POSITION SWITCH under ADJUSTMENTS.
9. Install the air cleaner intake duct.

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10. Remove the blocks from the wheels.

11. Release the parking brake.

Fig. 54: Removing & Installing PNP Switch Harness Connectors

Courtesy of GENERAL MOTORS CORP.

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Fig. 55: Removing & Installing PNP Switch

Courtesy of GENERAL MOTORS CORP.

PRESSURE CONTROL SOLENOID

Removal

Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring
harness. Remove the pressure control solenoid (322). See Fig. 56 .

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Fig. 56: Removing & Installing Pressure Control Solenoid

Courtesy of GENERAL MOTORS CORP.
Installation

Install the pressure control solenoid (322). See Fig. 56 . Connect the transaxle wiring harness.
Install the case side cover. See CASE SIDE COVER .

REVERSE SERVO

Removal

1. Remove the throttle body air inlet duct. See AIR CLEANER ASSEMBLY . Depress the
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reverse servo cover (40). See Fig. 57 .

2. Remove the snap ring (39). Pull the O-ring seal (41) out through the slot in the case. See
Fig. 58 . Use side cutting pliers in order to cut the servo cover O-ring seal (41).
3. Depress the reverse servo cover (40), grasp one end of the cut seal (41) and pull the seal
(41) out of the servo cover (40).
4. Remove the reverse servo cover (40). Remove the servo assembly (42-48). See Fig. 59 .
Remove the servo spring (49).

Fig. 57: Identifying Reverse Servo Cover & Snap Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 58: Removing Reverse Servo Cover O-ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 59: Removing & Installing Reverse Servo Assembly

Courtesy of GENERAL MOTORS CORP.
Installation

CAUTION: Follow this procedure exactly or the transaxle will have no

reverse gear due to the servo pin missing the band.

1. Jack up the driver side (channel plate side) of the car until it is higher than the differential
side. This ensures that the reverse band is in the proper location and not cocked to the
channel plate side of the case.
2. Install the servo spring (49). See Fig. 59 . Install the servo assembly (42-48). Install the
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reverse servo cover (40) with new O-ring seal (41).

3. Install the snap ring (39). See Fig. 57 . Install the throttle body air inlet duct. See AIR
CLEANER ASSEMBLY .

SHIFT CABLE (AT COLUMN SHIFT CONTROL)

Removal

1. Remove the shift cable retainer from the stud in the engine compartment. Remove the
steering column filler. See STEERING COLUMN FILLER .
2. Remove the shift cable from the shift control lever. See Fig. 60 . Remove the shift cable
from the manual control lever. See SHIFT CABLE (AT MANUAL CONTROL
LEVER) .
3. Remove the shift cable through the hole in the dash. See Fig. 61 .

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Fig. 60: Removing & Installing Shift Cable At Steering Column

Courtesy of GENERAL MOTORS CORP.

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Fig. 61: Locating Shift Cable Pass-Through At Firewall

Courtesy of GENERAL MOTORS CORP.
Installation

1. If installing NEW cable, see SHIFT CABLE (NEW CABLE INSTALLATION

ONLY) . If reinstalling used cable, go to next step.
2. Install the shift cable through the hole in the dash. See Fig. 61 . Properly route and position
the shift cable. See Fig. 62 . Install the shift cable to the manual control lever. See SHIFT
CABLE (AT MANUAL CONTROL LEVER) .
3. Install the shift cable to the shift control lever. See Fig. 60 . Install the steering column
filler. See STEERING COLUMN FILLER .
4. Install the shift cable retainer to the stud in the engine compartment. Adjust the shift cable
(transaxle side). See SHIFT CABLE under ADJUSTMENTS.

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Fig. 62: Identifying Shift Cable Routing

Courtesy of GENERAL MOTORS CORP.

SHIFT CABLE (AT MANUAL CONTROL LEVER)

Removal

1. Remove the shift cable from the wiring harness clip. Remove the shift cable from the manual
control lever. See Fig. 63 .
2. Remove the shift cable from the bracket. See Fig. 64 . Remove the shift cable from the
column shift control. See SHIFT CABLE (AT COLUMN SHIFT CONTROL) . Pull the
shift cable through the dash from the engine compartment side.

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Fig. 63: Removing & Installing Shift Cable At Manual Control Lever (1 Of 2)
Courtesy of GENERAL MOTORS CORP.

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Fig. 64: Removing & Installing Shift Cable At Manual Control Lever (2 Of 2)
Courtesy of GENERAL MOTORS CORP.
Installation

1. If installing NEW cable, see SHIFT CABLE (NEW CABLE INSTALLATION

ONLY) . If reinstalling used cable, go to next step.
2. Insert the shift cable through the dash from the engine compartment side. Install the shift
cable to the bracket. See Fig. 64 .
3. Install the shift cable to the manual control lever. See Fig. 63 . Install the shift cable to the
wiring harness clip. Install the shift cable to the column shift control.
4. Adjust the shift cable. See SHIFT CABLE under ADJUSTMENTS.

SHIFT CABLE (NEW CABLE INSTALLATION ONLY)

Installation

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1. Set the parking brake. Block the wheels. Place the transaxle in the Neutral position. Place
the shift control in the Neutral position. Connect each cable section to the following before
connecting the 2 cable sections:
To the manual control lever and shift cable bracket.

To the column or the console shift control and retainer or wiring harness clip.

2. Insert the metal end fitting of the shift cable into the transaxle cable end. See Fig. 65 . Use
the molded end fittings to push the metal end fitting of the shift cable and the transaxle cable
end together until the metal post snaps into place.
3. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end
fitting. Line up the end fittings so they slide together until you feel the parts cam together
and lock.
4. Depress the adjuster clip completely. This locks the cable into its adjusted service position.
Pull the conduit in the opposite direction to assure full system adjustment of the shift cable.
The horseshoe clip with the tab is flush when fully engaged. See Fig. 13 .
5. Ensure the conduit is fully engaged. The horseshoe clip with the tab is not flush when not
fully engaged. Install the shift cable retainer and the wiring harness clip or the wiring
harness strap.

Fig. 65: Installing New Shift Cable

Courtesy of GENERAL MOTORS CORP.

STEERING COLUMN FILLER

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Removal

1. Remove the right hand instrument panel insulator retainers. Remove the instrument panel
steering column opening filler panel screws (2). See Fig. 66 . Remove the steering column
opening filler panel retainer.
2. Disconnect the electrical connector (5) from the rear compartment lid release switch.
Remove the instrument panel steering column opening filler panel (4).
3. Release the retainers in order to remove the rear compartment lid release switch (3).

Fig. 66: Removing & Installing Steering Column Filler

Courtesy of GENERAL MOTORS CORP.
Installation

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1. Install the rear compartment lid release switch (3) to the instrument panel steering column
opening filler panel. See Fig. 66 . Position the instrument panel steering column opening
filler panel (4) to the instrument panel.
2. Connect the electrical connector (5) to the rear compartment lid release switch. Install the
steering column opening filler panel retainer. Install and finger tighten the instrument panel
steering column opening filler panel screws.
3. Tighten the right hand instrument panel steering column opening filler screw first in order to
properly install the instrument panel steering column opening filler panel. Tighten the right
hand instrument panel steering column opening filler panel screw to 17 INCH lbs. (1.9
N.m).
4. Tighten the left hand instrument panel steering column opening filler panel screw to 17
INCH lbs. (1.9 N.m). Install the right hand instrument panel insulator retainers.

TCC PULSE WIDTH MODULATION SOLENOID

Removal

Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring
harness. Remove the torque converter clutch PWM solenoid (334). See Fig. 67 .

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Fig. 67: Removing & Installing Torque Converter Pulse Width Modulation Solenoid
Courtesy of GENERAL MOTORS CORP.
Installation

Install the torque converter clutch PWM solenoid (334). See Fig. 67 . Connect the transaxle
wiring harness. Install the case side cover. See CASE SIDE COVER .

TFP MANUAL VALVE POSITION SWITCH

Removal

Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring
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harness. Remove the control valve body bolts (375, 379 and 381) that mount the fluid
pressure manual valve position switch to the control valve body (300). See Fig. 68 .
Carefully remove the fluid pressure manual valve position switch (395). Handle the switch
carefully, the fluid pressure manual valve position switch is very delicate.
Inspect the fluid pressure manual valve position switch (395) for the following conditions:
Damaged electrical connector terminals.

Damaged seals.

Damaged switch membranes.

Debris on the switch membranes.

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Fig. 68: Identifying Transmission Fluid Pressure Manual Valve Position Switch
Bolts
Courtesy of GENERAL MOTORS CORP.
Installation

Carefully install the fluid pressure manual valve position switch (395). See Fig. 68 . Handle
the switch carefully, the fluid pressure manual valve position switch is very delicate.
Install the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual
valve position switch to the control valve body (300).

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Tighten the control valve body bolt (375) to 106 INCH lbs. (12 N.m). Tighten the control
valve body bolt (379) to 97 INCH lbs. (11 N.m). Tighten the control valve body bolt (381)
to 70 INCH lbs. (8 N.m). Connect the transaxle wiring harness. Install the case side cover.
See CASE SIDE COVER .

THERMO ELEMENT

Removal

1. Raise and support the vehicle. Remove the oil pan. See DRAINING & REFILLING under
LUBRICATION.
2. Remove the thermo element pins and washers (120 and 123). See Fig. 69 .
3. Remove the thermo element (121) and the thermo element plate (122).

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Fig. 69: Removing & Installing Thermo Element

Courtesy of GENERAL MOTORS CORP.
Installation

1. Use the Thermo Element Height Gage (J-34094-A) to set the middle thermo pin (123). See
Fig. 70 . Install the new thermo element plate (122). Install the pin and washer (120).
2. Use the thermo element height gage to set the height of the pin and washer (120) furthest
from the accumulator. Use the thermo element height gage to set the height of the second pin
and washer (120).
3. Carefully install the thermo element (121) between the 2 pin and washers (120). The "V" in
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the thermo element (121) must contact the thermo element plate (122). Install the oil pan.
See DRAINING & REFILLING under LUBRICATION.

Fig. 70: Identifying Thermo Element Height Gage

Courtesy of GENERAL MOTORS CORP.

TRANSAXLE BRACE

Removal

Disconnect the negative battery cable. Raise and support the vehicle. Remove the right front tire
and wheel. Remove the transaxle brace bolts. See Fig. 71 . Remove the transaxle brace.

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Fig. 71: Removing & Installing Transaxle Brace

Courtesy of GENERAL MOTORS CORP.
Installation

Install the transaxle brace. Hand start the bolts to the engine and to the transaxle. Install the
transaxle brace bolts to the transaxle. See Fig. 71 . Tighten the transaxle brace bolts to the
transaxle to specification. See TORQUE SPECIFICATIONS . Install the transaxle brace bolts
to the engine. Tighten the transaxle brace bolts to the engine to specification. Install the right
front tire and wheel. Lower the vehicle. Connect the negative battery cable.

TRANSAXLE MOUNT & BRACKET

Removal

1. Raise and support the vehicle. Remove the left front tire and wheel.
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2. Remove the left engine splash shield. Use floor stands to support the transaxle.
3. With a jack, slightly take the weight off mount, and remove the transaxle bracket to
transaxle mount upper nuts. See Fig. 73 .
4. Remove the transaxle bracket to transaxle mount lower nuts. See Fig. 72 . Remove the
transaxle bracket to transaxle bolts. See Fig. 74 . Remove the transaxle bracket.

Fig. 72: Removing & Installing Transaxle Lower Mount Nuts

Courtesy of GENERAL MOTORS CORP.

MY
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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 73: Removing & Installing Transaxle Upper Mount Nuts

Courtesy of GENERAL MOTORS CORP.

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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 74: Removing & Installing Transaxle Bracket Bolts

Courtesy of GENERAL MOTORS CORP.
Installation

1. Position the transaxle bracket to the transaxle. Hand start the transaxle mount bracket to
transaxle bolts. Install the transaxle bracket bolts. See Fig. 74 . Start with the forward lower
bolt and work clockwise to tighten the transaxle bracket bolts to specification. See
TORQUE SPECIFICATIONS .
2. Install the transaxle bracket to transaxle mount lower nuts. See Fig. 72 . Remove the
support from the transaxle. Install the transaxle bracket to the transaxle mount upper nuts.
See Fig. 73 . Tighten the transaxle mount upper nuts to specification. See TORQUE
SPECIFICATIONS .
3. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle.

TRANSAXLE VENT

Removal

Remove the throttle body air inlet duct. See AIR CLEANER ASSEMBLY . Remove the
transaxle vent (press fit) (37). See Fig. 75 .

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Fig. 75: Removing & Installing Transaxle Vent Tube

Courtesy of GENERAL MOTORS CORP.
Installation

Install the transaxle vent (press fit) (37). See Fig. 75 . Install the throttle body air inlet duct. See
AIR CLEANER ASSEMBLY .

VEHICLE SPEED SENSOR

Removal

1. Raise and support the vehicle. Remove the right front tire and wheel.
2. Remove the right engine splash shield by removing the push-in retainers from the engine
MY
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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

splash to the lower flange of the engine compartment side rail using Trim Remover (J-
38778). Remove the engine splash shield from the lower flange of the engine compartment
side rail.
3. Remove the vehicle speed sensor wiring harness connector. See Fig. 76 . Remove the
vehicle speed sensor bolt (9). See Fig. 77 . Remove the vehicle speed sensor (10) from the
extension case. Remove the O-ring (11) from the vehicle speed sensor (10). See Fig. 78 .

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Fig. 76: Removing & Installing Vehicle Speed Sensor Harness Connector
Courtesy of GENERAL MOTORS CORP.

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Fig. 77: Removing & Installing Vehicle Speed Sensor

Courtesy of GENERAL MOTORS CORP.

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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Fig. 78: Removing & Installing Vehicle Speed Sensor O-ring

Courtesy of GENERAL MOTORS CORP.
Installation

1. Install the O-ring (11) to the vehicle speed sensor (10). See Fig. 78 . Install the vehicle
speed sensor (10) to the extension case. See Fig. 77 . Install the vehicle speed sensor bolt
(9).
2. Tighten the vehicle speed sensor bolt (9) to specification. See TORQUE
SPECIFICATIONS . Install the vehicle speed sensor wiring harness connector. See Fig.
76 .
3. Install the right engine splash shield by positioning the engine splash shield to the lower
flange of the engine compartment side rail. Align the holes in the engine splash shield to the
holes in the outboard side engine compartment side rail. Install the push-in retainers to the
MY
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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

engine splash shield. Install the right front tire and wheel. Lower the vehicle.

1-2 SHIFT SOLENOID VALVE

Removal

Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring
harness. Remove the 1-2 shift solenoid (315A). See Fig. 79 .

Fig. 79: Removing & Installing 1-2 Shift Solenoid

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2000-01 AUTOMATIC TRANSMISSIONS Servicing - Lumina

Courtesy of GENERAL MOTORS CORP.

Installation

Install the 1-2 shift solenoid (315A). See Fig. 79 . Connect the transaxle wiring harness. Install
the case side cover. See CASE SIDE COVER .

2-3 SHIFT SOLENOID VALVE

Removal

Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring
harness. Remove the 2-3 shift solenoid (315B). See Fig. 80 .

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Fig. 80: Removing & Installing 2-3 Shift Solenoid

Courtesy of GENERAL MOTORS CORP.
Installation

Install the 2-3 shift solenoid (315B). See Fig. 80 . Connect the transaxle wiring harness. Install
the case side cover. See CASE SIDE COVER .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Auxiliary Transaxle Oil Cooler Bolt 18 (24)
Brace-To-Engine Bolt 46 (62)
Brace-To-Transaxle Bolt 32 (43)
Case Extension Housing Bolt 27 (37)
Engine Mount Strut 35 (48)
Manual 2-1 Band Servo Cover Bolt 17 (23)
Oil Cooler Hose Clip Bolt 18 (24)
Oil Cooler Hose Fitting 17 (23)
Oil Cooler Pipe Fitting 45 (61)
PNP Switch Mounting Bolt 18 (24)
Selector Lever Nut 15 (20)
Transaxle Bracket Bolt 70 (95)
Transaxle Mount Upper Nut 35 (48)
INCH Lbs. (N.m)
Accumulator Bolt 97 (11)
Air Cleaner Retainer Screw 44-61 (5-7)
Auxiliary Transaxle Oil Cooler Nut 97 (11)
Fluid Filler Tube Bracket Bolt 115 (13)
Forward Servo Cover Attaching Bolt 97 (11)
Line Pressure Pipe Plug 97 (11)
Oil Cooler Pipe Clip Bolt 27 (3)
Oil Pan Bolt 124 (14)
Vehicle Speed Sensor Bolt 97 (11)

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Fastener Tightening Specifications

Specification
Application Metric English
Air Compressor Bracket to Vehicle Bolt 9 N·m 80 lb in
Air Compressor Bracket to Vehicle Nuts 9 N·m 80 lb in
Air Compressor Head Bolts 6 N·m 53 lb in
Air Compressor to Bracket Bolts 3 N·m 26 lb in
Brackets to Air Compressor Screws 7 N·m 62 lb in
Harness Tie to Air Compressor Head Bolt 3 N·m 26 lb in
Heat Shield to Air Compressor Bracket Bolts 4 N·m 35 lb in
Height Sensor to Vehicle Nut 9 N·m 80 lb in

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Suspension Position Sensor

(1) Suspension Position Sensor

(2) Suspension Position Sensor Link

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Automatic Level Control Compressor

(1) Automatic Level Control (ALC) Air Compressor

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Automatic Level Control Connector End Views

Automatic Level Control (ALC) Compressor

• 12015788
Connector Part Information
• 4-Way F Weather Pack (BLK)
Pin Wire Color Circuit No. Function
A RED 1342 Battery Positive Voltage
B DK GRN 322 ALC Compressor Motor Control
C WHT 320 ALC Exhaust Solenoid Control
D BLK 1050 Ground

Automatic Level Control (ALC) Sensor

Connector Part • 12110293

Information • 3-Way F Metri-Pack 150 Series (BLK)

Circuit
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Pin Wire Color No. Function

A GRY 2165 Automatic Level Control Sensor 5 Volt Reference
B BRN 2184 Automatic Level Control Position Sensor Signal
Automatic Level Control Position Sensor Low
C PPL 2185
Reference

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Document ID: 631015 Page 1 of 1

| Aurora (VIN G) Service Manual | Suspension | Automatic Level Control |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 631015

Automatic Level Control Schematics

© 2014 General Motors Corporation. All rights reserved.

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Air Compressor Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the right rear wheelhouse extension. Refer to Wheelhouse Panel Replacement in
Body Rear End.

Important: Before disconnecting the air hose from the intake air filter or the air compressor,
clean the components and the surrounding area to prevent dirt and other foreign material
from entering the ELC system.

4. Disconnect the air tube from the air dryer.

5. Remove the bolt and the harness tie with the air tube from the air compressor bracket.

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6. Remove the intake air filter from the vehicle.

7. Disconnect the air compressor connector.
8. Remove the 2 nuts, the bolt, and the air compressor from the vehicle.

9. Slide the air compressor connector off of the connector anchor.

10. Remove 2 bolts and the heat shield from the air compressor bracket.

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11. Remove 3 bolts and the air compressor from the bracket.
12. Remove the air dryer from the air compressor. Refer to Automatic Level Control Air Dryer
Replacement .

13. Disconnect the air hose from the air compressor.

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14. Remove the 2 screws and the 2 brackets from the air compressor.

Installation Procedure
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

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1. Install the 2 brackets on the air compressor with 2 screws.

Tighten
Tighten the screws to 7 N·m (62 lb in).

2. Connect the air hose to the air compressor.

3. Install the air dryer on the air compressor. Refer to Automatic Level Control Air Dryer
Replacement .

4. Install the air compressor onto the bracket with 3 bolts.

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Tighten
Tighten the bolts to 3 N·m (26 lb in).

5. Install the heat shield on the air compressor bracket with 2 bolts (Do not install the third
heat shield bolt. It must be installed after the air tube is connected).

Tighten
Tighten the bolts to 4 N·m (35 lb in).

6. Install the air compressor connector to the connector anchor.

7. Install the air compressor on the vehicle with 2 nuts and a bolt.

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Tighten
• Tighten the bolt to 9 N·m (80 lb in).
• Tighten the nuts to 9 N·m (80 lb in).
8. Connect the air compressor connector.
9. Install the intake air filter on the vehicle.

10. Connect the air tube to the air dryer.

11. Connect the air tube and the harness tie to the air compressor bracket with the bolt.

Tighten
Tighten the bolt to 4 N·m (35 lb in).

12. Install the right rear wheelhouse extension. Refer to Wheelhouse Panel Replacement in Body
Rear End.
13. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.

Important: Before driving the vehicle, turn the ignition on and wait approximately 45
seconds. This will ensure that the air adjustable shock absorbers are filled with residual
pressure.

14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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Air Tube Replacement

At the rear shock absorbers, the air tube connectors are held on with spring clips which snap into
the grooves of the shock absorber air fittings. Air tube connectors are sealed using 2 O-rings.

Important: Before disconnecting any air tube, clean the connector and the surrounding area to
prevent dirt and other foreign material from entering the ELC system.

To disconnect an air tube from a shock absorber, rotate the spring clip 90 degrees out of the slots,
and pull the connector from the shock absorber.

Important: Ensure that the air tube is routed correctly and all fasteners are used.

To connect an air tube to a shock absorber, lubricate the 2 O-rings using silicone lubricant, rotate
the spring clip 90 degrees into the slots, and push the air tube connector on the shock absorber
fitting until spring clip snaps into fitting groove.

Removal Procedure

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1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove both rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Disconnect the air tube from the air dryer.
4. Remove the bolt and the harness tie from the air compressor bracket.

5. Disconnect the air tube from the left and right rear shock absorbers.
6. Remove the 2 metal clips from the air tube and the vehicle.
7. Remove the air tube with the 3 clips from the vehicle.

Installation Procedure

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1. Connect the air tube to the air dryer.

2. Install the air tube with the harness tie and the bolt on the air compressor bracket.

3. Install the air tube on the vehicle with 3 clips.

4. Connect the air tube to the left and right rear shock absorbers.
5. Install 2 metal clips on the air tube and the vehicle. Place each clip immediately forward of
the wheel house fold-over tabs on the LH and RH side of the vehicle.
6. Install both rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.

Important: Before driving the vehicle, turn the ignition on and wait approximately 45
seconds. This will ensure that the air adjustable shock absorbers are filled with residual
pressure.

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7. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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Automatic Level Control Air Compressor Air Filter

Replacement
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the intake air filter from the body rail and the air hose.

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3. Slide the air compressor connector off of the connector anchor.

4. Remove 3 bolts and the heat shield from the air compressor bracket.

5. Disconnect the air hose from the air compressor.

Installation Procedure

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1. Connect the air hose to the air compressor.

2. Connect the intake air filter to the air hose and the body rail.

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3. Install the heat shield and the harness tie with 3 bolts.

Tighten
Tighten bolts to 4 N·m (35 lb in).

4. Install the air compressor connector onto the connector anchor.

5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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Automatic Level Control Air Compressor Head

Replacement
Disassembly Procedure

1. Remove the air compressor. Refer to Air Compressor Replacement .

2. Remove the air compressor connector from the connector anchor (slide the air compressor
connector away from the air compressor and off of the anchor).
3. Remove the 2 bolts and the heat shield from the air compressor bracket.
4. Remove the air dryer. Refer to Automatic Level Control Air Dryer Replacement .

© 2014 General Motors Corporation. All rights reserved.

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5. Cut the harness tie.

6. Remove the bolt and the harness tie.

Important: Note the wire colors and the terminal numbers to ensure correct assembly.

7. Remove the 2 harness ties and the wrap from the wires.

8. Remove 2 wire terminals from the air compressor connector.

9. Remove the air hose from the air compressor head.
10. Remove the 3 head bolts and the air compressor head.
11. Remove the head gasket.

Assembly Procedure

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1. Install the new gasket on the air compressor.

2. Install the air compressor head on the air compressor with the 3 bolts.

Tighten
Tighten the bolts to 6 N·m (53 lb in).

3. Connect the air hose.

4. Install the 2 wire terminals in the air compressor connector.

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5. Install the wrap around 4 wires and secure with 2 harness ties.
6. Install the wiring harness and the harness clamp on the air compressor head with the bolt.

Tighten
Tighten the bolt to 3 N·m (26 lb in).

7. Install the air dryer. Refer to Automatic Level Control Air Dryer Replacement .

8. Install the heat shield with the 2 bolts.

Tighten
Tighten the bolts to 4 N·m (35 lb in).

9. Connect the air compressor connector to the connector anchor.

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10. Install the air compressor on the vehicle. Refer to Air Compressor Replacement .

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Automatic Level Control Air Dryer Replacement

Removal Procedure

1. Remove the air compressor. Refer to Air Compressor Replacement .

2. Rotate the spring clip 90 degrees out of the slot.
3. Remove the air dryer from the air compressor.
4. Remove the seal from the air compressor.

Installation Procedure
Important:
• Lubricate the seal with silicone lubricant.
• The spring clip must not be in the slots of the air compressor.

© 2014 General Motors Corporation. All rights reserved.

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1. Install a new seal onto the air dryer.

2. Install the air dryer with the seal in the air compressor.
3. Rotate the spring clip 90 degrees to lock the air dryer in place.
4. Install the air compressor. Refer to Air Compressor Replacement .

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Automatic Level Control Sensor Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

2. Remove the wheel from the vehicle. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Disconnect the height sensor connector.
4. Disconnect the sensor link from the ball stud.
5. Loosen the sensor mounting nut.
6. Disengage the anti-rotation tab and slide the sensor downward.
7. Remove the sensor from the vehicle.

Installation Procedure

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1. Insert the head of the sensor mounting stud into the key hole.
2. Slide the sensor upward until the anti-rotation tab engages in the lower hole.

3. Tighten the sensor mounting nut.

Tighten
Tighten the nut to 9 N·m (80 lb in).

4. Connect the sensor link on the ball stud.

5. Connect the height sensor connector.
6. Install the wheel on the vehicle. Refer to Tire and Wheel Removal and Installation .
7. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

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Fastener Tightening Specifications

Specification
Application Metric English
Instrument Panel Module Fastener 2 N·m 18 lb in

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DIM Ignition Inputs

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DIM Input/Output (1 of 2)

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DIM Input/Output (2 of 2)

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DIM Power and Grounds

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IPM Input/Output (1 of 2)

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IPM Input/Output (2 of 2)

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IPM Power and Grounds

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Rim Input/Output (1 of 2)

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RIM Input/Output (2 of 2)

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RIM Power and Grounds

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Body Control System Connector End Views

Table 1: Dash Integration Module (DIM) C1
Table 2: Dash Integration Module (DIM) C2
Table 3: Dash Integration Module (DIM) C3
Table 4: Instrument Panel Module (IPM) C1
Table 5: Instrument Panel Module (IPM) C2
Table 6: Rear Integration Module (RIM) C1
Table 7: Rear Integration Module (RIM) C2

Dash Integration Module (DIM) C1

• 12064769
Connector Part Information
• 10 Way Metri-pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A-D -- -- Not Used
E BLK/WHT 351 Ground
F -- -- Not Used
G ORN 540 Battery Positive Voltage
H YEL 32 Instrument Panel Lamp Fuse Supply Voltage - 1
J -- -- Not Used
K YEL 1491 Backlight Lamps Control

Dash Integration Module (DIM) C2

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• 12160778
Connector Part Information
• 24 Way F Micro-pack 100 Series (BRN)
Pin Wire Color Circuit No. Function
A1 DK BLU 1796 Steering Wheel Controls Signal
A2-A5 -- -- Not Used
A6 BLK/WHT 2261 Low Reference
A7 GRY 731 A/C Refrigerant Low Temperature Sensor Signal
A8-A10 -- -- Not Used
A11 PPL 1807 Class 2 Serial Data - Primary
A12 PPL 1807 Class 2 Serial Data - Primary
B1 -- -- Not Used
B2 WHT 103 Headlamp Switch Headlamps On Signal
B3 BRN/WHT 301 Park Lamp Switch On Signal
B4 WHT 1538 Headlamp On With Wipers Signal
B5-B7 -- -- Not Used
B8 PNK/BLK 1484 Flash to Pass Signal
B9-B12 -- -- Not Used

Dash Integration Module (DIM) C3

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• 12110088
Connector Part Information
• 24 Way F Micro-pack 100 Series (GRY)
Pin Wire Color Circuit No. Function
A1 WHT 1390 Off/Run/Crank Voltage
A2 BRN 4 Accessory Voltage
A3 PNK 3 Run/Crank Voltage
A4 LT GRN/BLK 592 DRL Relay Control
A5 -- -- Not Used
A6 BLK 28 Horn Relay Control
A7 DK GRN/WHT 1317 Front Fog Lamp Relay Control
A8 LT GRN 1652 Reverse Lockout Solenoid Control
A9 YEL 2263 Air Conditioning Orifice Solenoid Control
A10-A11 -- -- Not Used
A12 ORN 3340 Battery Positive Voltage
B1 ORN 300 Ignition 3 Voltage
B2 -- -- Not Used
B3 PPL 1375 Remote Radio Control Supply Voltage
B4 PNK/WHT 1970 Headlamp Low Beam Relay Control
B5 WHT 1080 Park Lamp Relay Control
B6 -- -- Not Used
B7 BLK/WHT 1969 Headlamp High Beam Relay Control
B8 DK GRN 1483 Control Power Control
B9-B11 -- -- Not Used
B12 BLK/WHT 51 Ground

Instrument Panel Module (IPM) C1

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• 12110245
Connector Part Information
• 32-Way F Micro - Pack 100 Series (PNK)
Pin Wire Color Circuit No. Function
C1 ORN 1140 Battery Positive Voltage
C2 BRN 141 Ignition 3 Voltage
C3-C4 -- -- Not Used
C5 GRY/BLK 1598 Interior Lamp Switch Off Signal
C6 PNK/BLK 1597 Interior Lamp Switch On Signal
C7 PPL 1807 Class 2 Serial Data - Primary
C8 PPL 1807 Class 2 Serial Data - Primary
C9 ORN 192 Front Fog Lamp Switch Signal
C10 LT BLU 187 Rear Fog Lamp Switch Signal
C11 LT BLU 1788 Traction Control Switch Signal
C12 LT BLU 1880 HVAC Control Module Data Signal
C13 PPL 1881 HVAC Control Module Clock Signal
C14-C16 -- -- Not Used
D1-D2 -- -- Not Used
D3 BLK 520 Lower Right Air Temperature Sensor Signal
D4-D6 -- -- Not Used
D7 LT GRN 80 Key In Ignition Switch Signal
D8 PPL 1783 Twilight Sentinel Delay Signal
D9-D10 -- -- Not Used
D11 GRY/BLK 754 Blower Motor Speed Control
D12 -- -- Not Used
D13 LT BLU/WHT 1595 Key Cylinder Lamp Control
D14-D15 -- -- Not Used
D16 BLK/WHT 451 Ground

Instrument Panel Module (IPM) C2

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• 12110244
Connector Part Information
• 24-Way F Micro - Pack 100 Series (PNK)
Pin Wire Color Circuit No. Function
A1 GRY 705 5 Volt Reference
A2 YEL/BLK 1814 Lower Mode Door Position Signal
A3 -- -- Not Used
A4 PPL 1838 Recirculation Door Position Signal
A5 LT BLU 733 Air Temperature Door Position Signal
A6 DK BLU 1646 Air Temperature Door Position Signal - Right
A7 YEL 1791 Low Reference
A8 YEL 1318 Mode Door Control
A9 -- -- Not Used
A10 DK GRN 1614 Recirculation Door Control
A11 DK BLU 1199 Air Temperature Door Control
A12 WHT/BLK 1236 Air Temperature Door Control - Right
B1 LT GRN/BLK 735 Ambient Air Temperature Sensor Signal
B2 LT BLU/BLK 590 Drivers Solar Sensor Signal
B3 GRY 1548 Passenger Solar Sensor Signal
B4 DK GRN 734 Inside Air Temperature Sensor Signal
B5 WHT 278 Ambient Light Sensor Signal
B6 BLK 516 Upper Left Air Temperature Sensor Signal
B7 TAN 517 Air Temperature Sensor Signal - Upper Right
B8 YEL 61 Low Reference
B9 BLK 518 Lower Left Air Temperature Sensor Signal
B10 -- -- Not Used
B11 DK GRN 44 Instrument Panel Lamps Dimmer Switch Signal
B12 LT BLU/BLK 1688 5 Volt Reference

Rear Integration Module (RIM) C1

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Connector Part • 12084944

Information • 16 Way F Micro-pack 100 Series (BLK)
Circuit
Pin Wire Color No. Function
A1-A3 -- -- Not Used
A4 PNK 1039 Ignition 1 Voltage
A5 DK BLU/WHT 149 Courtesy Lamp Supply Voltage
Automatic Level Control Position Sensor 5 Volt
A6 GRY 2165
Reference
A7 -- -- Not Used
A8 BLK/WHT 851 Ground
B1 -- -- Not Used
Passenger Heated Seat Control Module Status
B2 DK BLU 2181
Signal
B3 RED/BLK 744 Trunk Adjar Switch Signal
B4 -- -- Not Used
B5 LT BLU/WHT 181 Heated Seat Control Module Status Signal
Automatic Level Control Position Sensor Low
B6 PPL 2185
Reference
B7 -- -- Not Used
B8 BLK/WHT 851 Ground

Rear Integration Module (RIM) C2

Connector Part • 12110206

Information • 24 Way F Micro-pack 100 Series (LT BLU)
Circuit
Pin Wire Color No. Function
A1 BLK 755 RAP Relay Coil Control
A2 YEL 182 Heated Seat Control Module Enable Signal
A3 GRY/BLK 690 Rear Courtesy Lamp Relay Control

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A4 -- -- Not Used
A5 PNK/BLK 1615 Park Brake Relay Control
A6 DK GRN 1399 RAP Relay Coil Supply Voltage
Automatic Level Control Relay Coil Supply
A7 YEL 321
Voltage
A8 YEL 1977 Rear Fog Lamp Relay Control
A9 BRN 2184 Automatic Level Control Position Sensor Signal
A10 GRY 157 Interior Lamp Control
A11 ORN 540 Battery Positive Voltage
A12 PPL 1807 Class 2 Serial Data - Primary
B1 WHT 193 Rear Defog Relay Control
B2 LT BLU 2182 Reverse Lamp Relay Control
B3 WHT 93 Fuel Door Release Relay Control
B4 LT BLU 1344 Trunk Release Relay Control
B5 TAN 2183 Inadvertent Power Relay Control
B6-B7 -- -- Not Used
Automatic Level Control Exhaust Solenoid
B8 WHT 320
Control
B9 -- -- Not Used
B10 GRY 157 Interior Lamp Control
B11 -- -- Not Used
B12 PPL 1807 Class 2 Serial Data - Primary

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Dash Integration Module (DIM)

(1) Dash Integration Module (DIM) C3

(2) Dash Integration Module (DIM) C2
(3) Dash Integration Module (DIM) C1

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Instrument Panel Integration Module (IPM)

(1) Instrument Panel Integration Module (IPM)

(2) Instrument Panel Integration Module (IPM) - C1
(3) Instrument Panel Integration Module (IPM) - C2
(4) C201

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Rear Integration Module (RIM)

(1) Rear Integration Module (RIM) C1

(2) Rear Integration Module (RIM) C2

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Body Control Module (BCM) Programming/RPO

Configuration (DIM)
Procedure to Set Up a Dash Integration Module
(DIM)
Important: The Air Bag Indicator light may remain ON after the DIM Module is replaced and
during the programming procedure for the DIM until after the procedure is completed and the
ignition key is cycled OFF and ON .

After replacement or to reprogram the DIM perform the following procedure:

1. Ensure the scan tool has been updated with the latest software version.
2. Ensure the battery is fully charged.
3. Ensure all modules on the serial data line are connected.
4. Connect a scan tool to the data link connector (DLC).
5. Turn ON the ignition, with the engine OFF.
6. Under the DIM Main Menu, select Special Functions. Under the Special Functions menu, one
of the choices is New VIN.
7. The user selects one of the following:
7.1. New VIN, to continue with the procedure.
7.2. Exit, to go back to Special Functions menu.
8. After the user chooses New VIN, follow the scan tool on screen instructions to edit VIN:
• Press Save to save VIN information.
• Press Done to go back to Special Functions menu.
9. Under the Special Functions menu, one of the choices is Setup SDM Serial Number in DIM.
10. The user selects one of the following:
• Setup SDM Serial Number in DIM, to continue with the procedure.
• Exit, to go back to Special Functions menu.
11. After the user chooses Setup SDM Serial Number in DIM, the scan tool displays a screen as
follows:
• Do you want to set up a Dash Integration Module?
• Press Yes to set up module.
• Press No to Exit.
12. Choose Yes or No.
• If the user selects No, the scan tool display returns to the DIM Special Function Menu.
• If the user selects Yes, the scan tool displays Initializing New Module.
13. Once complete, the scan tool displays Module Initialized.
14. To complete the procedure, select :EXIT: Go to Special Functions Menu.
15. The user selects one of the following:
• Set Options, to continue with the procedure.
• Exit, to go back to Special Functions menu.
16. Under the Set Options menu, the user selects from the following as available:
• Automatic/Manual HVAC Options, to continue with the procedure follow the scan tool on
screen instructions to Select the RPO option configuration.
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• Headlamp Type Option, to continue with the procedure follow the scan tool on screen
instructions to Select the Headlamp Type option configuration.
• LH Drvr. Personalization, to continue with the procedure follow the scan tool on screen
instructions to Select the LH Drvr Personalization option configuration.
• Magna Steer Option, to continue with the procedure follow the scan tool on screen
instructions to Select the RPO option configuration.
• Miscellaneous Options #1, to continue with the procedure follow the scan tool on screen
instructions to Select the RPO option configuration.
• Miscellaneous Options #2, should be turned ON.
• Personalization Option, to continue with the procedure follow the scan tool on screen
instructions to Select the RPO option configuration.
• Point of Sale, to continue with the procedure follow the scan tool on screen instructions to
Select the Point of Sale.
• RH Drvr. Personalization, to continue with the procedure follow the scan tool on screen
instructions to Select the RH Drvr Personalization option configuration.
• Right Hand Drive, to continue with the procedure follow the scan tool on screen
instructions to Select Right Hand Drive option configuration.
• Universal Theft Deterrent, to continue with the procedure follow the scan tool on screen
instructions to Select the RPO option configuration.
• Nav. Module Not Present, to continue with the procedure follow the scan tool on screen
instructions to Select the RPO option configuration.
17. Exit, to go back to Special Functions menu.
18. Cycle the ignition key OFF and ON.

Important: After programming, perform the following to avoid future misdiagnosis:

1. Turn the ignition OFF for 10 seconds.

2. Connect the scan tool to the data link connector.
3. Turn the ignition ON with the engine OFF.
4. Use the scan tool in order to retrieve history DTCs from all modules.
5. Clear all history DTCs.

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Body Control Module (BCM) Programming/RPO

Configuration (IPM)
Procedure to Calibrate an Instrument Panel
Integration Module (IPM)
Ensure the scan tool has been updated with the latest software version.

The following steps should be followed to perform the recalibration update.

1. Ensure the scan tool has been updated with the latest software version.
2. Connect a scan tool to the Data Link Connector (DLC).
3. The ignition should be ON, but the engine should not be operating.
4. Select Instrument Panel Module.
5. Select Special Functions.
6. Select Miscellaneous Test.
7. Select IPM Recalibration.

The scan tool will recalibrate the IPM with the latest version. To verify the proper version has been
installed follow these steps:

1. Select Data Display.

2. Select Module Information.
3. View the calibration ID number. The calibration number must match the version loaded on
the scan tool.

Important: After programming, perform the following to avoid future misdiagnosis:

1. Turn the ignition OFF for 10 seconds.

2. Connect the scan tool to the data link connector.
3. Turn the ignition ON with the engine OFF.
4. Use the scan tool in order to retrieve history DTCs from all modules.
5. Clear all history DTCs.

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Body Control Module (BCM) Programming/RPO

Configuration (RIM)
Procedure to Calibrate a Rear Integration Module
(RIM)
After replacement of the RIM, perform the following procedure to recalibrate the automatic level
control.

1. Ensure the scan tool has been updated with the latest software version.
2. Connect a scan tool to the Data Link Connector (DLC).
3. Turn ON the ignition, with the engine OFF.
4. Under the Chassis Main Menu, select Rear Integration Module.
5. Under the Rear Integration Module Main Menu, select Recalibration.
6. Follow the scan tool on screen instructions to recalibrate the automatic level control.
7. Perform the vehicle personalization settings. Refer to Personalization Description and
Operation in Personalization.

Important: After programming, perform the following to avoid future misdiagnosis:

1. Turn the ignition OFF for 10 seconds.

2. Connect the scan tool to the data link connector.
3. Turn the ignition ON with the engine OFF.
4. Use the scan tool in order to retrieve history DTCs from all modules.
5. Clear all history DTCs.

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Dash Integration Module Replacement

Removal Procedure
1. Before replacing the Dash Integration Module (DIM), record the personaization settings to
transfer to the new module (if they are available).
2. Remove the right closeout/ insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gages and Console.

3. Remove the DIM from the bracket by releasing the tab behind the module.
4. Disconnect the electrical connectors (1) from the DIM (2).

Installation Procedure

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1. Connect the electrical connectors (1) to the DIM (2).

2. Install the Dash Integration Module (DIM) into the bracket.
3. Install the right closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gages and Console.
4. Reprogram the DIM. Refer to Body Control Module (BCM) Programming/RPO Configuration .

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Instrument Panel Module Replacement

Removal Procedure
1. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gages and Console.

2. Remove the fastener (2) from the instrument panel module (IPM).
3. Rotate the IPM up and out of the instrument panel (IP) retainer.
4. Disconnect the electrical connectors from the IPM (1).

Installation Procedure

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1. Connect the electrical connectors to the instrument panel module (IPM) (1).
2. Install the IPM (1) to the instrument panel (IP) retainer by inserting the top tab of the
module into the slot on the IP retainer and rotating down.

3. Install the fastener.

Tighten
Tighten the fastener to 2 N·m (18 lb in).

4. Install the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gages and Console.
5. Reprogram the IPM. Refer to Body Control Module (BCM) Programming/RPO Configuration .

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Rear Integration Body Control Module Replacement

Removal Procedure
1. Before replacing the rear integration module (RIM), record the personalization settings to
transfer to the new module (if they are available).
2. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
3. Remove the rear seat belt buckle anchor bolts.
4. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
5. Move the rear seat back insulator aside.

6. Remove the push pin retainers (1).

7. Disconnect the RIM electrical connectors (3).
8. Remove the RIM (2).

Installation Procedure
1. Install the rear integration module (RIM).

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2. Connect the RIM electrical connectors (3).

3. Install the RIM (2) with the push pin retainers (1).
4. Reposition the rear seat back insulator.
5. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
6. Install the rear seat belt buckle anchor bolts.
7. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
8. Reprogram the RIM. Refer to Body Control Module (BCM) Programming/RPO Configuration .

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Fastener Tightening Specifications

Specification
Application Metric English
Front Fender Fasteners 9 N·m 80 lb in
Headlamp/Fascia Mounting Panel Bracket Fasteners 9 N·m 80 lb in
Headlamp/Fascia Mounting Panel Fasteners 9 N·m 80 lb in
Hood Adjustment Link Fasteners 24 N·m 18 lb ft
Hood Assist Rod Ball Stud Fasteners 9 N·m 80 lb in
Hood Hinge to Body Fasteners 24 N·m 18 lb ft
Hood Hinge to Hood Fasteners 9 N·m 80 lb in
Hood Latch Fasteners 9 N·m 80 lb in
Hood Latch Striker Fasteners 9 N·m 80 lb in
Radiator Support Fasteners 9 N·m 80 lb in
Upper Tie Bar Fasteners 10 N·m 89 lb in

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Hood Adjustment
Fore and Aft Adjustment

1. Loosen the lower hood hinge fasteners (1). Oversized holes allow fore and aft adjustment of
the hood.

2. Install the lower hood hinge fasteners (1).

Tighten
Tighten the fasteners to 24 N·m (18 lb ft).

Up and Down Adjustment

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1. Loosen the adjustment link fasteners (2) on the lower hinge (1).
2. Adjust the hood as necessary.

3. Tighten the adjustment link fastener (2).

Tighten
Tighten the fastener to 24 N·m (18 lb ft).

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4. Adjust the front hood bumpers (1, 2) so that the hood is flush with the fenders.
5. Adjust the hood latch.

6. After the hood adjustment is performed, sufficient load must remain on the front and rear
hood bumpers to eliminate hood flutter. This can be achieved by lowering the hood latch an
additional 3 mm (1/8 in), for front flutter, and raising the rear bumper (2) for rear flutter.

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Hood Replacement
Removal Procedure
1. Open the hood.
2. Using a grease pencil, mark the location of the hinge on the hood assembly.

Notice: When removing body panels, apply tape to corners of panel and adjacent surfaces to
help prevent paint damage.

3. Apply tape to the edges of the hood and the fenders to prevent any paint damage.
4. Remove the hood assist rods (1). Refer to Hood Open Assist Rod Replacement .

5. Remove the fasteners (2) securing the hood to the hood hinge.
6. With the aid of an assistant, remove the hood from the vehicle.

Installation Procedure

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1. With an assistant , position the hood to the vehicle.

2. Align the hinge to the grease pencil marks on the hood.

3. Install the fasteners (2) in order to secure the hood to the hood hinge.

Tighten
Tighten the fasteners (2) to 9 N·m (80 lb in).

4. Install the hood assist rods (1). Refer to Hood Open Assist Rod Replacement .
5. Adjust the hood, if necessary. Refer to Hood Adjustment .
6. Remove the tape from the hood and the fenders.
7. Using touch up paint, touch up any exposed or unpainted surface after the hood is installed.
8. Close the hood.

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Hood Latch Adjustment

Important: Ensure that you have the proper alignment before you tighten the mounting bolts
under the following conditions:
• After removing the hood latch assembly
• After loosening the mounting bolts
• After changing the hood adjustment

1. With the attaching bolts (1) loose, slowly lower the hood onto the latch in order to achieve
the proper cross vehicle adjustment of the hood latch.
2. Raise the hood.

3. Tighten the bolts.

Tighten
Tighten the bolts (1) to 9 N·m (80 lb in).

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Hood Primary and Secondary Latch Replacement

Removal Procedure

1. Open the hood.

2. Remove the bolts (1) that retain the hood latch.

3. Disconnect the hood release cable from the hood latch (1).
4. Remove the hood latch (2).
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Installation Procedure

1. Connect the hood release cable (1) to the hood latch (2).

2. Install the hood latch (2).

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3. Install the bolts (1) in order to retain the hood latch.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

4. Adjust the hood primary latch (2). Refer to Hood Latch Adjustment .

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Hood Primary Latch Release Cable Replacement

Removal Procedure
1. Open the hood.

2. Remove the hood latch. Refer to Hood Primary and Secondary Latch Replacement .
3. Disconnect the hood release cable (1) from the hood latch (2).
4. Tie a piece of string around the hood release cable. This will ease the installation of the hood
release cable through the engine compartment.
5. Remove the front wheelhouse extension. Refer to Wheelhouse Extension Replacement .
6. Remove the front wheelhouse panel. Refer to Wheelhouse Panel Replacement .

© 2014 General Motors Corporation. All rights reserved.

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7. Open the clips (1) retaining the hood release cable (2) to the vehicle.

8. Remove the screws (2) retaining the hood release handle (1) to the vehicle.
9. Disconnect the hood release cable from the hood release handle (1).
10. Tie a piece of string around the hood release cable. This will ease the installation of the hood
release cable through the passenger compartment.

11. Remove the hood release cable grommet (2) from the wheel opening.
12. Remove the hood release cable from the vehicle.

Installation Procedure

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1. Transfer the string to either end of the hood release cable.

2. Route the string and the hood release cable into the passenger compartment.
3. Remove the string from the hood release cable.

4. Connect the hood release cable to the hood release handle (1).
5. Install the fasteners (2) in order to secure the hood release handle (1) to the vehicle.

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6. Position and press the hood release cable grommet (2) into the wheel opening.

7. Pull the string and the hood release cable into the engine compartment.
8. Remove the string from the hood release cable.
9. Position the hood release cable (2) in the clips (3) and close the clips (3).
10. Install the front wheel panel. Refer to Wheelhouse Panel Replacement .
11. Install the front wheelhouse extension. Refer to Hood Latch Adjustment .

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12. Attach the hood release cable (1) to the hood latch (2).
13. Install the hood latch (2). Refer to Hood Primary and Secondary Latch Replacement .
14. Close the hood.

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Hood Primary Latch Striker Replacement

Removal Procedure
1. Open the hood.
2. Mark the location of the hood striker on the underside of the hood.

3. Remove the fasteners retaining the hood striker to the hood.

4. Remove the hood striker from the hood.

Installation Procedure

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1. Position the hood striker to the marks on the underside of the hood.

2. Install the fasteners to retain the hood striker to the hood.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

3. Close the hood.

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Hood Insulator Replacement

Removal Procedure

1. Open the hood.

2. Remove the Front Hood Seal. Refer to Hood Front Seal Replacement .
3. Remove the push in retainers retaining the hood insulator to the hood.
4. Remove the hood insulator from the hood.

Installation Procedure

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1. Install the hood insulator to the hood.

2. Install the push in retainers to retain the hood insulator to the hood.
3. Install the Front Hood Seal. Refer to Hood Front Seal Replacement .
4. Close the hood.

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Hood Open Assist Rod Replacement

Removal Procedure
Caution: When a hood hold open device is being removed or installed, provide alternate
support to avoid the possibility of damage to the vehicle or personal injury.

1. Open and support the hood.

2. Using a small flat bladed tool, release the clip retaining the hood assist rod to the lower assist
rod ball stud.
3. Using a small flat bladed tool, release the clip retaining the hood assist rod to the upper
assist rod ball stud.

Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing
or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will
result.

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4. Remove the hood assist rod (2) from the vehicle.

Installation Procedure

1. Press the hood assist rod (2) onto the upper hood assist rod ball stud (1).
2. Press the hood assist rod (2) onto the lower hood assist rod ball stud (3).
3. Ensure that both clips are fully seated on the hood assist rod (2).
4. Close the hood.

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Hood Open Assist Rod Stud Replacement

Removal Procedure
Caution: When a hood hold open device is being removed or installed, provide alternate
support to avoid the possibility of damage to the vehicle or personal injury.

1. Open and support the hood.

2. Release the clip retaining the hood assist rod to the lower hood assist rod ball stud (1).
3. Remove the lower hood assist rod ball stud (1) from the fender (2).

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4. Release the clip retaining the hood assist rod to the upper hood assist rod ball stud (2).

Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing
or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will
result.

5. Remove the upper hood assist rod ball stud (2) from the hood (1).

Installation Procedure

1. Install the upper hood assist rod ball stud (2) to the hood (1).

Tighten
Tighten the upper hood assist rod ball stud (2) to 9 N·m (80 lb in).

2. Press the hood assist rod onto the upper hood assist rod ball stud (2).
3. Ensure that the clip is fully seated on the hood assist rod.

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4. Install the lower hood assist rod ball stud (1) to the fender (2).

Tighten
Tighten the lower hood assist rod ball stud (1) to 9 N·m (80 lb in).

5. Press the hood assist rod onto the lower hood assist rod ball stud (1).
6. Ensure that the clip is fully seated on the hood assist rod.
7. Close the hood.

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Front Air Deflector Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the retainers (1, 2, 3, 4) from the front air deflector.

3. Remove the front air deflector (5).

Installation Procedure

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1. Install the front air deflector (5).

2. Install the front air deflector retainers (1, 2, 3, 4).
3. Lower the vehicle.

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Front Fender Replacement

Removal Procedure
Notice: When removing body panels, apply tape to corners of panel and adjacent surfaces to
help prevent paint damage.

1. Remove the rocker molding. Refer to Rocker Panel Molding Replacement in Exterior Trim.
2. Remove the air deflector. Refer to Front Air Deflector Replacement .
3. Remove the fascia to fender fasteners. Refer to Front Bumper Fascia Replacement .
4. Remove the fender fasteners (2).
5. Remove the fender (1) from the vehicle.

Installation Procedure

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1. Install the fender (1) to the vehicle.

2. Install the fender fasteners (2).

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

3. Install the fascia to fender fasteners. Refer to Front Bumper Fascia Replacement in Bumpers.
4. Install the air deflector. Refer to Front Air Deflector Replacement .
5. Install the rocker molding. Refer to Rocker Panel Molding Replacement in Exterior Trim.

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Headlamp and Front End Fascia Mount Panel

Replacement
Removal Procedure
1. Remove the front fascia. Refer to Front Bumper Fascia Replacement in Bumpers.
2. Remove both headlamps. Refer to Headlamp Replacement in Lighting Systems.
3. Disconnect the hood release cable from the hood latch. Refer to Hood Primary Latch Release
Cable Replacement .

4. Remove the headlamp/fascia mounting panel stabilizer bars from the vehicle.

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5. Remove the headlamp/fascia mounting panel fasteners from the vehicle.

6. Remove the headlamp/fascia mounting panel from the vehicle.

Installation Procedure

1. Install the headlamp/fascia mounting panel to the vehicle.

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2. Install the headlamp/fascia mounting panel fasteners to the vehicle.

Tighten
Tighten the mounting fasteners to 9 N·m (80 lb in).

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3. Install the headlamp/fascia mounting panel stabilizer bars and fasteners to the vehicle.

Tighten
Tighten the stabilizer fasteners to 9 N·m (80 lb in).

4. Connect the hood release cable to the hood latch. Refer to Hood Primary Latch Release Cable
Replacement .
5. Install both headlamps. Refer to Headlamp Replacement in Lighting Systems.
6. Install the front fascia. Refer to Front Bumper Fascia Replacement in Bumpers.

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Radiator Support Replacement

Removal Procedure

1. Open the hood.

2. Remove the radiator support bracket fasteners (1).
3. Remove the radiator support brackets (2) from the vehicle.

Installation Procedure

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1. Install the radiator support brackets (2) onto the vehicle.

2. Install the radiator support bracket fasteners (1).

Tighten
Tighten the radiator support bracket fasteners to 9 N·m (80 lb in).

3. Close the hood.

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Front End Upper Tie Bar Replacement

Removal Procedure

1. Remove the headlamp/fascia panel support bracket fasteners (1).

2. Remove the headlamp/fascia panel support brackets (5).
3. Remove the radiator support brackets (4). Refer to Radiator Support Replacement .
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
5. Position the power control module (PCM) out of the way.
6. Remove the upper tie bar fasteners (2).
7. Remove the upper tie bar (3) from the vehicle.

Installation Procedure

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1. Install the upper tie bar (3) onto the vehicle.

2. Install the upper tie bar fasteners (2).

Tighten
Tighten the upper tie bar fasteners to 10 N·m (89 lb in).

3. Reposition the PCM back to its original position.

4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
5. Install the radiator support brackets (4). Refer to Radiator Support Replacement .
6. Install the headlamp/fascia panel support brackets (5) .
7. Install the headlamp/fascia panel support bracket fasteners (1).

Tighten
Tighten the headlamp/fascia panel support bracket fasteners to 9 N·m (80 lb in).

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Air Inlet Grille Panel Replacement

Removal Procedure
1. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in
Wipers/Washer Systems.

2. Remove the push in retainer caps from the air inlet grille panel (2, 3, 4, 5, 6, 7, 8, 10).
3. Remove the push in retainers from the air inlet grille panel.
4. Disconnect the washer hose connector.
5. Push the washer hose grommet into the plenum area.
6. Lift the right side of the air inlet grille panel over the wiper arm drive spindles and remove
the panel from the vehicle.

Installation Procedure

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1. Position the washer hose and the washer hose grommet through the hole in the plenum area.
2. Press the washer hose grommet into position and ensure that it is fully seated.
3. Install the air inlet grille panel to the vehicle, positioning four way locating post (1) to cowl.
4. Connect the washer hose connector.
5. Install the air inlet grille panel retainers (2, 3, 4, 5, 6, 7, 8, 10).
6. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in
Wipers/Washer Systems.

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Hood Front Seal Replacement

Removal Procedure

1. Using a common trim pad clip removal tool, carefully work the seal (1) off the hood from side
to side.
2. Remove the front hood seal from the hood.

Installation Procedure

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1. Align the front hood seal (1) and retainers to the hood.
2. Install the seal by pushing the retainers into the hood. Once the seal is fastenend to the hood
be sure that all of the retainers are fully seated in their holes.

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Hood Rear Seal Replacement

Removal Procedure

1. Remove the push-in retainers securing the outer rear hood seal to the body.
2. Remove the outer rear hood seal from the vehicle.

3. Starting on either side, work the center rear hood seal off by pulling it straight away from the
flange.
4. Remove the seal from©the2014vehicle.
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Installation Procedure

1. Install the center rear hood seal to the vehicle by pushing it firmly over the flange.
2. Use the bends in the flange behind the strut towers to align the seal properly.

3. Position the outer rear hood seal to the vehicle.

4. Install the push-in retainers in order to secure the outer rear hood seal to the vehicle.

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Wheelhouse Panel Replacement

Removal Procedure
1. Remove the front wheelhouse panel retainers (1).

2. Remove the wheelhouse panel (2).

Installation Procedure

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1. Install the wheelhouse panel (1).

2. Install the wheelhouse panel retainers (1).

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Wheelhouse Extension Replacement

Removal Procedure

1. Remove the push-in retainers from the wheelhouse extension .

2. Remove the wheelhouse extension from the vehicle.

Installation Procedure

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1. Install the front wheelhouse extension to the vehicle.

2. Install the push-in retainers to the wheelhouse extension.

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Front Fender Insulator Replacement

Removal Procedure
1. Remove the front wheelhouse extension. Refer to Wheelhouse Extension Replacement .
2. Remove the front wheelhouse panel. Refer to Wheelhouse Panel Replacement .

3. Remove the push in retainers (2) from the front fender sound insulator (1).
4. Remove the front fender sound insulator (1) from the vehicle.

Installation Procedure

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1. Install the front fender sound insulator (1) to the vehicle.

2. Install the push in retainers (2) to the front fender sound insulator (1).
3. Install the front wheelhouse panel. Refer to Wheelhouse Panel Replacement .
4. Install the front wheelhouse extension. Refer to Wheelhouse Extension Replacement .

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Cowl Drain Valve Replacement

Removal Procedure
1. Remove the left front wheelhouse panel. Refer to Wheelhouse Panel Replacement .

2. Remove the push in retainer (2) from the cowl drain valve (3).
3. Remove the cowl drain valve (3) from the vehicle.

Installation Procedure

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1. Install the cowl drain valve (3) and push in retainers (2) to the vehicle.
2. Install the front wheelhouse panel. Refer to Wheelhouse Panel Replacement .

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Fastener Tightening Specifications

Specification
Application Metric English
Fuel Filler Door Fasteners 9 N·m 80 lb in
Rear Compartment Lid Hinges to the Body Fasteners 9 N·m 80 lb in
Rear Compartment Lid Latch Fasteners 9 N·m 80 lb in
Rear Compartment Lid Latch Sriker Fasteners 9 N·m 80 lb in
Rear Compartment Lid Lock Cylinder Fasteners 9 N·m 80 lb in
Rear Compartment Lid to the Hinges Fasteners 25 N·m 18 lb ft

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Body Rear End Schematics

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Body Rear End Connector End Views

Table 1: Rear Compartment Lid Release Actuator
Table 2: Rear Compartment Lid Release Switch
Table 3: Valet Switch

Rear Compartment Lid Release Actuator

• 12045813
Connector Part Information
• 4-Way F Metri-pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A BLK/WHT 56 Trunk Release Motor Control
B BLK 1050 Ground
C RED/BLK 744 Trunk Ajar Switch Signal
D ORN/BLK 737 Trunk Lamp Control

Rear Compartment Lid Release Switch

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• 12064993
Connector Part Information
• 6-Way F Metri-pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
5-6 -- -- Not Used
7 BLK/WHT 351 Ground
8 BLK 1576 Trunk Release Switch Signal
9 PNK/WHT 1447 Fuel Door Release Switch Signal
10 YEL 1491 Backlight Lamps Control

Valet Switch

• 12064868
Connector Part Information
• 2-Way M Metri-pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A ORN 3640 Battery Positive Voltage
B BRN 253 Trunk Release Relay Control

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Fuel Tank Filler Door Lock Actuator Replacement

Removal Procedure
1. Open the fuel filler door.
2. Open the rear compartment lid.
3. Route the fuel filler door manual release cable through the opening in the LH side rear
compartment trim panel.
4. Remove the LH side rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .

5. Remove the push pins retaining the fuel filler door actuator to the fuel filler pocket.
6. Remove the fuel filler door actuator from the fuel filler pocket by pushing the actuator
outward from the inside of the rear compartment.

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7. Remove the fuel filler door actuator from the vehicle.

8. Disconnect the electrical connector from the fuel filler door actuator.

Installation Procedure

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1. Connect the electrical connector to the fuel filler door actuator.

2. Route the fuel filler door manual release cable through the hole in the fuel filler pocket.

3. Install the fuel filler door actuator to the fuel filler pocket.

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4. Install the push pins to retain the fuel filler door actuator to the fuel filler pocket.
5. Install the LH side rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .
6. Route the fuel filler door manual release cable through the opening in the LH side rear
compartment trim panel.
7. Close the rear compartment lid.
8. Close the fuel filler door.

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Fuel Tank Filler Door Lock Release Switch Replacement

Removal Procedure

1. Using a small flat bladed tool, gently pry the fuel filler door release switch (1) from the door
trim panel (2).

2. Disconnect the electrical connector (1) from the fuel filler door release switch (2).

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Installation Procedure

1. Connect the electrical connector (1) to the fuel filler door release switch (2).
2. Position the fuel filler door release switch (2) into the opening in the door trim panel.
3. Push downward on the fuel filler door release switch (2) in order to engage the retainer clips.

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Fuel Tank Filler Door Replacement

Removal Procedure
1. Open the fuel filler door.

2. Remove the fuel filler cap tether (3) from the fuel filler door (1).
3. Remove the fuel filler cap (2).

4. Remove the fasteners (1) retaining the fuel filler door (2) to the vehicle.
5. Remove the fuel filler door (2) from the vehicle.
© 2014 General Motors Corporation. All rights reserved.

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6. Check the condition of the fuel filler door bumpers (2). If they are damaged, they should be
replaced.

Installation Procedure

1. If the fuel filler door bumpers (2) are removed, install new fuel filler door bumpers (2).

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2. Install the fuel filler door (2) to the vehicle.

3. Install the fasteners (1) to retain the fuel filler door (2) to the vehicle.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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4. Install the fuel filler cap tether (3) to the fuel filler door (1).
5. Install the fuel filler cap (2).
6. Close the fuel filler door.

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Pressure Relief Valve Replacement

Removal Procedure
1. Remove the right rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .

2. Press the tabs in order to release the pressure relief valve (1) from the quarter panel.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Press the pressure relief valve (1) in order to engage the tabs to the quarter panel.
2. Install the right rear compartment side trim. Refer to Rear Compartment Trim Panel
Replacement .

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Rear Compartment Lid Adjustment

1. Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
2. Perform the front-to-rear lid adjustment at the hinge to rear shelf fasteners.
3. Loosen the hinge fasteners.

4. Align the lid so as to achieve an equal 3 mm +/- 1 mm gap around the entire perimeter of
the rear compartment lid.

Tighten
Tighten the bolts to 24 N·m (18 lb ft).

© 2014 General Motors Corporation. All rights reserved.

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5. Up and down adjustment at the front of the rear compartment lid is achieved by turning the
adjustment screw (1) located on the hinge arms.

This procedure is performed from inside the passenger compartment.

6. Adjust the rear compartment lid flush with the rear quarter panels.
7. Up and down adjustment at the rear of the rear compartment lid is achieved by turning the
overslam bumpers in or out.
8. Adjust the rear compartment lid flush with the rear quarter panels.
9. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.

Torque Rod Adjustment

Tools Required
J 43300 Rear Deck Lid Torsion Rod Adjuster

Caution: When a rear compartment lid hold open device is being removed or installed,
provide alternate support to avoid the possibility of damage to the vehicle or personal injury.

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1. Support the rear compartment lid.

2. Remove the front rear compartment trim. Refer to Rear Compartment Trim Panel
Replacement .
3. Install the J 43300 (1) to the torque rod.

Use a ratchet extension (2) for extra leverage.

4. Adjust the torque rods to 1 of 3 positions in the adjustment bracket for the desired tension.
4.1. Moving the torque rod to a lower notch in the adjustment bracket increases the effort
in raising the lid, but decreases the effort in closing the lid.
4.2. Moving the torque rod to a higher notch in the adjustment bracket decreases the effort
in raising the lid, but increases the effort in closing the lid.

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Rear Compartment Lid Applique Replacement

Removal Procedure

1. Remove the compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
2. Remove the 5 fasteners that retain the applique to the rear compartment lid.
3. Remove the applique from the vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the applique to the rear compartment lid.

2. Install the fasteners (1-5) in order to secure the applique to the rear compartment lid.

Tighten the fasteners in the following order (3, 2, 4, 1, 5).

Tighten
Tighten the fasteners to 5 N·m (44 lb in).

3. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

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Rear Compartment Lid Hinge Replacement

Removal Procedure

1. Remove the rear compartment lid. Refer to Rear Compartment Lid Replacement .
2. Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
3. Remove the torque rods (1) from the rear compartment lid hinges (2). Refer to Rear
Compartment Lid Hinge Torque Rod Replacement .

© 2014 General Motors Corporation. All rights reserved.

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4. Remove the fasteners securing the rear compartment lid hinges to the vehicle.
5. Remove the rear compartment lid hinge from the vehicle.

Installation Procedure

1. Position the rear compartment lid hinges (2) to the vehicle.

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surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the fasteners in order to secure the rear compartment lid hinge to the vehicle.

Tighten
Tighten the fasteners to 24 N·m (18 lb ft).

3. Install the torque rods (1) to the rear compartment lid hinges (2). Refer to Rear
Compartment Lid Hinge Torque Rod Replacement .
4. Install the rear compartment lid. Refer to Rear Compartment Lid Replacement .
5. Adjust the rear compartment lid as necessary.

Refer to Rear Compartment Lid Adjustment .

6. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.

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Rear Compartment Lid Hinge Torque Rod Replacement

Tools Required
J 43300 Rear Deck Lid Torsion Rod Adjuster

Removal Procedure
Caution: When a rear compartment lid hold open device is being removed or installed,
provide alternate support to avoid the possibility of damage to the vehicle or personal injury.

1. Prop open the rear compartment lid in the fully up position.

2. Remove the front rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .
3. Note the location of the torque rod in the adjustment bracket for reinstallation.
4. Use the J 43300 (1) in order to disconnect the torque rod from the adjustment bracket.
4.1. Install the J 43300 (1) over the end of the torque rod.
4.2. Use a ratchet extension (2) for extra leverage.
4.3. Pry rearward, releasing the torque rod from the adjuster bracket.
4.4. Carefully move the J 43300 toward the front of the car releasing the pressure on the
torque rod.
5. Slide the opposite end of torque rod out of the rear compartment hinge.
6. Remove the torque rod from the vehicle.

Installation Procedure
© 2014 General Motors Corporation. All rights reserved.

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1. Install the torque rod into the rear compartment hinge.

2. Use the J 43300 (1) in order to install the torque rod to a notch in the adjustment bracket.
2.1. Install the J 43300 (1) over the end of the torque rod.
2.2. Use a ratchet extension (2) for extra leverage.
2.3. Pry rearward on the J 43300 (1) and install the torque rod into a notch in the
adjustment bracket.
2.4. Remove the J 43300 (1) off the end off the torque rod.
3. Inspect the operating effort of the rear compartment lid.
4. Adjust the torque rods. Refer to Rear Compartment Lid Adjustment .
5. Install the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement .

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Rear Compartment Lid Inner Panel Trim Replacement

Removal Procedure

1. Open the rear compartment lid.

2. Remove the push-in retainers securing the rear compartment lid trim (1) to the rear
compartment lid.
3. Remove the rear compartment lid trim (1) from the compartment lid.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the rear compartment lid trim assembly (1) to the rear compartment inner lid.
2. Install the top 2 push-in retainers (2) first.
3. Install the remaining push-in retainers in order to secure the trim assembly (1) to the inner
lid.
4. Check and assure proper fit to the compartment lid.
5. Check and correct any visible gaps around the perimeter of the rear compartment trim.

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Rear Compartment Lid Interior Release Latch Handle

Replacement
Removal Procedure
The rear compartment lid release handle (2) is not serviced separately from the rear compartment
lid latch (3). Refer to Rear Compartment Lid Latch Replacement .

© 2014 General Motors Corporation. All rights reserved.

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Rear Compartment Lid Latch Replacement (With Inside

Release Handle)
Removal Procedure
1. Remove the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

2. Disconnect the electrical connectors from the lid latch assembly.

3. Remove the latch cable from the back of the lock cylinder (1).
4. Remove the fastener (2) securing the T-handle to the rear compartment lid.
5. Remove the fasteners (3) securing the lid latch assembly to the rear compartment lid.
6. Remove the rear compartment lid interior release handle and latch assembly from the
vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the rear compartment lid interior release handle and latch assembly to the rear
compartment lid.

2. Install the fasteners in order to secure the lid latch assembly to the rear compartment lid.

Tighten
Tighten the fasteners 10.5 N·m (93 lb in).

3. Install the fastener (2) in order to secure the T-handle to the rear compartment lid.
4. Install the latch cable to the back of the lock cylinder (1).
5. Connect the electrical connectors to the lid latch assembly.
6. Adjust the rear compartment lid latch if necessary. Refer to Rear Compartment Lid
Adjustment .
7. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

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Rear Compartment Lid Latch Replacement (w/o Inside

Release Handle)
Removal Procedure
1. Remove the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

2. Disconnect the electrical connectors from the lid latch assembly.

3. Remove the latch cable from the back of the lock cylinder.
4. Remove the fasteners retaining the lid latch assembly to the rear compartment lid.
5. Remove the lid latch assembly.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the lid latch assembly to the rear compartment lid.

2. Install the fasteners in order to retain the lid latch assembly to the rear compartment lid.

Tighten
Tighten the fasteners 10.5 N·m (93 lb in).

3. Connect the electrical connectors to the lid latch assembly.

4. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

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Rear Compartment Lid Latch Striker Replacement

Removal Procedure
1. Remove the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate
Replacement .
2. Remove the rear facia. Refer to Rear Bumper Fascia Replacement in Bumpers.

3. Remove the nuts retaining latch striker from outside the rear compartment.
4. Remove the rear compartment latch striker.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear compartment latch striker.

2. Install the nuts in order retain the latch striker.

3. Adjust the rear compartment latch striker as necessary.

Tighten
Tighten the latch striker nuts to 9 N·m (80 lb in).

4. Install the rear facia. Refer to Rear Bumper Fascia Replacement in Bumpers.
5. Install the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate
Replacement .

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Rear Compartment Lid Lock Cylinder Replacement (L47

Engine/Aluminum Lid)
Removal Procedure

1. Open the rear compartment lid.

2. Remove the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
3. Remove the latch cable from the back side of the lock cylinder.
4. Remove the fasteners (1) retaining the lock cylinder bracket (2) to the lid.
5. Remove the lock cylinder and bracket (2) from the lid.
6. Remove the lock cylinder from the bracket.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the lock cylinder to the bracket (2).

2. Install the bracket and cylinder (2) to the rear compartment lid.

3. Install the fasteners (1) in order to retain the lock cylinder bracket to the lid.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Install the latch cable to the back of the lock cylinder.

5. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
6. Close the lid.

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Rear Compartment Lid Lock Cylinder Replacement (LX5

Engine/Steel Lid)
Removal Procedure

1. Open the rear compartment lid.

2. Remove the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
3. Remove the latch cable assembly from the back of the lock cylinder.
4. Remove the rear compartment lid applique. Refer to Rear Compartment Lid Applique
Replacement .
5. Remove the lock cylinder retaining clip (3) from inside the compartment lid.
6. Remove the lock cylinder from the rear compartment lid.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the lock cylinder (2) into the rear compartment lid.
2. Install the retainer clip (3) to the back side of the rear compartment lid in order to retain the
lock cylinder (2) to the rear compartment lid.
3. Install the rear compartment lid applique. Refer to Rear Compartment Lid Applique
Replacement .
4. Install the latch cable to the back side of the lock cylinder.
5. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
6. Close the rear compartment lid.

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Rear Compartment Lid Release Switch Replacement

Removal Procedure

1. Using a small flat bladed tool, gently pry the rear compartment lid switch (1) from the door
trim panel (2).

2. Disconnect the electrical connector (1) from the rear compartment lid switch (2).

© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure

1. Connect the electrical connector (1) to the rear compartment lid switch (2).
2. Position the rear compartment lid switch (2) into the opening in the door trim panel.
3. Push downward on the rear compartment lid switch in order to engage the retainer clips.

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Rear Compartment Lid Replacement

Removal Procedure

1. Remove the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .
2. Remove the rear compartment lid latch assembly. Refer to Rear Compartment Lid Latch
Replacement .
3. Disconnect the electrical connectors from the rear compartment lid latch assembly.
4. Disconnect the wiring harness from the rear compartment lid (1).
5. Remove the bolts (2, 4) retaining the lid (1) to the hinges (3).
6. Remove the rear compartment lid (1) from the vehicle, with the aid of an assistant.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear compartment lid (1) to the vehicle, with the aid of an assistant.

2. Install the bolts (2, 4) in order to retain the lid (1) to the hinges (3).

Tighten
Tighten the bolts to 24 N·m (18 lb ft).

3. Connect the wiring harness to the rear compartment lid (1).

4. Connect the electrical connectors to the rear compartment lid latch assembly.
5. Install the rear compartment lid latch assembly. Refer to Rear Compartment Lid Latch
Replacement .
6. Install the rear compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement .

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Rear Compartment Lid Weatherstrip Replacement

Removal Procedure

1. Open the rear compartment lid.

2. Pull the weatherstrip (1) from the rear compartment lid pinch-weld flange (2).
3. Lift the weatherstrip (1) over the top of the lid.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the weatherstrip (1) over the top of the rear compartment lid.
2. Press the weatherstrip (1) to the rear compartment pinch-weld flange (2).
3. Insure that the weatherstrip is secured properly to the entire pinch-weld flange.
4. Close the rear compartment lid.

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Rear Compartment Sill Trim Plate Replacement

Removal Procedure

1. Remove the sill plate retainers (1, 2).

2. Pull upward on the sill plate (3) to release the spring clips and remove the sill plate from the
vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear compartment sill plate (3) to the vehicle.

1.1. Align the sill plate spring clips with their slots.
1.2. Push downward and snap the sill plate into place.
2. Install the sill plate retainers (1, 2).

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Rear Compartment Trim Panel Replacement

Removal Procedure
1. Remove the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate
Replacement .

2. Remove the rear compartment floor trim panel retainers.

3. Remove the rear compartment floor trim panel (2).
4. Remove the rear compartment side trim panel retainers.
5. Remove the rear compartment side trim panels (1, 3).

© 2014 General Motors Corporation. All rights reserved.

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6. Remove the rear compartment front trim panel retainers.

7. Remove the rear compartment front trim panel.

Installation Procedure

1. Install the rear compartment front trim panel.

2. Install the rear compartment front trim panel retainers.

3. Install the rear compartment side trim panels (1, 3).

4. Install the rear compartment side trim panel retainers.
5. Install the rear compartment floor trim panel (2).
6. Install the rear compartment floor trim panel retainers.
7. Install the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate

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Replacement .

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Spare Tire Cover Replacement

Removal Procedure

1. Fold back the rear compartment floor trim.

2. Remove the spare tire cover nut.
3. Remove the spare tire cover.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the spare tire cover.

2. Install the spare tire cover nut.
3. Reposition the rear compartment floor trim.

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Wheelhouse Panel Replacement

Removal Procedure

1. Remove the fasteners securing the rear wheelhouse panel to the vehicle.
2. Remove the push in retainers securing the rear wheelhouse panel to the rear fascia.
3. Remove the rear wheelhouse panel from the vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear wheelhouse panel to the vehicle.

2. Install the push in retainers in order to secure the rear wheelhouse panel to the rear fascia.

3. Install the wheelhouse panel retaining fasteners in order to secure the rear wheelhouse panel
to the vehicle.

Tighten
Tighten the wheelhouse panel fasteners to 2 N·m (18 lb in).

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Fastener Tightening Specifications

Specification
Application Metric English
Front Bumper Fascia to the Body 9 N·m 80 lb in
Front Bumper Impact Bar Bracket to the Body 50 N·m 37 lb ft
Front Bumper Impact Bar to the Body 25 N·m 18 lb ft
Front Bumper Impact Bar to the Bracket 25 N·m 18 lb ft
Rear Bumper Fascia to the Body 4 N·m 35 lb in
Rear Bumper Impact Bar to the Body 25 N·m 18 lb ft

© 2014 General Motors Corporation. All rights reserved.

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Front Bumper Fascia Energy Absorber Replacement

Removal Procedure

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
2. Remove the fasteners (1) securing the energy absorber to the fascia, using a # 3 square
drive bit.
3. Remove the energy absorber from the fascia.

Installation Procedure

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1. Align the energy absorber to front bumper fascia.

2. Install the fasteners (1) to secure the energy absorber to the fascia using a # 3 square drive
bit.
3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

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Front Bumper Fascia Replacement

Tools Required
J 36346 Fascia Retainer Remover

Removal Procedure
1. Open the hood.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

3. Use theJ 36346 in order to remove the push pin retainers that retain the front bumper fascia
to the front wheelhouse extensions.
4. Disconnect the electrical connectors at the fog lamps.

© 2014 General Motors Corporation. All rights reserved.

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5. Loosen the captive stud and nuts (2) at the fender.

6. Tap the captive studs (2) up to clear the keyhole slots in the fenders.
7. Remove the fastener (1) from the fender.
8. Use theJ 36346 in order to remove the push pin retainers (3) securing the front bumper
fascia to the upper support panel.

9. Use theJ 36346 in order to remove the push pin retainers (3) securing the front bumper
fascia to the air deflector.
10. Remove the front bumper fascia and the front energy absorber from the front impact bar.
11. Remove the energy absorber from the fascia. Refer to Front Bumper Fascia Energy Absorber
Replacement .
12. Remove the fog lamps from the fascia. Refer to Front Fog Lamp Replacement .

Installation Procedure

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1. Install the fog lamps to the fascia. Refer to Front Fog Lamp Replacement .

2. Install the energy absorber to the front bumper fascia. Refer to Front Bumper Fascia Energy
Absorber Replacement .
3. Hand start the fasteners (1, 2) into the front bumper fascia.
4. Align the front bumper fascia (3) and the front energy absorber to the front impact bar.

5. Insert the fasteners (2) into the keyhole slots in the front fenders.

Tighten
Tighten the fasteners, bolt (1) to 9 N·m (80 lb in).

6. Install the push pin retainers (3) to secure the front bumper fascia to the upper filler panel.

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7. Connect the fog lamp electrical connectors.

8. Install the push pin retainers to secure the front bumper fascia to the front wheelhouse
extensions.

9. Install the push pin retainers to secure the front bumper fascia to the air deflector.
10. Lower the vehicle.
11. Close the hood.

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Front Bumper Impact Bar Bracket Replacement

Removal Procedure
1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
2. Remove the front impact bar. Refer to Front Bumper Impact Bar Replacement .

3. Remove the fastener retaining the rear of the front bumper impact bar bracket.
4. Remove the fasteners retaining the front of the front bumper impact bar bracket.
5. Remove the front bumper impact bar bracket from the vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front bumper impact bar bracket to the vehicle.

2. Install the fasteners to secure the front of the front bumper impact bar bracket.

Tighten
Tighten the fasteners to 50 N·m (37 lb ft).

3. Install the fastener to secure the rear of the front bumper impact bar bracket.

Tighten
Tighten the fastener to 50 N·m (37 lb ft).

4. Install the front impact bar. Refer to Front Bumper Impact Bar Replacement .
5. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

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Front Bumper Impact Bar Replacement

Removal Procedure
1. Open the hood.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

4. Remove the fasteners (3, 4) retaining the front bumper impact bar.
5. Remove the front bumper impact bar.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front bumper impact bar.

2. Loose assemble fastener (4) through the bracket.

3. Install the fasteners to secure the front bumper impact bar to the bracket.

Tighten
Tighten the fasteners (3) first, then (4) to 25 N·m (18 lb ft).

4. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
5. Lower the vehicle.
6. Close the hood.

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Front Bumper Lower Fascia Grille Replacement

Removal Procedure

1. Remove the fastener retaining the outboard edge of the front bumper fascia lower grille to
the front bumper fascia (2).
2. Pull the outer edge of the front bumper fascia lower grille forward and outboard to remove.

Installation Procedure

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1. Insert the tab on the grille into the slot in the fascia.
2. Snap the outboard edge of the grille into the fascia (2).
3. Install the fastener.

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Front License Plate Mount Trim Cover Replacement

Removal Procedure

1. Remove the fasteners (2) from the underside of the front bumper fascia (1).
2. Pull the bottom of the front license pocket cover outward .
3. Pull the license pocket cover downward to remove.

Installation Procedure
1. Insert the tabs on the top of the license pocket cover into the slots in the license pocket of
the fascia.
2. Push the cover upward to engage the tabs.

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3. Align the holes in the license pocket cover to the holes in the front bumper fascia.
4. Install the fasteners (2) into the fascia (1).

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Rear Bumper Fascia Replacement

Tools Required
J 36346 Fascia Retainer Remover

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Use theJ 36346 in order to remove the push pin retainers that retain the rear bumper fascia
to the rear wheelhouse extensions.

© 2014 General Motors Corporation. All rights reserved.

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3. Remove the fastener (4) retaining the rear bumper fascia at the wheelhouse opening.
4. Disconnect the license lamp electrical connector (1).
5. Remove the rear fog lamp bulb socket from the rear fog lamp, if equipped.
6. Open the rear compartment.
7. Remove the rear compartment sill trim. Refer to Rear Compartment Trim Panel Replacement
in Body Rear End.
8. Fold back the rear compartment side trim panels.
9. Remove the fasteners (5) retaining the rear bumper fascia (3) to the quarter panels.
10. Remove the fasteners retaining the fascia (3) to the rear quarter panel.
11. Remove the rear bumper fascia (3) and the energy absorber from the vehicle.
12. Remove the rear fog lamps, if equipped. Refer to Rear Fog Lamp Replacement in Lighting.
13. Remove the energy absorber from the fascia. Refer to Rear Energy Absorber Replacement .

Installation Procedure
1. Install the rear fog lamps, if equipped. Refer to Rear Fog Lamp Replacement in Lighting.
2. Install the energy absorber to the fascia. Refer to Rear Energy Absorber Replacement .

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3. Align the fasteners (2, 4, 5) in the rear bumper fascia (3) to the body.

4. Connect the license lamp electrical connector (2).

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5. Install the fasteners to secure the rear bumper fascia to the rear end panel.

Tighten
Tighten the fasteners to 6 N·m (53 lb in).

6. Install the fasteners (4, 5) to secure the rear bumper fascia (3) to the quarter panels.

Tighten
Tighten the fasteners to 6 N·m (53 lb in).

7. Reinstall the rear compartment side trim panels.

8. Install the rear compartment sill trim. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.
9. Close the rear compartment.

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10. Install the push pin retainers to secure the rear bumper fascia to the rear wheelhouse
extensions.
11. Lower the vehicle.

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Rear Bumper Impact Bar Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .

3. Remove the fasteners retaining the rear bumper impact bar to the body.
4. Remove the rear bumper impact bar from the body.
5. Remove the stud plate (1) from the rear bumper impact bar bracket.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the stud plate (1) into the rear bumper impact bar bracket.
2. Install the rear bumper impact bar to the body.

3. Install the fasteners to secure the rear bumper impact bar to the body.

Tighten
Tighten the fasteners to 25 N·m (18 lb ft).

4. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
5. Lower the vehicle.

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Rear Energy Absorber Replacement

Removal Procedure

1. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .
2. Remove the fasteners (1), using a # 3 square drive bit.
3. Remove the energy absorber from the fascia (2).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Align the energy absorber to the fascia (2).

2. Install the fasteners (1).
3. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .

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Keypad Microphone Signals

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Power and Ground

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VIU and VCU Signals

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Cellular Communication Component Views (2.6)

Rear Compartment, Behind the Rear Seat Back
(w/UE1)

(1) Vehicle Interface Unit (VIU)

(2) OnStar® GPS Antenna Lead
(3) Vehicle Communication Unit (VCU)
(4) S360 and S361
(5) C345 (Body Harness to OnStar® Harness)
(6) OnStar® Cellular Antenna Lead

© 2014 General Motors Corporation. All rights reserved.

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Cellular Communication Connector End Views (2.6)

Inside Rear View Mirror

• 153224871
Connector Part Information
• 16-Way BLK
Pin Wire Color Circuit No. Function
1 -- -- Not Used
2 BARE 814 Drain Wire
3-9 -- -- Not Used
10 GRY 655 Cellular Telephone Microphone Signal
11 DK GRN/WHT 2514 Keypad Signal
12 LT GRN/BLK 2515 Keypad Supply Voltage
13 -- -- Not Used
14 YEL/BLK 2516 Keypad Green LED Signal
15 BRN/WHT 2517 Keypad Red LED Signal
16 -- -- Not Used

Vehicle Interface Unit (VIU) C1

© 2014 General Motors Corporation. All rights reserved.

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• 12110113
Connector Part Information
• 32-Way F Micro-Pack 150 Series RED
Pin Wire Color Circuit No. Function
A1 -- -- Not Used
A2 PPL 1807 Class 2 Serial Data
A3-A5 -- -- Not Used
A6 LT BLU/BLK 659 Cellular Telephone Voice Low Reference
A7 -- -- Not Used
A8 DK BLU 658 Cellular Telephone Voice Signal
A9 BARE 814 Drain Wire
A10 LT BLU 1235 Audio Low Reference
A11 BRN/WHT 2506 Audio Return Signal
A12 DK GRN/WHT 2507 Audio Transmit Signal
A13 BARE 1792 Drain Wire
A14 GRY/BLK 2508 Microphone Signal
A15 BARE 1782 Drain Wire
A16 ORN 2540 Battery Positive Voltage
B1-B8 -- -- Not Used
B9 GRY 655 Cellular Telephone Microphone Signal
B10 BARE 814 Drain Wire
B11 TAN/BLK 2510 OnStar® Serial Data Return
B12 WHT 2511 OnStar® Serial Data (-)
B13 LT BLU/BLK 2512 OnStar® Serial Data (+)
B14 GRY/BLK 2520 Transceiver Low Reference
B15 PPL/WHT 2513 Ignition On Signal
B16 -- -- Not Used

Vehicle Interface Unit (VIU) C2

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• 12110115
Connector Part Information
• 32-Way F Micro-Pack 100 Series (BLU)
Pin Wire Color Circuit No. Function
E1 BLK 1051 Ground
E2-E3 -- -- Not Used
E4 DK GRN/WHT 2514 Keypad Signal
E5 YEL/BLK 2516 Keypad Green LED Signal
E6 LT GRN/BLK 2515 Keypad Supply Voltage
E7-E15 -- -- Not Used
E16 ORN 2240 Battery Positive Voltage
F1 BLK 1051 Ground
F2-F8 -- -- Not Used
F9 BRN/WHT 2517 Keypad Red LED Signal
F10-F15 -- -- Not Used
F16 ORN 2240 Battery Positive Voltage

Vehicle Communication Unit (VCU)

• AMP 205207-1

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Connector Part Information • 25-Way F DB-25 (GRY)

Pin Wire Color Circuit No. Function
1 DK GRN/WHT 2507 Audio Transmit Signal
2 -- -- Not Used
3 GRY/BLK 2520 Transceiver Low Reference
4 ORN 2540 Battery Positive Voltage
5 PPL/WHT 2513 Ignition ON Signal
6 BRN/WHT 2506 Audio Return Signal
7-10 -- -- Not Used
11 LT BLU/WHT 2512 OnStar® Serial Data (+)
12 WHT 2511 OnStar® Serial Data (-)
13 -- -- Not Used
14 BARE 1792 Drain Wire
15 GRY/BLK 2508 Microphone Signal
16-17 -- -- Not Used
18 TAN/BLK 2510 OnStar® Serial Data Return
19-23 -- -- Not Used
24 LT BLU 1235 Audio Low Reference

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Mobile Telephone Antenna Inner Coupling Replacement

Removal Procedure
Important:
• The adhesion promoter must be used to assure adequate bonding of the coupling.
• To obtain maximum adhesion between the new mobile antenna couplings and the glass
surface, the couplings and the glass must be kept dry and above 15°C (60°F) during
the installation. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after
installation. Otherwise the new coupling may come not adhere.
• Do not use using any type of glue, adhesive tapes, etc. to reinstall the original
couplings. Doing so may eliminate the cellular signal transfer through the glass and
reduce the maximum performance of the system, including the air bag deployment
notification.

1. Disconnect the coaxial cable from the inner coupling of the mobile communication antenna.

Notice: If you use a razor blade or other sharp tool in order to remove the adhesives or
foreign objects from the inside of the rear window, use the blade carefully. Damage to the
grid lines may result.

2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on
the inner antenna coupling.

Installation Procedure
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1. Clean the inside of the back glass with an alcohol wipe.

2. Dry the glass thoroughly using a lint free cloth.

Important:
• The adhesion promoter must be used to assure adequate bonding of the coupling.
• Mask off or protect areas before applying the adhesion promoter.

3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the rear
window in the area where you will install the antenna coupling. Follow the Glass Adhesion
Promoter instructions on the product label.

Important:
• The RF connections for the inner antenna coupling should run parallel to the defogger
gridline.
• Align the inner and outer antenna couplings.
• Do not touch the adhesive backing on the antenna coupling.

4. Remove the protective film from the adhesive backing on the inner antenna coupling.

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5. Align the inner antenna coupling to the 4 locating marks on the back glass above the
defogger gridline, or to the existing exterior coupling.

6. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to
ensure proper adhesion to the back glass (4).

Hold pressure on the inner coupling (2) for 10-30 seconds.

7. Ensure that no gaps occur between the couplings (5, 2) and the back glass (4).
8. Connect the coaxial cable to the inner coupling (2).
9. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after
installation.

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Mobile Telephone Antenna Outer Coupling Replacement

Removal Procedure
Important:
• The adhesion promoter must be used to assure adequate bonding of the coupling.
• To obtain maximum adhesion between the new mobile antenna couplings and the glass
surface, the adhesion promoter must be used and the couplings and the glass must be
kept dry and above 15°C (60°F) during the installation. Allow 6-8 hours, at 15°C (60°
F), for the adhesive to cure after installation, otherwise the new couplings may come
off.
• Do not use using any type of glue, adhesive tapes, etc. to reinstall the original
couplings. Doing so may eliminate the cellular signal transfer through the glass and
reduce the maximum performance of the system, including the air bag deployment
notification.

1. Install the inner coupling first if both the inner and the outer coupling are to be replaced.
Refer to Mobile Telephone Antenna Inner Coupling Replacement .

2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on
the outer antenna coupling.

Installation Procedure
© 2014 General Motors Corporation. All rights reserved.

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1. Clean the back glass with an alcohol wipe.

2. Dry the glass thoroughly using a lint free cloth.

Important:
• The adhesion promoter must be used to assure adequate bonding of the coupling.
• Mask off or protect areas before applying the adhesion promoter.

Important:
• Align the inner and outer antenna couplings.
• Do not touch the adhesive backing on the antenna coupling.

4. Remove the protective film from the adhesive backing on the outer antenna coupling.

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5. Align the outer antenna coupling to the inner antenna coupling.

6. Press firmly on all 4 corners, and on the center of the antenna outer coupling (5) in order to
ensure proper adhesion to the back glass (4).

Hold pressure on the outer coupling (5) for 10-30 seconds.

7. Ensure that no gaps occur between the couplings (5, 2) and the back glass (4).
8. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after
installation.

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Mobile Telephone Antenna Replacement

Removal Procedure

1. Disconnect the cellular coaxial cable (1) from the coupling box (2).
2. Mark the cellular antenna location with a grease pencil on the exterior surface of the rear
window.
3. Remove the coupling box from the interior of the rear window using a small wide-bladed
plastic tool in order to release the adhesive.

© 2014 General Motors Corporation. All rights reserved.

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4. Remove the cellular antenna (1) from the exterior of the rear window using a small wide-
bladed plastic tool in order to release the adhesive.

5. Clean the adhesive residue from the rear window using a razor blade, isopropyl alcohol pad
and a clean lint-free cloth.

Installation Procedure

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1. Clean the interior and the exterior surface of the rear window in the cellular antenna
mounting location, using an isopropyl alcohol pad, a clean lint-free cloth and allow to air dry.

Important: Do not attempt to reinstall the original cellular antenna exterior base or interior
coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular
signal through the glass and reduce the maximum performance of the system that includes
air bag deployment notification.

Important: To obtain maximum adhesion between the new cellular exterior base or interior
coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°
C (60°F) during the installation and for the 24 hours immediately following the installation.
Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the
new cellular antenna exterior base or interior coupling coming off.

2. Connect the cellular coaxial cable (1) to the coupling box (2).

Important: Do not touch the adhesive backing.

3. Remove the protective backing from the adhesive backing of the coupling box.
4. Install the new coupling box (2) to the marked location on the interior surface of the rear
window with the cellular coaxial cable toward the outboard side of the vehicle.

Press the coupling box into place until fully seated for approximately 30 seconds.

5. Clean the exterior surface of the rear window in the cellular antenna mounting location, using
an isopropyl alcohol pad and a clean lint-free cloth to remove the grease pencil marks and
allow to air dry.

Important: Do not touch the adhesive backing.

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6. Remove the protective backing from the adhesive backing of the cellular antenna.

Important: Failure to exactly follow the location foot print will result in severe phone and
vehicle audio performance degradation.

7. Install the cellular antenna base (1) to the foot print location of the coupling box on the
exterior surface of the rear window with the cellular antenna mast in a straight up position.

Important: Press firmly around the entire periphery of the coupling base in order to ensure
the wetting out of the adhesive and to eliminate any air bubbles.

8. Press the cellular antenna coupling base into place until fully seated for approximately
30 seconds.
9. Clean the rear window with glass cleaner GM P/N 1050427 (Canadian P/N 992727) or the
equivalent in order to remove any finger prints.

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OnStar GPS Antenna Replacement

Removal Procedure
1. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
2. Remove the forward rear compartment trim. Refer to Rear Compartment Trim Panel
Replacement in Body Rear End.

3. Remove the Global Positioning System (GPS) antenna module push-in fasteners (2).
4. Lower the GPS module (1) to the rear compartment floor.
5. Disconnect the GPS antenna coaxial cable connector from the Communication Interface
Module.
6. Disengage the coaxial cable to the rear shelf carrier retainers.
7. Remove the GPS antenna from the rear shelf carrier.

Installation Procedure

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1. Install the Global Positioning System (GPS) antenna coaxial cable into the retainers in the
rear shelf carrier.
2. Close the cable retainers.
3. Secure the GPS antenna module (1) to the rear shelf carrier with the push-in fasteners (2).
4. Connect the GPS antenna coaxial cable connector to the Communication Interface Module.
5. Install the forward rear compartment trim. Refer to Rear Compartment Trim Panel
Replacement in Body Rear End.
6. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.

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OnStar Vehicle Communication Unit Replacement

Removal Procedure

Important: The vehicle communication unit (VCU) has a specific set of unique numbers that
tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-
digit electronic serial number, are used by the National Cellular Network and OnStar® to
identify the specific vehicle. Because these numbers are tied to the vehicle identification
number of the vehicle, you must never exchange these parts with those of another vehicle.

1. Open the rear compartment lid.

2. Remove the forward rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .
3. Disconnect the cellular coaxial cable (2) from the OnStar® VCU by pulling upward on the
spring loaded snap connector.
4. Disconnect the electrical connector.
5. Remove the VCU (6) by lifting the retainer tab (1).
6. Remove the VCU (6).
7. The old VCU must be returned for core credit.

Installation Procedure
1. Record the 11-digit ESN from the label on the new VCU module.

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2. Install the OnStar® VCU (6) into the module bracket assembly.
3. Connect the electrical connector.
4. Connect the cellular coaxial cable (2) to the VCU (6) until fully seated.
5. Ensure the locking tab (1) is secure to the VCU.
6. Install the forward rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .

Important: After replacing the VCU, you must reconfigure the OnStar® system. Failure to
reconfigure the system will result in an additional customer visit for repair.

7. Reconfigure the OnStar® system. Refer to OnStar Reconfiguration .

8. Close the rear compartment lid.

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OnStar Vehicle Interface Unit Replacement

Removal Procedure
Important: The vehicle interface unit (VIU) has a specific set of unique numbers that tie the
module to each vehicle. These numbers, the 10-digit station identification and the 11-digit
electronic serial number, are used by the National Cellular Network and OnStar® to identify
the specific vehicle. Because these numbers are tied to the vehicle identification number of
the vehicle, you must never exchange these parts with those of another vehicle.

1. Open the rear compartment lid.

2. Remove the forward rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .

3. Disconnect the OnStar® global positioning satellite (GPS) antenna coaxial cable (4) from the
OnStar® VIU (5).
4. Disconnect the 2 electrical connectors.
5. Remove the VIU (5) by lifting the retainer tabs (3) upward.
6. Remove the VIU (5) from the vehicle.
7. The old VIU must be returned for core credit.

Installation Procedure
1. Record the 10-digit STID number from the label on the VIU module.

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2. Install the OnStar® vehicle interface unit (VIU) (5) into the module bracket assembly.

Notice: In order to avoid damage to the circuit board, do NOT over-tighten the thumb
screws. Using your fingers, apply only a light pressure.

3. Connect the 2 electrical connectors.

Tighten
Apply 0.2 N·m (2 lb in) of torque, or less, to the thumb screw electrical connectors.

4. Connect the OnStar® GPS antenna coaxial cable (4) to the VIU (5) until fully seated.
5. Ensure the locking tabs (3) are secure to the VIU.
6. Install the forward rear compartment trim panel. Refer to Rear Compartment Trim Panel
Replacement .

Important: After replacing the VIU, you must reconfigure the OnStar® system. Failure to
reconfigure the system will result in an additional customer visit for repair.

7. Reconfigure the OnStar® system. Refer to OnStar Reconfiguration .

8. Close the rear compartment lid.

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Fastener Tightening Specifications

Specification
Application Metric English
Cruise Control Module Fasteners 9 N·m 80 lb in
Cruise Control Module to Bracket Fasteners 7.5 N·m 66 lb in
Cruise Control Switch Fasteners 2.3 N·m 20 lb in

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| Aurora (VIN G) Service Manual | Body and Accessories | Cruise Control |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 427255

CCM, PCM Controls and Vehicle Speed Input

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Cruise Control Module (CCM)

(1) Throttle Cable

(2) Cruise Control Cable
(3) Cruise Control Module (CCM)

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| Aurora (VIN G) Service Manual | Body and Accessories | Cruise Control |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 427268

Cruise Control Switch, CCM Power and Grounds

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Front Left Side of the Passenger Compartment

(1) Blower Motor Switch

(2) Volume Control Switch
(3) Windshield Wiper Switch
(4) Cruise Control Lever
(5) Seek/Program Switch
(6) Temperature Control Switch

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Cruise Control Connector End Views

Cruise Control Module
.

• 12065425
Connector Part Information
• 10-Way Metri-Pack 150 Series Black
Pin Wire Color Circuit No. Function
A GRY 397 Cruise Control ON Switch Signal
B DK BLU 84 Cruise Control SET/COAST Switch Signal
C GRY/BLK 87 Cruise Control RESUME/ACCEL Switch Signal
D LT GRN 696 Cruise Control Cancel Signal
E BLK 150 Ground
F PNK 639 Ignition 1 Voltage
G WHT 17 Stoplamp Switch Signal
H DK GRN 83 Cruise Control Inhibit Signal
J LT BLU/BLK 396 Cruise Control Engaged Signal
K DK GRN/WHT 817 Vehicle Speed Signal

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Cruise Control Cable Adjustment (w/L47)

1. Disengage adjustment lock (3) on the cruise control cable (2) by pulling the button wings
upward. The cable will move freely in and out of the adjuster body when lock is disengaged.
Do not remove the lock.
2. Assure that the throttle body is in the closed position.
3. Assure the cable adjuster moves freely in adjuster body.
4. Press the lock firmly until fully seated.

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Cruise Control Cable Adjustment (w/LX5)

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Cruise Control Cable Replacement (w/L47)

Removal Procedure

Important: Note the cable routing for replacement.

1. Disconnect the cruise control cable from the throttle body cam (1).
2. Disconnect the cruise control cable from the throttle body bracket.

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3. Twist the cruise control cable housing counterclockwise in order to release the cable housing
from the cruise control module.

4. Disconnect the cruise control cable ball stud (1) from the actuator strip (2) on the cruise
control module.

5. Remove the cable from the retainer (2).

Installation Procedure

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1. Install the cruise control cable ball stud (1) into the slot in the cruise control module actuator
strip (2).
2. Insert the cruise control cable housing into the cruise control module and twist clockwise to
secure.

3. Connect the cruise control cable to the throttle body cam (1).
4. Snap the cable clip (3) to the throttle body bracket.

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5. Install the cable into the retainers (2).

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Cruise Control Cable Replacement (w/LX5)

Removal Procedure

Important: Note the cable routing for replacement.

1. Disconnect the cruise control cable (2) from the throttle body cam.
2. Disconnect the cruise control cable (1) from the throttle body bracket.

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3. Twist the cruise control cable housing counter clockwise in order to release the cable housing
from the cruise control module.

4. Disconnect the cruise control cable ball stud (1) from the actuator strip (2) on the cruise
control module.
5. Remove the cable from the cable retainer.

Installation Procedure

1. Install the cruise control cable ball stud (1) into the slot in the cruise control module actuator

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strip (2).
2. Insert the cruise control cable housing into the cruise control module and twist clockwise to
secure.

3. Connect the cruise control cable (2) to the throttle body cam.
4. Snap the cable clip (1) to the throttle body bracket.
5. Install the cable to the retainers.

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Cruise Control Module Replacement

Removal Procedure
1. Remove the cruise control cable from the cruise control module. Refer to Cruise Control Cable
Replacement .

2. Disconnect the electrical connector (2) from the cruise control module.

3. Remove the module bracket retaining fasteners (1, 3).

4. Remove the cruise control module and bracket assembly (2) from vehicle.
5. Remove the module to bracket
© 2014 fasteners.
General Motors Corporation. All rights reserved.

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6. Remove the module from the bracket.

Installation Procedure

1. Install the cruise control module (2) to the bracket.

2. Install the module to bracket fasteners.

Tighten
Tighten the fasteners to 7.5 N·m (66 lb in).

3. Install the cruise control module and bracket assembly to the vehicle.
4. Install the module retaining fasteners (1, 3).

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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5. Connect the electrical connector (2) to the cruise control module.

6. Install the cruise control cable. Refer to Cruise Control Cable Replacement .
7. Inspect the component operation.

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Cruise Control Release Switch Replacement

Removal Procedure

1. Remove the left insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.
2. Twist the cruise control release switch (5) counter-clockwise and remove from the
bracket (1).
3. Disconnect the electrical connector from the cruise control release switch (5).

Installation Procedure

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Important: When installing the brake pedal switches it is very important that the brake
pedal remain in the full up or at rest position or damage to the brake system and or switch
misadjustment may occur.

1. Connect the electrical connector to the cruise control release switch (5).
2. Install the cruise control release switch (5) into the opening in the bracket (1).
3. Turn the cruise control release switch clockwise until the switch connector is at the 6 o'clock
position.

Important: The release switch assembly and the stoplamp switch assembly cannot be
adjusted until after the brake booster pushrod is assembled to brake pedal assembly.
Incorrect adjustment could cause the cruise control system to not work properly.

4. Adjust the switch. Refer to Cruise Control Cable Adjustment .

5. Install the left insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.

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Cruise Control Switch Replacement

Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or
equipment come in contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle or its components.

1. Remove the steering wheel from the vehicle. Refer to Steering Wheel Replacement in
Steering Wheel Column-Tilt.
2. Turn the steering wheel upside down on a clean flat surface.

3. Remove the access plate covering the back of the switch.

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4. Remove the fasteners (1) retaining the switch (2) to the steering wheel.
5. Disconnect the electrical connector.

Installation Procedure

1. Connect the electrical connector.

2. Position the switch (2) in the opening on the steering wheel.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

3. Install the fasteners (1) to retain the switch (2) to the steering wheel.

Tighten
Tighten the fasteners (1) to 2.30 N·m (20 lb in).

4. Install the access plate.

5. Install the steering wheel. Refer to Steering Wheel Replacement in Steering Wheel Column-
Tilt.

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Cruise Release Switch Adjustment

Important: Do not depress the brake pedal during the adjustment procedure.

1. Insert the release switch (1) into the retainer until the switch is fully seated against the brake
pedal arm.
2. Twist the switch in order to lock the switch into position.

Measure
Measure the distance from the end of the barrel on the switch to the pedal arm, ensure that
the clearance is 1.5 mm to 1.7 mm (1/16 in). If the distance is not correct, perform step 1
and step 2 again.

Measure
The following pedal travel statement may be used in order to inspect for proper adjustment
of the release switch:

• Release switch assembly must be closed at 3.5 mm to 12.5 mm (1/8 in to 1/2 in) brake
pedal travel, measured at the centerline of the brake pedal assembly.
• Nominal actuation of the release assembly contacts is about 4.5 mm (3/16 in).

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Fastener Tightening Specifications

Specification
Application Metric English
Brake Caliper Bleeder Valve 13 N·m 115 lb in
Brake Hose to Caliper Bolt 44 N·m 32 lb ft
Brake Pipe Fitting Tube Nut 15 N·m 11 lb ft
Front Brake Caliper Bracket Bolt 185 N·m 137 lb ft
Front Brake Caliper Pin Bolt 85 N·m 63 lb ft
Park Brake Cable Guide Bolt 24 N·m 18 lb ft
Rear Brake Caliper Bracket Bolt 128 N·m 94 lb ft
Rear Brake Caliper Park Brake Cable Bracket Bolt 43 N·m 32 lb ft
Rear Brake Caliper Pin Bolt 27 N·m 20 lb ft

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Component Specifications
Specification
Application Metric English
Front Brake Pads
l Taper 0.15 mm 0.006 in
Front Brake Rotors
l Rotor Diameter 16 inch Wheels (New) 303.0 mm 11.9 in
l Lateral Runout (New) 0.06 mm 0.002 in
l Thickness Variation (New) 0.025 mm 0.001 in
Front Brake Rotor
l Rotor Thickness (New) 32.20 mm 1.267 in
l Minimum Thickness after Refinish 31.08 mm 1.224 in
l Discard Thickness* 30.7 mm 1.209 in
Rear Brake Pads
l Taper 0.15 mm 0.006 in
Rear Brake Rotors
l Rotor Diameter (New) 281.00 mm 11.06 in
l Lateral Runout (New) 0.06 mm 0.002 in
l Thickness Variation (New) 0.025 mm 0.001 in
l Rotor Thickness (New) 11.00 mm 0.433 in
l Minimum Thickness after Refinish 10.25 mm 0.404 in
l Discard Thickness* 9.00 mm 0.354 in
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not
meet this specification. After refinishing the rotor, replace any rotor that does not meet the
minimum thickness specification.

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Brake Pad Inspection

• l Inspect the brake pads every 9 654 km (6,000 mi).
• l Inspect the brake pads any time that the wheels are removed (tire rotation, etc.).
•

l Inspect both ends of the outer pad by looking in at each end of the caliper. The highest rate
of wear normally occurs at these points. The outboard pad (3) has a wear sensor (1) that will
make noise when the linings wear to the point of needing replacement.
• l Inspect the brake pad thickness on the inner pad in order to ensure that the brake pad has
not worn prematurely. Some inboard brake pads have a thermal layer against the pad,
integrally molded with the pad. Do not confuse this thermal layer with uneven inboard-
outboard pad wear. View the inner brake pad through the inspection hole in the top of the
caliper.

Replace the disc brake pads whenever the thickness of any brake pad is worn to within
0.76 mm (0.030 in) of the pad. In the case of riveted brake pads, replace the pads when the
pad wears to within 0.76 mm (0.030 in) of any rivet head. Replace disc brake pads in axle
sets (front/rear) at the same time.

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Front Disc Brake Pads Replacement

Removal Procedure
1. Remove 2/3 of the brake fluid from the master cylinder.
2. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove the Wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

4. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the
rear of the caliper body and against the outer brake pad.
5. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to
allow the caliper to slide past the brake rotor.
6. Remove the C-clamp from the caliper.

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7. Remove the bottom caliper slide pin.

8. Pivot the caliper body upward.

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9. Remove the inboard and outboard pads from the anchor bracket.

10. Remove and inspect the pad retainers.

11. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the
rear of the caliper body and against an old inner brake pad or a wood block installed against
the caliper piston.
12. Tighten the C-clamp until the caliper piston is compressed completely into the caliper bore.
13. Remove the C-clamp and the old brake pad or wood block from the caliper.

Installation Procedure
Important: Do not attempt to clean away corrosion. Corrosion is typically caused by damaged pin
boots. Refer to Brake Caliper Bracket Overhaul .

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1. Inspect the caliper bolt suspension boots for cuts, tears, or deterioration. If damaged,
replace the pin boots.
2. Inspect the caliper pin bolts for damage or corrosion. Replace if damaged or corroded.
3. Inspect the piston boot for deterioration, replace if damaged. Refer to Front Brake Caliper
Overhaul .

4. Install the brake pad retainers into the brake caliper bracket.

5. Install both brake pads into the brake caliper bracket.

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6. Pivot the caliper down over the brake pads and into the brake caliper bracket.

7. Insert the lower caliper slide pin.

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Tighten
Tighten the caliper slide pin to 85 N·m (63 lb ft).

8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
9. Lower the vehicle.
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10-11 until a firm brake pedal apply is obtained; this will
properly seat the brake caliper pistons and brake pads.
13. Refill the brake fluid. Refer to Master Cylinder Reservoir Replacement .
14. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .

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Rear Disc Brake Pads Replacement

Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a
caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm
(0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the
internal adjusting mechanism and/or the integral park brake mechanism.

4. Disconnect the park brake cable (1) from the brake caliper.
5. Remove the bottom caliper pin bolt.

© 2014 General Motors Corporation. All rights reserved.

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6. Pivot the caliper body (6) upward and support the brake caliper; do NOT disconnect the
hydraulic brake flexible hose from the caliper.
7. Remove the inboard (2) and outboard (3) pads from the brake caliper bracket (5).
8. Remove and inspect the pad retainers (1).

Installation Procedure
Important: Do not attempt to clean away corrosion. Corrosion is typically caused by damaged pin
boots.

1. Inspect the caliper pin bolts and pin boots for cuts, tears, thread damage, or deterioration. If
damaged, replace the pin bolts or boots. Refer to Brake Caliper Bracket Overhaul .
2. Inspect the caliper pin bolts for damage or corrosion. Replace if damaged or corroded. Refer
to Brake Caliper Bracket Overhaul .
3. Inspect the piston boot (3) for deterioration, repair or replace the caliper if damaged. Refer
to Front Brake Caliper Overhaul .

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4. Retract the caliper piston (2) into the caliper bore. Use a spanner type wrench to turn the
piston clockwise until it bottoms out fully in the caliper and align the piston.

5. Install the brake pad retainers (1) into the caliper anchor bracket (5).
6. Install the inboard (2) and outboard (3) brake pads into the brake caliper bracket.
7. Pivot the caliper down over the brake pads and into the brake caliper bracket.

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8. Insert the lower caliper pin bolt.

Tighten
Tighten the caliper pin bolt to 85 N·m (63 lb ft).

9. Connect the park brake cable (1) to the brake caliper.

10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
11. Lower the vehicle.
12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
13. Slowly release the brake pedal.
14. Wait 15 seconds, then repeat steps 12-13 until a firm brake pedal apply is obtained; this will
properly seat the brake caliper pistons and brake pads.
15. Refill the brake fluid. Refer to Master Cylinder Reservoir Replacement .
16. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .

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Brake Pad and Rotor Burnishing

• Burnish the new braking surface after the brake pads have been replaced.
• Burnish the new braking surface after the rotors have been refinished or replaced.
• Burnish the new braking surface by making 20 stops from 48 km/h (30 mph).
• Use medium to firm pressure on the brake pedal. Do not overheat the brakes.

© 2014 General Motors Corporation. All rights reserved.

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Front Brake Caliper Replacement (First Design)

Removal Procedure
1. Remove 2/3 of brake fluid from master cylinder.
2. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.

4. Compress the caliper piston into caliper bore to allow the piston enough clearance to pass by
the bosses on the brake pads.
• Install a large C-clamp over top of the caliper housing and against back of the outboard
pad.
• Slowly tighten C-clamp until piston is pushed into caliper bore far enough to slide caliper
off rotor.

© 2014 General Motors Corporation. All rights reserved.

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5. If the caliper is to be removed for repair, remove the bolt attaching the inlet fitting to the
caliper, and plug the opening in the caliper and/or pipe to prevent fluid loss and
contamination.

6. Remove the caliper pin bolts.

7. Remove the caliper.

Installation Procedure

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1. Install the caliper over the brake pads into the caliper anchor bracket.

2. Install the caliper pin bolts.

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Tighten
Tighten the caliper pin bolts to 85 N·m (63 lb ft).

3. Install the brake hose inlet fitting to the caliper.

Tighten
Tighten the brake hose fitting bolt to 45 N·m (33 lb ft).

4. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .

5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
6. Lower the vehicle.

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Front Brake Caliper Replacement (Second Design)

Removal Procedure
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum
allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the
minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
6. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.

7. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the
rear of the caliper body and against the outer brake pad.
8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to
allow the caliper to slide past the brake rotor.
9. Remove the C-clamp from the caliper.

© 2014 General Motors Corporation. All rights reserved.

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10. Remove the brake hose to caliper bolt attaching the brake hose to the brake caliper.
11. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the
brake caliper and/or the brake hose end.
12. Plug the opening in the brake caliper and pipe to prevent fluid loss and contamination.

Important: Note the location of the caliper pin bolts. The upper caliper pin bolt, has a
bushing as part of the assembly. The lower caliper pin bolt, is a solid design pin bolt.

13. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The upper caliper
pin, has a bushing as part of the assembly. The lower caliper pin bolt , is a solid design pin
bolt .
14. Remove the caliper (2) from the rotor and the caliper bracket (3).

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15. Inspect the caliper bolt boots in the caliper bracket for the following conditions:
• Cuts
• Tears
• Deterioration
• Replace any damaged the caliper bolt boots.

Installation Procedure
1. If reusing the brake caliper pin bolts and retainers, wipe the old grease from the brake
caliper pin bolts and retainers with a clean shop towel.

Important: DO NOT apply lubricant to the brake pad hardware.

2. Apply NIGLUBE® grease to the brake caliper pin bolts. It is not necessary to apply lubricant
to the brake pad hardware or the threads of the pin bolts.

3. Install the brake caliper (2) over the brake pads into the brake caliper bracket (3).

Important: The upper caliper pin, has a bushing as part of the assembly. The lower caliper
pin, a solid design pin bolt.

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4. Install the caliper pin bolts (1). The upper caliper pin bolt, has a bushing as part of the
assembly. The lower caliper pin bolt, a solid design pin bolt. Ensure that the bolt boots fit
securely around the caliper pin bolts. If the boots are damaged, they must be replaced.

Tighten
Tighten the brake caliper pin bolts to 85 N·m (63 lb ft).

Important: Install NEW copper brake hose gaskets.

5. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.

6. Install the brake hose to caliper bolt to the brake caliper.

Tighten

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Tighten the brake hose to caliper bolt to 45 N·m (33 lb ft).

7. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel
distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 9-10 until a firm brake pedal is obtained. This will
properly seat the brake caliper pistons and brake pads.
11. Remove the 2 wheel lug nuts retaining the rotor to the hub.
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
13. Lower the vehicle.

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Rear Brake Caliper Replacement

4. Remove the park brake cable from the caliper.

5. If the caliper is to be removed for repair, remove the bolt attaching the inlet fitting to the
caliper, and plug the opening in the caliper and/or pipe to prevent fluid loss and
contamination.
6. Remove the caliper pin bolt.
7. Remove the caliper.

Installation Procedure
1. Install the caliper over the brake pads into the brake caliper bracket.

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requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the caliper pin bolts.

Tighten
Tighten the caliper pin bolts to 85 N·m (63 lb ft).

3. Install the brake hose inlet fitting to the caliper.

Tighten
Tighten the brake hose fitting bolt to 45 N·m (33 lb ft).

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4. Install the park brake cable (1) to the caliper.

5. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
7. Lower the vehicle.

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Brake Caliper Inspection

Check the calipers for outward signs of leaking fluid and cracked or damaged piston boots. Also,
check for excessive corrosion in the brake pad guiding surface. All other types of caliper inspections
should be performed during unit repair.

© 2014 General Motors Corporation. All rights reserved.

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Front Brake Caliper Overhaul

Tools Required
Caliper Piston Seal Installer

1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement .

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.

Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just
enough air to ease the pistons out of the bores. If the pistons are blown out, even with the
padding provided, it may be damaged.

2. Remove the caliper piston by directing low pressure compressed air into the brake caliper
through the fluid inlet hole.

© 2014 General Motors Corporation. All rights reserved.

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Important: Care must be used when removing the piston boot and seal from the caliper.
Use a small plastic or wood tool for removal.

3. Remove the piston boot (2) from the caliper (1).

4. Remove the piston seal (4) from the caliper (1).
5. Remove the bleeder valve (5) and cap (6) from the caliper (1).
6. Clean all of the parts. Use clean denatured alcohol.
7. Dry all of the parts with low pressure non-lubricated filtered air.
8. Blow out all of the passages in the caliper body and the bleeder valve.
9. Inspect all of the parts as follows:
• Piston - Inspect for scoring, nicks, cracks, wear, or corrosion. Replace the piston if any
damage is found.
• Caliper Bore - Inspect for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to
polish out light corrosion. Otherwise, replace the caliper. Do not hone the caliper bore.
• Seal groove - Inspect for nicks or burrs in the seal groove in the caliper bore. If found,
replace the caliper.

10. Install the bleeder valve cap and bleeder valve into the caliper.

Tighten
Tighten the bleeder valve to 13 N·m (115 lb in).

11. Install the new piston seal. Lubricate the seal with new Delco Supreme 11® (GM
P/N 12377967) or equivalent brake fluid before installing.

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12. Install the new piston boot over the piston.

13. Using the J 35777 fully seat the boot in the caliper.
14. Install the caliper onto the vehicle. Refer to Front Brake Caliper Replacement .

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Rear Brake Caliper Overhaul

1. Remove the rear caliper from vehicle. Refer to Rear Brake Caliper Replacement .
2. Remove piston and piston boot by turning the piston (2) counterclockwise with a spanner
type wrench.

Important: Do not use a metal tool for removal of the boot ring or piston seal.

© 2014 General Motors Corporation. All rights reserved.

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3. Remove the boot ring from the groove in the caliper bore with a small wooden or plastic tool.

4. Remove the piston seal with a small wooden or plastic tool.

5. Remove the piston boot from the piston.

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6. Remove the bleeder valve from the caliper body.

Important: The park brake lever, lever return spring and seal are the only components in
the park brake mechanism that can be removed or replaced. Do not disassemble the park
brake mechanism. Replace the caliper if the park brake is damaged or inoperative.

7. Replace the lever return spring if damaged.

Important: Replace the caliper piston if any of the internal parts are damaged.

8. The brake caliper piston is replaced as an assembly.

9. Clean all of the parts with denatured alcohol.

10. Dry all of the parts with dry filtered compressed air.

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11. Blow out all of the passages in the caliper body and the bleeder valve.

Important: The piston sliding surface is plated. Do not polish with emery paper.

12. Inspect the piston for scoring, rust , wear, damage, or presence of foreign objects. Replace
the piston if any of these conditions have occurred.

Important: Use new brake fluid to clean the caliper cylinder, do not use mineral oil.

Minor damage from light rust or foreign objects may be eliminated by polishing the cylinder
surface with a fine emery paper.

13. Inspect the inside surface of the cylinder for scoring, rust, wear, damage, or presence of
foreign objects. Replace the caliper body if any of these conditions have occurred.
14. Install the bleeder valve in the caliper body.

15. Lubricate the new piston seal with clean brake fluid .
16. Install the piston seal in the caliper bore.

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17. Install the new boot on the piston.

18. Screw the piston (2) into the caliper body (1) with a spanner type wrench.

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19. Install the boot ring inside the caliper counterbore against the piston boot.
20. Install the caliper onto the vehicle. Refer to Rear Brake Caliper Replacement .

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Front Brake Caliper Bracket Replacement

Removal Procedure
1. Remove the caliper. Refer to Front Brake Caliper Replacement .
2. Remove the brake pads from the brake caliper bracket.

3. Remove the brake caliper bracket bolts (1).

4. Remove the brake caliper bracket.

Installation Procedure
Important: Apply a few drops of GM Loctite™ or equivalent to the threads of the brake caliper
bracket bolts before installing or replace the bolts with new pre-coated bolts.

© 2014 General Motors Corporation. All rights reserved.

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1. Install the brake caliper bracket to the steering knuckle.

2. Install the brake caliper bracket bolts (1).

Tighten
Tighten the brake caliper bracket bolts to 185 N·m (137 lb ft).

3. Install the brake caliper. Refer to Front Brake Caliper Replacement .

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Rear Brake Caliper Bracket Replacement

Removal Procedure
1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement .
2. Remove the brake pads from the brake caliper bracket.

3. Remove the brake caliper bracket bolts (1).

4. Remove the brake caliper bracket.

Installation Procedure
Important: Apply a few drops of GM Loctite™ or equivalent to the threads of the brake caliper
bracket bolts before installing or replace the bolts with new pre-coated bolts.

© 2014 General Motors Corporation. All rights reserved.

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1. Install the brake caliper bracket to the lower control arm.

2. Install the brake caliper bracket bolts (1).

Tighten
Tighten the brake caliper bracket bolts to 128 N·m (94 lb ft).

3. Install the brake caliper. Refer to Rear Brake Caliper Replacement .

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Brake Caliper Bracket Overhaul

1. Remove the brake caliper. Refer to Front Brake Caliper Replacement or Rear Brake Caliper
Replacement .
2. Remove the brake caliper bracket. Refer to Front Brake Caliper Bracket Replacement or Rear
Brake Caliper Bracket Replacement .
3. Mount the brake caliper bracket (13) in a vise.
4. Remove the pin bolt boots (4) from the brake caliper bracket (13).

5. Remove the bushings (2) from the brake caliper bracket mounting bores. Use a screwdriver
or punch to bend the ©
bushings inward
2014 General and
Motors extract bushings
Corporation. with needle nose pliers.
All rights reserved.

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Important:
• Clean all parts with clean denatured alcohol. Dry with non-lubricated compressed air.
• Inspect the brake caliper bracket for cracks. If cracked, replace bracket.

6. Lubricate and install new bushings into bracket mounting bores.

7. Lubricate and install new pin bolt boots onto the brake caliper bracket.
8. Install the brake caliper bracket onto the vehicle. Refer to Front Brake Caliper Bracket
Replacement or Rear Brake Caliper Bracket Replacement .
9. Install the brake caliper. Refer to Front Brake Caliper Replacement or Rear Brake Caliper
Replacement .

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Brake Rotor Replacement

Removal Procedure
Tools Required
J 42450-A Hub Cleaning Kit

1. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
3. Remove the brake caliper. Refer to Front Brake Caliper Replacement or Rear Brake Caliper
Replacement .
4. Remove the brake caliper bracket from the steering knuckle (front) or the lower control arm
(rear). Support the caliper assembly away from the rotor. Refer to Front Brake Caliper
Bracket Replacement or Rear Brake Caliper Bracket Replacement .
5. Remove the brake rotor.

Installation Procedure
Important: Whenever the rotor has been separated from the wheel bearing flange, clean any rust
or contaminants from the wheel bearing flange and the brake rotor mating surfaces. Failure to do
this may result in increased lateral runout of the rotor, and brake pulsation.

1. Use the J 42450-A in order to clean the mating surfaces on the rotor and the wheel bearing
flange.
2. Install the rotor over the wheel studs onto the wheel bearing flange.
3. Install the brake caliper bracket assembly. Refer to Front Brake Caliper Bracket Replacement
or Rear Brake Caliper Bracket Replacement .
4. Install the brake caliper. Refer to Front Brake Caliper Replacement or Rear Brake Caliper
Replacement .
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
6. Lower the vehicle.

© 2014 General Motors Corporation. All rights reserved.

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Brake Rotor Refinishing

Tools Required
• J 42450-A Hub Cleaning Kit
• J 41013 Rotor Resurfacing Kit

Important: DO NOT refinish the brake rotors in order to correct any of the following conditions:
• Brake noise, such as a growl or squeal
• Premature brake lining wear
• Superficial corrosion of the rotor braking surface
• Rotor discoloration
Refinish the brake rotors ONLY when one or more of the following conditions exist:
• Severe scoring of the rotor braking surface (groove depth in excess of specification
• Brake pulsation that is caused by the following conditions:
- Lateral runout in excess of specification
- Brake rotor thickness variation in excess of specification
- Corrosion or pitting that is deeper than the rotor braking surface

Notice: Whenever the brake rotor has been separated from the wheel bearing flange, clean
any rust or foreign material from the mating surface of the rotor and flange with the J 42450
hub cleaning kit. Failure to do this may result in increased lateral runout of the rotor and
brake pulsation.

1. Use the J 42450-A in order to clean the wheel bearing and the wheel bearing hub.
2. Use a micrometer in order to measure the thinnest point of the brake rotor. If the thinnest
point of the brake rotor exceeds the brake rotor minimum thickness, do NOT refinish the
brake rotor. Replace the brake rotor.
3. Use the J 41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake
rotor flange.
4. Refinish the brake rotor. Refer to the brake lathe manufacturer's operating instructions.

Important: Failure to obtain the best possible surface finish may cause poor braking.

5. After machining the rotor, use 120-grit aluminum oxide sandpaper and, if available, a non-
directional rotor finisher in order to create a non-directional braking surface.
6. Clean the braking surfaces with GM P/N 12377981, or with an equivalent brake parts cleaner.

© 2014 General Motors Corporation. All rights reserved.

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Fastener Tightening Specifications

Specification
Application Metric English
Check Link Fasteners 9 N·m 80 lb in
Door Control Module Fasteners 7 N·m 62 lb in
Door Latch Fasteners 10 N·m 90 lb in
Door Striker Fasteners 28 N·m 21 lb ft
Energy Absorber Fastener 2 N·m 18 lb in
Front Window Channel Fasteners 9 N·m 80 lb in
Hinge-to-Body Fasteners 35 N·m 26 lb ft
Hinge-to-Door Fasteners 34 N·m 24 lb ft
Inside Door Handle Fasteners 2 N·m 18 lb in
Mirror Fasteners 9 N·m 80 lb in
Outside Door Handle Fasteners 7 N·m 62 lb in
Rear Door Stationary Window Division Post Fastener 9 N·m 80 lb in
Upper Auxiliary Weatherstrip Screws 2 N·m 18 lb in
Window Clamp Fasteners 11 N·m 95 lb in
Window Motor Fasteners 4 N·m 35 lb in
Window Regulator Fasteners 9 N·m 80 lb in

© 2014 General Motors Corporation. All rights reserved.

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Driver Door Lock Actuator and Driver Door Lock Switch

© 2014 General Motors Corporation. All rights reserved.

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Driver Door Module (DDM) Inputs/Outputs

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Driver Door Module (DDM) Power and Ground

© 2014 General Motors Corporation. All rights reserved.

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Driver Door Switch Assembly

© 2014 General Motors Corporation. All rights reserved.

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Driver Outside Rearview Mirror (W/A45)

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Driver Outside Rearview Mirror

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Front Passenger Door Module (FPDM) Inputs/Outputs

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Front Passenger Outside Rearview Mirror (W/A45)

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Front Passenger Outside Rearview Mirror

© 2014 General Motors Corporation. All rights reserved.

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Front Passenger Window Switch and Window Motor

© 2014 General Motors Corporation. All rights reserved.

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Heated Mirrors

© 2014 General Motors Corporation. All rights reserved.

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Left Rear Door Module (LRDM) Power, Ground and I/O

© 2014 General Motors Corporation. All rights reserved.

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Left Rear Window Switch and Window Motor

© 2014 General Motors Corporation. All rights reserved.

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Passenger Door Lock Actuator and Door Lock Switch

© 2014 General Motors Corporation. All rights reserved.

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Passenger Door Module (PDM) Power and Ground

© 2014 General Motors Corporation. All rights reserved.

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Power Door Serial Data

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Rear Door Lock Actuator

© 2014 General Motors Corporation. All rights reserved.

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Right Rear Door Lock Actuator

© 2014 General Motors Corporation. All rights reserved.

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Right Rear Door Module (RRDM) Power, Ground and

I/O

© 2014 General Motors Corporation. All rights reserved.

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Right Rear Window Switch and Window Motor

© 2014 General Motors Corporation. All rights reserved.

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Power Door Systems Connector End Views

Table 1: Door Lock Actuator -- Driver C1
Table 2: Door Lock Actuator -- Driver C2
Table 3: Door Lock Actuator -- LR C1
Table 4: Door Lock Actuator -- LR C2
Table 5: Door Lock Actuator -- Front Passenger C1
Table 6: Door Lock Actuator -- Front Passenger C2
Table 7: Door Lock Actuator -- RR C1
Table 8: Door Lock Actuator -- RR C2
Table 9: Door Lock Cylinder Switch -- Driver (w/UA6)
Table 10: Door Lock Cylinder Switch -- Front Passenger (w/UA6)
Table 11: Door Lock Switch -- Driver
Table 12: Door Lock Switch -- Front Passenger
Table 13: Driver Door Module (DDM) C1
Table 14: Driver Door Module (DDM) C2
Table 15: Driver Door Module (DDM) C3
Table 16: Driver Door Module (DDM) C4
Table 17: Driver Door Switch Assembly (DDSA)
Table 18: Front Passenger Door Module (FPDM) C1
Table 19: Front Passenger Door Module (FPDM) C2
Table 20: Front Passenger Door Module (FPDM) C3
Table 21: Front Passenger Door Module (FPDM) C4
Table 22: Left Rear Door Module (LRDM) C1
Table 23: Left Rear Door Module (LRDM) C2
Table 24: Right Rear Door Module (RRDM) C1
Table 25: Right Rear Door Module (RRDM) C2
Table 26: Window Motor -- Driver
Table 27: Window Motor -- Front Passenger
Table 28: Window Motor -- LR
Table 29: Window Motor -- RR
Table 30: Window Switch -- Front Passenger
Table 31: Window Switch -- LR
Table 32: Window Switch -- RR

Door Lock Actuator -- Driver C1

© 2014 General Motors Corporation. All rights reserved.

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• 12162189
Connector Part Information
• 4-Way F Metri-pack 150.2 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 126 Left Front Door Open Switch Signal
B GRY/BLK 745 Left Front Door Ajar Switch Signal
C -- -- Not Used
D BLK/WHT 351 Ground

Door Lock Actuator -- Driver C2

• 15300008
Connector Part Information
• 2-Way F Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 694 Driver Door Lock Actuator Unlock Control
B GRY 295 Door Lock Actuator Lock Control

Door Lock Actuator -- LR C1

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Connector Part • 12162189

Information • 4-Way F Metri-pack 150.2 Series Pull to Seat (BLK)
Circuit
Pin Wire Color No. Function
Driver Door Ajar Switch Signal Door Open Switch
A DK BLU 49
Signal
B LT BLU/BLK 747 Left Rear Door Ajar Switch Signal
C -- -- Not Used
D BLK/WHT 751 Ground

Door Lock Actuator -- LR C2

• 15300008
Connector Part Information
• 2-Way F Metri-pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 294 Door Lock Actuator Unlock Control
B GRY 295 Door Lock Actuator Lock Control

Door Lock Actuator -- Front Passenger C1

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Connector Part • 12162189

Information • 4-Way F Metri-pack 150.2 Series (BLK)
Circuit
Pin Wire Color No. Function
A BLK/WHT 451 Ground
B -- -- Not Used
C BLK/WHT 746 Right Front Door Ajar Switch Signal
Driver Door Ajar Switch Signal Door Open Switch
D DK BLU 49
Signal

Door Lock Actuator -- Front Passenger C2

• 15300027
Connector Part Information
• 2-Way M Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 294 Door Lock Actuator Unlock Control
B GRY 295 Door Lock Actuator Lock Control

Door Lock Actuator -- RR C1

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Connector Part • 12162189

Information • 4-Way F Metri-pack 150.2 Series (BLK)
Circuit
Pin Wire Color No. Function
A BLK/WHT 651 Ground
B -- -- Not Used
C LT GRN/BLK 748 Right Rear Door Ajar Switch Signal
Driver Door Ajar Switch Signal Door Open Switch
D DK BLU 49
Signal

Door Lock Actuator -- RR C2

• 15300008
Connector Part Information
• 2-Way M Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 294 Door Lock Actuator Unlock Control
B GRY 295 Door Lock Actuator Lock Control

Door Lock Cylinder Switch -- Driver (w/UA6)

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• 12052642
Connector Part Information
• 2-Way F Metri-pack 150 Series (GRN)
Pin Wire Color Circuit No. Function
A LT GRN 262 Driver Door Key Switch Signal
B BLK/WHT 351 Ground

Door Lock Cylinder Switch -- Front Passenger

(w/UA6)

• 12052642
Connector Part Information
• 2-Way F Metri-pack 150 Series (GRN)
Pin Wire Color Circuit No. Function
A LT GRN 262 Driver Door Key Switch Signal
B BLK/WHT 451 Ground

Door Lock Switch -- Driver

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• 12124997
Connector Part Information
• 5-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A YEL 1491 Backlight Lamps Control
B -- -- Not Used
C BLK/WHT 351 Ground
D RED/BLK 780 Driver Door Lock Switch Lock Signal
E ORN/BLK 781 Driver Door Lock Switch Unlock Signal

Door Lock Switch -- Front Passenger

• 12124997
Connector Part Information
• 5-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A YEL 1491 Backlight Lamps Control
B -- -- Not Used
C BLK/WHT 451 Ground
D LT BLU 244 Passenger Door Lock Switch Lock Signal
E DK BLU 245 Passenger Door Lock Switch Unlock Signal

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Driver Door Module (DDM) C1

• 12084944
Connector Part Information
• 16-Way F Micro-pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
A1 YEL 1491 Backlight Lamps Control
A2-A3 -- -- Not Used
A4 TAN/WHT 2076 Power Door Serial Data
A5 BLK/WHT 351 Ground
A6 PPL 1807 Class 2 Serial Data (Primary)
A7 ORN 640 Battery Positive Voltage
A8 ORN 640 Battery Positive Voltage
B1-B3 -- -- Not Used
B4 TAN/WHT 2076 Power Door Serial Data
B5 BLK/WHT 351 Ground
B6 PPL 1807 Class 2 Serial Data (Primary)
B7-B8 -- -- Not Used

Driver Door Module (DDM) C2

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• 15324258
Connector Part Information
• 8-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
1 LT GRN 262 Driver Door Key Switch Signal
2 TAN 126 Left Front Door Open Switch Signal
3 GRY/BLK 745 Left Front Door Ajar Switch Signal
4 BLK/WHT 351 Ground
5 -- -- Not Used
6 GRY 295 Door Lock Actuator Lock Control
7 TAN 694 Driver Door Lock Actuator Unlock Control
8 BLK/WHT 351 Ground

Driver Door Module (DDM) C3

• 12052856
Connector Part Information
• 4-Way F Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A ORN 1040 Battery Positive Voltage
B BRN 165 Power Window Motor Left Front Down Control
C DK BLU 164 Power Window Motor Left Front Up Control
D BLK 350 Ground

Driver Door Module (DDM) C4

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• AMP Connector 17404-5-2

Connector Part Information
• 12-Way (BLK)
Pin Wire Color Circuit No. Function
A -- -- Left Mirror Vertical Position Sensor Signal
B -- -- Left Mirror Horizontal Position Sensor Signal
C-D -- -- Not Used
E -- -- Low Reference
F -- -- Left Mirror Heating Element Low Reference
G -- -- Left Mirror Motor LEFT
H -- -- Left Mirror Heating Element Supply Voltage
J -- -- Left Mirror Motor RIGHT
K -- -- Left Mirror Motor DOWN
L -- -- Left Mirror Motor UP
M -- -- 5 V Reference

Driver Door Switch Assembly (DDSA)

• 12047531
Connector Part Information
• 10-Way F Micro-pack 100 Series (BLK)

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Pin Wire Color Circuit No. Function

1 BLK 1576 Trunk Release Switch Signal
2 PPL 616 Memory 2 Switch Signal
3 WHT 615 Memory 1 Switch Signal
4 PNK/WHT 1447 Fuel Door Release Switch Signal
5 YEL 1491 Backlight Lamps Control
6 ORN/BLK 781 Driver Door Lock Switch Unlock Signal
7 RED/BLK 780 Driver Door Lock Switch Lock Signal
8 BLK/WHT 351 Ground
9 ORN 640 Battery Positive Voltage
10 TAN/WHT 2076 Power Door Serial Data

Front Passenger Door Module (FPDM) C1

• 12162820
Connector Part Information
• 20-Way F Metri-pack Mixed Series (BLK)
Pin Wire Color Circuit No. Function
1 -- -- Not Used
2 PNK 2145 Air Temperature Switch Signal - Right
3 PPL 2146 Low Reference
4 BLK/WHT 451 Ground
5 LT BLU 244 Passenger Door Lock Switch Lock Signal
6 DK BLU 245 Passenger Door Lock Switch Unlock Signal
7-10 -- -- Not Used
11 ORN 740 Battery Positive Voltage
12 DK GRN 1184 Power Window Switch Right Front Up Signal
13 BRN 501 Power Window Switch Right Front Down Signal
14 BLK/WHT 451 Ground
15 TAN/WHT 2076 Power Door Serial Data
16 - 19 -- -- Not Used

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20 YEL 1491 Backlight Lamps Control

Front Passenger Door Module (FPDM) C2

Connector Part • 15324258

Information • 8-Way F Metri-pack 150 Series (BLK)
Circuit
Pin Wire Color No. Function
1 LT GRN 262 Door Key Switch Signal
Driver Door Ajar Switch Signal Door Open Switch
2 DK BLU 49
Signal
3 BLK/WHT 746 Right Front Door Ajar Switch Signal
4 BLK/WHT 451 Ground
5 -- -- Not Used
6 GRY 295 Door Lock Actuator Lock Control
7 TAN 294 Door Lock Actuator Unlock Control
8 BLK/WHT 451 Ground

Front Passenger Door Module (FPDM) C3

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• 15324258
Connector Part Information
• 4-Way Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A ORN 1040 Battery Positive Voltage
B BRN 667 Power Window Motor Right Front Down Control
C DK BLU 666 Power Window Motor Right Front Up Control
D BLK 450 Ground

Front Passenger Door Module (FPDM) C4

• AMP Connector 17404-5-2

Connector Part Information
• 12-Way (BLK)
Pin Wire Color Circuit No. Function
A -- -- Right Mirror Vertical Position Sensor Signal
B -- -- Right Mirror Horizontal Position Sensor Signal
C-D -- -- Not Used
E -- -- Low Reference
F -- -- Right Mirror Heating Element Low Reference
G -- -- Right Mirror Motor LEFT
H -- -- Right Mirror Heating Element Supply Voltage
J -- -- Right Mirror Motor RIGHT
K -- -- Right Mirror Motor DOWN
L -- -- Right Mirror Motor UP
M -- -- 5 V Reference

Left Rear Door Module (LRDM) C1

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Connector Part • 12064799

Information • 12-Way F Metri-pack 100 Series (BLK)
Circuit
Pin Wire Color No. Function
"Driver Door Ajar Switch Signal Door Open Switch
A DK BLU 49
Signal"
B LT BLU/BLK 747 Left Rear Door Ajar Switch Signal
C BLK/WHT 751 Ground
D BLK/WHT 751 Ground
E BRN 501 Left Rear Window Switch Signal Down
F DK GRN 1184 Left Rear Window Switch Up Signal
G TAN/WHT 2076 Power Door Serial Data
H BLK/WHT 751 Ground
J YEL 1491 Backlight Lamps Control
K TAN 294 Door Lock Actuator Unlock Control
L GRY 295 Door Lock Actuator Lock Control
M ORN 840 Battery Positive Voltage

Left Rear Door Module (LRDM) C2

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• 12052856
Connector Part Information
• 4-Way F Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A ORN 1040 Battery Positive Voltage
B BRN 669 Power Window Motor Left Rear Down Control
C DK BLU 668 Power Window Motor Left Rear Up Control
D BLK 750 Ground

Right Rear Door Module (RRDM) C1

Connector Part • 12064799

Information • 12-Way F Micro-pack 100 Series (BLK)
Circuit
Pin Wire Color No. Function
"Driver Door Ajar Switch Signal Door Open Switch
A DK BLU 49
Signal"
B LT GRN/BLK 748 Right Rear Door Ajar Switch Signal
C BLK/WHT 651 Ground
D BLK/WHT 651 Ground
E BRN 501 Power Window Switch Right Rear Window Down
F DK GRN 1184 Power Window Switch Right Rear Window Up
G TAN/WHT 2076 Power Door Serial Data
H BLK/WHT 651 Ground
J YEL 1491 Backlight Lamps Control
K TAN 294 Door Lock Actuator Unlock Control
L GRY 295 Door Lock Actuator Lock Control
M ORN 840 Battery Positive Voltage

Right Rear Door Module (RRDM) C2

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• 12052856
Connector Part Information
• 4-Way F Metri-pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A ORN 1040 Battery Positive Voltage
B BRN 671 Power Window Motor Right Rear Down Control
C DK BLU 670 Power Window Motor Right Rear Up Control
D BLK 650 Ground

Window Motor -- Driver

• 12129486
Connector Part
Information • 2-Way F Metri-pack 280 Series Flexlock Sealed (MD
GRY)
Pin Wire Color Circuit No. Function
A DK BLU 164 Power Window Motor Left Front Up Control
B BRN 165 Power Window Motor Left Front Down Control

Window Motor -- Front Passenger

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• 12129487
Connector Part Information
• 2-Way F Metri-pack 280 Series (GRY)
Pin Wire Color Circuit No. Function
A DK BLU 666 Power Window Motor Right Front Up Control
B BRN 667 Power Window Motor Right Front Down Control

Window Motor -- LR

• 12129487
Connector Part Information
• 2-Way F Metri-pack 280 Series (GRY)
Pin Wire Color Circuit No. Function
A BRN 669 Power Window Motor Left Rear Down Control
B DK BLU 668 Power Window Motor Left Rear Up Control

Window Motor -- RR

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• 12129487
Connector Part Information
• 2-Way F Metri-pack 280 Series (GRY)
Pin Wire Color Circuit No. Function
A BRN 671 Power Window Motor Right Rear Down Control
B DK BLU 670 Power Window Motor Right Rear Up Control

Window Switch -- Front Passenger

• 12064982
Connector Part Information
• 5-Way F Micro-pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
1 DK GRN 1184 Power Window Switch Right Front Up Signal
2 BRN 501 Right Front Power Window Switch Signal Down
3 -- -- Not Used
4 BLK/WHT 451 Ground
5 YEL 1491 Backlight Lamps Control

Window Switch -- LR

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• 12066189
Connector Part Information
• 4-Way F Metri-pack 100 Series (NAT)
Pin Wire Color Circuit No. Function
1 BRN 501 Left Rear Window Switch Output Down
2 DK GRN 1184 Left Rear Window Switch Output Up
3 YEL 1491 Backlight Lamps Control
4 BLK/WHT 751 Ground

Window Switch -- RR

• 12066189
Connector Part Information
• 4-Way F Metri-pack 100 Series (NAT)
Pin Wire Color Circuit No. Function
1 BRN 501 Right Rear Power Window Switch Signal - Down
2 DK GRN 1184 Power Window Switch Right Front Up Signal
3 YEL 1491 Backlight Lamps Control
4 BLK/WHT 651 Ground

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Door Adjustment

Important: If the door hinge bolts (1) are removed, the anchor plate will fall into the door
causing a complete teardown to replace.

1. Loosen the hinge fasteners in order to adjust the door at the door hinge pillar in the following
directions:
• Up or down
• In or out
2. Reposition the door as needed.

© 2014 General Motors Corporation. All rights reserved.

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3. Adjust for a limited up or down movement at the body side hinge attachments.

4. Position the door fore or aft at the body hinge pillar attachment. Perform the following steps
as needed:
4.1. Loosen the fasteners.
4.2. Reposition the door.
4.3. Tighten the fasteners.

Tighten
Tighten the fasteners to 34 N·m (25 lb ft).

5.Adjust the lock striker. Refer to Door Lock Striker Adjustment .

6.If more adjustment is needed, remove the door.
7.Remove the hinges from the pillar and the door.
8.Ream the stud holes in the pillar side of the hinges in order to allow for more adjustment.
9.Reinstall the hinges to the pillar and the door. Leave the nuts on the pillar side of the hinge
loose.
10. Align the door as needed.
11. Position the door fore or aft at the body hinge pillar attachment. Perform the following steps
as needed:
11.1. Loosen the fasteners.
11.2. Reposition the door.
11.3. Tighten the fasteners.

Tighten
Tighten the fasteners to 34 N·m (25 lb ft).

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Door Check Link Replacement

Removal Procedure

1. Open the door.

2. Remove the check link to pillar fasteners.
3. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side
Door Trim Panel Replacement .
4. Remove the door module. Refer to Door Control Module Replacement .
5. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement or Rear
Side Door Water Deflector Replacement .

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6. Remove the close-out grommet.

7. Remove the check link to door fasteners.

8. Remove the door check link through the inside of the door.

Installation Procedure

1. Install the check link into the door.

2. Load the check link fasteners through the access hole in the inner panel.

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3. Install the check link to door fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Install the check link arm to the door hinge pillar.

Tighten
Tighten the check link arm fasteners to 9 N·m (80 lb in).

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5. Install the close-out grommet.

6. Install the water deflector. Refer to Front Side Door Water Deflector Replacement or Rear
Side Door Water Deflector Replacement .
7. Install the door module. Refer to Door Control Module Replacement .
8. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side
Door Trim Panel Replacement .

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Door Control Module Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side
Door Trim Panel Replacement .
2. Disconnect the electrical connectors.
3. Remove the door control module fasteners.
4. Remove the door control module.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the door control module.

2. Install the fasteners.

Tighten
Tighten the fasteners to 7 N·m (62 lb in).

3. Install the electrical connectors.

4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side
Door Trim Panel Replacement .

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Door Inside Handle Bezel Replacement

Removal Procedure
The front inside door handle bezel has electrical connectors, the rear does not.

1. Insert a flat bladed tool behind the forward edge of the door handle bezel.
2. Gently pry the bezel away from the door trim panel.
3. Pull the bezel forward over the inside door handle.
4. Using a small flat blade tool, gently pry the memory seat switch out of the Handle bezel.
5. Disconnect the electrical connector from the power door lock switch.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Connect the electrical connectors, if any, to the inside door handle bezel.
2. Install the memory seat switch into the door handle bezel.
3. Slide the inside door handle through the opening in the door handle bezel.
4. Insert the tabs on the rear of the bezel behind the door trim panel.
5. Snap the front of the door handle bezel into place.

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Door Lock Cylinder Replacement

Removal Procedure

1. Place the window in the full up position.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Peel back the water deflector far enough to access the outside door handle. Refer to Front
Side Door Water Deflector Replacement .
4. Remove the E-clip (3) on the lock cylinder to remove the lock rod and arm (2).
5. Spread the omega clip (1).
6. Remove the lock cylinder from the backside of the door handle (4).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the lock cylinder to the outside door handle from the back side.

2. Install the lock cylinder rod and arm (2) to the lock cylinder with the E-clip (3).
3. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Door Lock Striker Adjustment

Caution: Striker alignment is crucial for proper operation of the door systems. Do not hit the
striker with a hammer or force alignment in any other way. Failure to properly adjust striker will
result in excessive door efforts or extensive damage to door system operation which could result in
personal injury.

1. Loosen the 2 mini-wedge striker fasteners (1).

2. Pull the striker outboard to the end of the adjustment travel.
3. Tighten the 2 striker fasteners so that the striker can still be moved.
4. Hold the outside door handle out and gently push the door flush against the body in order to
locate the striker.
5. Slowly open the door.

6. Secure the striker assembly.

Tighten
Tighten the striker fasteners to 28 N·m (21 lb ft).

7. After adjusting the striker, touch up any exposed or unpainted surfaces.

© 2014 General Motors Corporation. All rights reserved.

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Door Lock Switch Replacement

Removal Procedure

1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .
2. Remove the power door lock switch by releasing the lock tabs on the door handle bezel with
a small flat bladed tool.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Snap the door lock switch into the door handle bezel.
2. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .

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Door Striker Replacement

Removal Procedure

Important: Observe the striker location and the number of spacers before removing the
striker fasteners.

1. Mark the location of the door striker on the pillar with a grease pencil.
2. Remove the door striker fasteners (1).
3. Remove the striker (2), spacer (3) and washer.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Assemble the washer, spacer (3), and striker (2).

2. Position the striker on the lock pillar, with the narrow part of the striker facing outward, to
the marks made on the door pillar during removal.
3. Secure the striker fasteners (1).
4. Align the door striker. Refer to Door Lock Striker Adjustment .

5. Tighten the striker fasteners.

Tighten
Tighten the striker fasteners to 28 N·m (21 lb ft).

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Front Door Frame Applique Replacement

Removal Procedure

1. Put the window in the down position.

2. Grasp the window weatherstrip at the lower rear corner.
3. Pull up and forward to release the window weatherstrip from the door frame far enough to
expose the door applique fasteners.

4. Remove the door applique

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5. Remove the door applique by sliding forward.

Installation Procedure

1. Install the applique by sliding rearward over the door frame.

2. Install the applique fasteners.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

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3. Install the rear portion of the window weatherstrip (1).

3.1. Slide the end down into the door frame, making sure the window (2) is in the run
channel.
3.2. Squeeze and push the remaining portion of the window weatherstrip into the door
frame.

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Front Door Opening Weatherstrip Replacement

Removal Procedure

1. Start at the joint at bottom of door opening and pull the weatherstrip away from the door
opening flange.
2. Work around the door opening and remove the weatherstrip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the paint dot in the upper corner of the center pillar.

Important: One paint dot on the weatherstrip indicates RH weatherstrip starting point, and
two paint dots on the weatherstrip indicates LH weatherstrip starting point.

2. Working downward along the rear edge, install the weatherstrip on the door opening flange.
3. From the center pillar corner working forward, install the weatherstrip along the roof rail and
the window-pillar flange.

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Front Door Switch Replacement

Removal Procedure

1. Place forefinger under the lower rear edge of the switch plate.
2. Place thumb at the upper rear end of the switch plate along the curved surface.
3. While pulling rearward with forefinger and holding pressure with thumb, flex and lift the rear
of the switch plate upwards.
4. Gently pry upwards to release the front edge of the trim plate from the door trim panel.
5. Insert a flat bladed tool under the front edge of the mirror and window switch pack.
6. Disconnect electrical connectors.

© 2014 General Motors Corporation. All rights reserved.

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7. Remove the switch pack (2) by releasing the retaining tabs on the switch trim plate (1).

Installation Procedure

1. Snap the switch into the switch trim plate.

2. Install the electrical connectors.
3. Slide the rear edge of the switch plate down into the slot in the door trim panel.
4. Snap the front of the switch plate down to engage the retainer clip.

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Front Side Door Bottom Auxiliary Sealing Strip

Replacement
Removal Procedure

1. With the door open remove the front door bottom sealing strip retainers.
2. Remove the front door bottom sealing strip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front door bottom sealing strip on to the inside lower door edge.
2. Secure the front door bottom sealing strip by inserting the retainers into the holes in the
lower door panel.

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Front Side Door Inside Handle Replacement

4. Remove the door handle fastener (2).

5. Install the lock and latch rods from the rod guide.
© 2014 General Motors Corporation. All rights reserved.

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6. Slide handle assembly forward to release the retainer tabs (1).

7. Tilt the handle and remove the rods from the handle in the following sequence:
7.1. Lock knob rod (1)
7.2. Handle lever rod (2)

Installation Procedure

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1. Install the rods to the inside door handle in the following sequence:
1.1. Handle lever rod (2)
1.2. Lock knob rod (1)

2. Align the retainer tabs (1) to the slots in the door and slide the door handle rearward.

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3. Install the lock and latch rods to the rod guide.

4. Install the inside door handle fastener.

Tighten
Tighten the fastener to 2 N·m (18 lb in).

5. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
6. Install the door module. Refer to Door Control Module Replacement .
7. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Latch Replacement

Removal Procedure
1. Place window in the full up position.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Remove the inside door handle. Refer to Front Side Door Inside Handle Replacement .
4. Peel back the water deflector far enough to access the door latch. Refer to Front Side Door
Water Deflector Replacement .

5. Disconnect the outside door General

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6. Remove the E-clip (3) on the lock cylinder to remove the lock rod and arm (2) from the
outside door handle.

7. Remove the window run channel bolt and move the window run channel aside.
8. Remove the fasteners from the door latch.
9. Disconnect the electrical connectors.
10. Remove the door latch from the door with the inside door handle, lock rod, and lock cylinder
rods attached.

Installation Procedure

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1. Install the inside door handle, lock rod and lock cylinder rods to door latch.
2. Install the door latch into the door.
3. Connect the electrical connectors.

4. Install the door latch fasteners.

Tighten
Tighten the fasteners to 10 N·m (89 lb in).

5. Install the window run channel bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

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6. Install outside door handle rod (1).

• Push the rod (1) upwards.
• Insert the rod into the clip (2) on the door latch assembly.
• Close the clip (2).

7. Install the lock cylinder rod and arm (2) to the lock cylinder.
8. Install the E-clip (3).
9. Install the inside door handle. Refer to Front Side Door Inside Handle Replacement .

Important: Check for the proper operation of the door handles and lock cylinder before
installing the water deflector and the door trim panel.

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10. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
11. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Lock Striker Anchor Plate Replacement

Removal Procedure

1. Remove the door striker. Refer to Door Striker Replacement .

2. Remove the center pillar trim panel. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
3. Remove the anchor plate (1) from the center pillar chute.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Load the anchor plate (1) into the center pillar chute.
2. Install the door striker. Refer to Door Striker Replacement .
3. Install the center pillar trim panel. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
4. Adjust the lock striker. Refer to Door Lock Striker Adjustment .

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Front Side Door Outside Handle Replacement

Removal Procedure

1. Place window in the full up position.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Remove the rear push in retainer on the water deflector.
4. Peel water deflector away from door panel far enough to access the outside door handle.
Refer to Front Side Door Water Deflector Replacement .

© 2014 General Motors Corporation. All rights reserved.

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5. Disconnect the outside door handle rod (1) by opening the retainer (2) at the door latch.

6. Remove the E-clip (3) on the lock cylinder to remove the lock rod and arm (2).

7. Remove the door handle fasteners.

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8. Remove the outside door handle with the handle rod attached, by applying an upward and
outward force.
9. Remove the handle rod from the outside door handle.

Installation Procedure

1. Install the handle rod to the outside door handle.

2. Install the handle and rod into the door.
2.1. Rotate them into a horizontal position.
2.2. Insert the rod through cut out.

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2.3. Rotate the handle into position.

2.4. Apply up and inward pressure.
2.5. Slide the handle downward until the door metal engages into the two lower retaining
tabs on the handle.

3. Install the outside door handle fasteners.

Tighten
Tighten the fasteners to 7 N·m (62 lb in).

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4. Install the lock cylinder rod and arm (2) to the lock cylinder.
5. Install the E-clip (3).

6. Connect the door handle rod to the latch.

6.1. Insert the rod (1) into the clip (2) on the door latch assembly.
6.2. Close the clip.

Important: Inspect for the proper operation of the door handle and lock cylinder
before installing the water deflector and the door trim panel.

7. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
8. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Replacement

Tools Required
J 38778 Door Trim Pad Clip Remover

Removal Procedure
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2. Remove the door module. Refer to Door Control Module Replacement .
3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
4. Remove the inside door handle. Refer to Front Side Door Inside Handle Replacement .
5. Remove the window inner belt seal strip. Refer to Front Side Door Window Belt Inner Sealing
Strip Replacement .
6. Remove the outside rear view mirror. Refer to Power Mirror Replacement .
7. Remove the window outer belt seal strip. Refer to Front Side Door Window Belt Outer Sealing
Strip Replacement .
8. Remove the window. Refer to Front Side Door Window Replacement .
9. Remove the window weatherstrip. Refer to Front Side Door Window Weatherstrip
Replacement .
10. Remove the door frame applique. Refer to Front Door Frame Applique Replacement .
11. Remove the window regulator. Refer to Front Side Door Window Regulator Replacement .
12. Remove the rear window channel. Refer to Front Side Door Window Rear Channel
Replacement .
13. Remove the outside door handle. Refer to Front Side Door Outside Handle Replacement .
14. Remove the door latch. Refer to Front Side Door Latch Replacement .
15. Remove the upper auxiliary weatherstrip. Refer to Front Side Door Upper Auxiliary
Weatherstrip Replacement .
16. Remove the door bottom auxiliary weatherstrip. Refer to Front Side Door Bottom Auxiliary
Sealing Strip Replacement .

© 2014 General Motors Corporation. All rights reserved.

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17. Insert a small flat bladed tool between the door wire harness conduit (2) and the hinge pillar
in order to depress and release the tab (3) on the door wiring harness connector.

18. Disconnect the electrical connection to the door wiring harness.

19. Remove the rubber conduit and the wiring harness (1) from the door.
20. Remove the door check link. Refer to Door Check Link Replacement .
21. Remove all the plastic nuts and retainers from the door shell.

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22. Remove the intermediate hinge fasteners (1) from both hinges.
23. Lift the door to remove.
24. Remove the door hinges. Refer to Front Side Door Hinge Replacement .

Installation Procedure
1. Install the door hinges to the door. Refer to Front Side Door Hinge Replacement .
2. Align the door hinge halves.
3. Lower the door so the hinge halves mate together.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners

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Important: Use Loctite® Blue GM P/N 12345382 or equivalent prior to the fastener
installation.

4. Install the intermediate door hinge fasteners.

Tighten
Tighten the intermediate front door hinge fasteners (1) to 24 N·m (18 lb ft).

5. Install the door check link. Refer to Door Check Link Replacement .
6. Touch up any paint damage to the intermediate hinge fasteners with body color paint.
7. Install all the retainers into the door shell that were removed during disassembly.

8. Route the wiring harness and the conduit into the door.
9. Install the door wire harness clips (2) to the inner door panel.

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10. Connect the door wiring harness electrical connector to the body wire harness electrical
connector.
11. Install the door bottom auxiliary weatherstrip. Refer to Front Side Door Bottom Auxiliary
Sealing Strip Replacement .
12. Install the upper auxiliary weatherstrip. Refer to Front Side Door Upper Auxiliary
Weatherstrip Replacement .
13. Install the door latch. Refer to Front Side Door Latch Replacement .
14. Install the outside door handle. Refer to Front Side Door Outside Handle Replacement .
15. Install the rear window channel. Refer to Front Side Door Window Rear Channel
Replacement .
16. Install the window regulator. Refer to Front Side Door Window Regulator Replacement .
17. Install the door frame applique. Refer to Front Door Frame Applique Replacement .
18. Install the window weatherstrip. Refer to Front Side Door Window Weatherstrip
Replacement .
19. Install the window. Refer to Front Side Door Window Replacement .
20. Install the window outer belt seal strip. Refer to Front Side Door Window Belt Outer Sealing
Strip Replacement .
21. Install the outside rearview mirror. Refer to Power Mirror Replacement .
22. Install the window inner belt seal strip. Refer to Front Side Door Window Belt Inner Sealing
Strip Replacement .
23. Install the inside door handle. Refer to Front Side Door Inside Handle Replacement .
24. Adjust the door if needed. Refer to Door Adjustment .
25. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
26. Install the door module. Refer to Door Control Module Replacement .
27. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Trim Panel Replacement

Tools Required
J 38778 Door Trim Pad Clip Remover

Removal Procedure
1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .

2. Remove the upper door trim panel (1).

2.1. Use the J 38778 in order to release the retainer at the top of the upper door trim
panel.
2.2. Lift upwards to remove.
2.3. Disconnect the wire harness to the tweeter.

© 2014 General Motors Corporation. All rights reserved.

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3. Use the J 38778 in order to release the retainers (2) around the outside edges of the door
trim panel.
4. Slide the door trim panel upwards to release the armrest pull cup retainers (1).
5. Disconnect the door trim panel wiring harness.
6. Remove the armrest pull cup retainers (1) from the inside of the door trim panel.

Installation Procedure

1. Install the armrest pull cup retainers into the supports on the inner door panel.
2. Connect the door wire harness to the door trim panel wire harness.

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3. Align the center of the door trim panel to the armrest pull cup retainers (1).

4. Push outwards at the center of the door trim panel until two engagement clicks are heard.
5. Pull on the arm rest to assure proper attachment.

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6. Secure the door trim panel around the outside edges with the retainers (2).
7. Insert the top door trim panel retainer into the channel in the window inner belt seal strip by
exerting outward pressure just below the upper edge of the door trim panel.
8. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .

9. Install the upper door trim panel (1).

9.1. Connect the wire harness to the tweeter.
9.2. Insert the tabs into the slots on the door trim panel.
9.3. Insert the retainer into the hole in the door frame.

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Front Side Door Upper Auxiliary Weatherstrip

Replacement
Removal Procedure
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2. Remove the door control module. Refer to Door Control Module Replacement .
3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
4. Remove the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
5. Remove the outside rearview mirror. Refer to Power Mirror Replacement .
6. Remove the window outer belt sealing strip. Refer to Front Side Door Window Belt Outer
Sealing Strip Replacement .
7. Remove the window. Refer to Front Side Door Window Replacement .
8. Remove the window weatherstrip. Refer to Front Side Door Window Weatherstrip
Replacement .

9. Remove the upper auxiliary weatherstrip screws (1-7).

10. Carefully pull the auxiliary weatherstrip away from the door header.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Align the rear screw hole (1) in the weatherstrip to the plastic nut in the door header.
2. Seat the top of the seal lip over the flange.
3. Starting at the rear, roll the weatherstrip over the flange on the door header while holding
the weatherstrip lip to prevent tucking under against the door.
4. Install the rear screw (1).

5. Install the remaining screws (2 --7).

Tighten
Tighten the screws in sequence to 2 N·m (18 lb in).

6. Install the window weatherstrip. Refer to Front Side Door Window Weatherstrip
Replacement .
7. Install the window. Refer to Front Side Door Window Replacement .
8. Install the window outer belt sealing strip. Refer to Front Side Door Window Belt Outer
Sealing Strip Replacement .
9. Install the outside rearview mirror. Refer to Power Mirror Replacement .
10. Install the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
11. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
12. Install the door control module. Refer to Door Control Module Replacement .
13. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Upper Hinge and Lower Hinge

Replacement
Removal Procedure
1. Open the front door.
2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .

4. Disconnect the door latch electrical connectors (1).

5. Disconnect the power window motor electrical connector.
6. Remove the door wiring harness retainers (2) from the door.
7. Pull the door wire harness out of the door.

© 2014 General Motors Corporation. All rights reserved.

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8. Remove the door check link fasteners from the body.

9. Remove the intermediate hinge fasteners (1) from both hinges.

10. Lift the door to remove, with the aid of an assistant.

11. Mark the position of the hinge half (2) on the body.
12. Mark the position of the hinge half on the door.
13. Remove the hinge fasteners (1) from the pillar.
14. Remove the hinge half from the pillar.

Important: Be careful to secure the studplate within the door, when removing the hinge half
from the door. The studplate is not attached to the door and could fall into the door.

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15. Remove the hinge fasteners from the door.

16. Remove the hinge half from the door.

Installation Procedure

1. Align the hinge half (2) to the body.

2. Install the hinge to body fasteners.

Tighten
Tighten the fasteners to 35 N·m (26 lb ft).

3. Align the door half of the hinge with the marks made on the door during removal.
4. Install the hinge to the door fasteners (1).

Tighten
Tighten the hinge to door fasteners (1) to 34 N·m (24 lb ft).

5. Align the door hinge halves.

6. Lower the door so the hinge halves mate together.

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7. Apply Loctite® Blue GM P/N 12345382 or Canadian P/N 10953489, or equivalent to the
intermediate door hinge fasteners (1).
8. Install the intermediate door hinge fasteners.

Tighten
Tighten the intermediate front door hinge fasteners (1) to 24 N·m (18 lb ft).

9. Install the door check link. Refer to Door Check Link Replacement .
10. Touch up any paint damage to the hinge and the check link fasteners with body color paint.

11. Install the door wire harness through the opening in the front of the door.
12. Install the wiring harness retainers (2) into the holes in the door.
13. Connect the power window motor electrical connector.
14. Install the door latch electrical connectors (2).

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15. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
16. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

Notice: Striker alignment is a crucial part of door latch operation. Do not use the door striker
to adjust the door to the vehicle. Failure to properly adjust the striker can result in damage
to the door latch and the striker.

17. Adjust the door for proper alignment. Refer to Door Adjustment .

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Front Side Door Water Deflector Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2. Remove the door module. Refer to Door Control Module Replacement .
3. Remove the nylon nuts (2).

4. Push the wiring harness through the hole in the water deflector.
5. Remove the retainers©at2014
theGeneral
upper Motors
corners of the water
Corporation. deflector.
All rights reserved.

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6. Gently peel the water deflector away from the door, being careful not to damage the sealer.
7. Remove the water deflector.

Installation Procedure

1. Clean the water deflector to the inner door panel mating surface with denatured alcohol or
the equivalent.
2. Route the wiring harness through the hole in the water deflector.
3. Align the water deflector to the door assembly.
4. Install the retainers at the upper corners of the water deflector.
5. Seat the water deflector to the door using a rolling tool.

6. Install the nylon nuts (2).

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7. Install the door module. Refer to Door Control Module Replacement .

8. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Belt Inner Sealing Strip

Replacement
Removal Procedure

1. Lower the window all the way down.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Starting at one end of the window inner belt seal strip (1), pull upward to release the seal
strip.

© 2014 General Motors Corporation. All rights reserved.

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4. If further disassembly of the door is required, remove the auxiliary water deflector.
4.1. Gently remove folded portion of deflector from the door flange.
4.2. Lift deflector up and out of the door.

Installation Procedure

1. If the auxiliary water deflector was removed during disassembly, install the water deflector to
the front door inner panel.
1.1. Insert the deflector through the belt line, inboard of the window.
1.2. Position the deflector against the mirror patch.
1.3. Fold the perforated portion of the deflector over the door flange.
1.4. Press to secure the water deflector to the door flange.

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Important: When reusing the window belt seal strip, the flange mounting area (2) must be
pinched together in order to counteract the splaying effect when removed. Use a thumb and
an index finger in order to pinch the carrier (3) back together.

2. Work from one end of the seal strip to the other.

3. Position the door window inner belt seal strip over the flange of the door inner panel.

Important: Do not distort the seal strip.

4. Press down in order engage the door window inner belt seal strip the entire length of the
door.
5. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Belt Outer Sealing Strip

Replacement
Removal Procedure
1. Remove the outside rearview mirror. Refer to Power Mirror Replacement .
2. Lower the front door window.

3. Remove the front door outer belt sealing strip from the door pinchweld flange.
3.1. Lift upwards, starting at the rear, to disengage sealing strip clips.
3.2. Slide sealing strip rearward to clear the upper auxiliary molding.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front door outer belt sealing strip to the pinchweld flange.
1.1. Align sealing strip to door.
1.2. Slide the strip forward and under upper auxiliary molding.
1.3. Ensure the end cap is flush to door cutline.
1.4. Rotate the sealing strip downward.
1.5. Align sealing strip clips to slots in the door pinchweld flange.
1.6. Push the sealing strip down to fully seat and secure to the door pinchweld flange.
2. Install the outside rearview mirror. Refer to Power Mirror Replacement .
3. Raise the front door window.

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Front Side Door Window Rear Channel Replacement

Removal Procedure
1. Lower the door window to the full down position.
2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Peel the rearward half of the water deflector away from the door. Refer to Front Side Door
Water Deflector Replacement .
4. Remove the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .

5. Pull the lower rear portion of the upper window seal out of the door frame far enough to gain
access to the lower fastener of the door frame applique.
6. Remove the upper run channel fastener, which is also the lower door applique fastener.
7. Reinstall the window seal into the door frame.
8. Connect the door trim panel wire harness connector.
9. Run the window up until there is about a 25 mm (1 in) opening at the top.

© 2014 General Motors Corporation. All rights reserved.

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10. Remove the lower run channel fastener.

11. Pull the run channel (1) down to clear the window.
12. Remove the run channel.

Installation Procedure

1. Insert the run channel (1) into the door through the front access hole.
2. Slide the run channel up along the window , making sure the upper portion is under the door
frame applique.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

3. Install the lower fastener.

Tighten
Tighten the fastener to 9 N·m (80 lb in).

4. Lower the window to the full down position.

5. Pull out enough of the lower rear edge of the window seal to install the upper fastener in the
run channel and door applique.
6. Install the fastener.
7. Reinstall the window seal to the door frame.
8. Install the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
9. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
10. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Regulator Motor Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .

Important: There is a binding effect on the power window motor drive when the window is
in the fully closed or open position.

3. Partially open the window.

4. Disconnect the power window motor electrical connector (2).
5. Remove the fasteners (1) securing the power window motor to the window regulator.
6. Remove the power window motor (3).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the power window motor (3) to the window regulator.

2. Install the power window motor to regulator fasteners (1).

Tighten
Tighten the power window motor fasteners to 4 N·m (62 lb in).

3. Connect the electrical connector (2).

4. Inspect for proper operation of the power window motor and window.
5. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
6. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Regulator Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2. Remove the door module. Refer to Door Control Module Replacement .
3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .

Caution: Disconnect the power window switch when working inside the driver door. When
operated, the Express Up/Down Feature allows the door window to move very quickly,
without stopping, which could cause personal injury.

4. Loosen the window retainer clamp fasteners.

Important: You may need to use masking tape to hold the window in place while replacing
the regulator.

5. Slide the window to the full up position.

6. Disconnect the electrical connector from the window regulator motor.
7. Remove the window regulator to inner door panel fasteners.
8. Remove the window regulator.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the window regulator into the door.

2. Install the window regulator fasteners.

Tighten
Tighten the fasteners in this order, (1, 3, 2), to 9 N·m (80 lb in).

3. Provide power to the window motor and run the regulator to the fully closed position.
4. Install the window to clamps.

Tighten
Tighten window clamp fasteners to 11 N·m (95 lb in).

5. Connect the electrical connector to the window regulator motor.

6. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
7. Install the door module. Refer to Door Control Module Replacement .
8. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Replacement

Removal Procedure

1. Lower the window to the full down position.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Remove the door module. Refer to Door Control Module Replacement .
4. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
5. Remove the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
6. Connect a power source to the window motor and position the window half way down.
7. Loosen the window regulator to window clamps.
8. Remove the window by tilting window forward then pulling the window up and out of the
door.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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Important: The window regulator should be at least half way down before installing the
window.

1. Install the window down into the door.

2. Locate the window into the two clamps.

3. Connect a power source to the window motor and run the window to the full-up position.

Tighten
Tighten the window clamp fasteners to 11 N·m (98 lb in).

4. Install the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
5. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
6. Install the door module. Refer to Door Control Module Replacement .
7. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Front Side Door Window Weatherstrip Replacement

6. Remove the window. Refer to Front Side Door Window Replacement .

7. Remove the fasteners from the front window channel (2).
8. Carefully pull the window weatherstrip from the door.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the window weatherstrip (1) to the door starting in the top corner working out in both
directions.
2. Firmly seat the window weatherstrip to the door.
3. Install the window channel (2) fasteners.
4. Install the door window. Refer to Front Side Door Window Replacement .
5. Install the window outer belt sealing strip. Refer to Front Side Door Window Belt Outer
Sealing Strip Replacement .
6. Install the window inner belt sealing strip. Refer to Front Side Door Window Belt Inner
Sealing Strip Replacement .
7. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
8. Install the door module. Refer to Door Control Module Replacement .
9. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

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Outside Rearview Mirror Glass Replacement

Removal Procedure
Caution: When working with any type of glass or sheet metal with exposed or rough edges,
wear approved safety glasses and gloves in order to reduce the chance of personal injury.

1. Remove the mirror and the plastic backing plate assembly.

1.1. Manually tilt the mirror glass inboard towards the vehicle.
1.2. Insert fingers behind the mirror glass assembly.
1.3. Gently pull the mirror glass assembly from the housing.
2. Disconnect the electrical connectors.

© 2014 General Motors Corporation. All rights reserved.

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3. Remove the actuators (2) that may have remained attached to the mirror face backing (1).

Push the actuator in the direction of one of the two slots of the molded ring where the
actuator ball attaches in order to disengage it from the mirror glass assembly (1).

Installation Procedure

1. Ensure the actuator springs (7) are not pushed down on the actuator shafts but are seated in
the groove provided.

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2. Install the actuator shafts (2) on to the power drive unit (4) by pressing and rotating the
actuator on to the power drive unit.
3. Connect the electrical connectors to the mirror glass assembly.

4. Align the mirror face assembly pivot points (3) to the actuator shafts (5) and the memory
pins (4).

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5. Install the mirror glass assembly.

5.1. Use a 5 cm by 10 cm (2 in by 4 in) sanding block and firmly press the mirror glass
assembly with enough force to engage the center pivot point on to the power drive
unit.
5.2. Apply pressure to the top of the mirror glass assembly with the sanding block until an
audible snap is heard.
5.3. Manually tilt the mirror glass assembly outboard away from the vehicle.
5.4. Apply pressure to the outboard portion of the mirror glass assembly with the sanding
block until an audible snap is heard.
6. Ensure proper operation of the outside rear view mirror by operating in all directions.

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Power Mirror Replacement

Removal Procedure

1. Remove the upper door trim panel (1) located above the door trim panel.
1.1. Use the J-tool to release retainer at the top of the panel.
1.2. Lift the panel up to remove.
1.3. Disconnect the wire harness from the tweeter.
2. Remove the sound barrier.
3. Remove the door trim panel to gain access to the power mirror wire harness. Refer to Front
Side Door Trim Panel Replacement .
4. Disconnect the electrical connector.

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the mirror fasteners.

6. Disconnect the wire harness from the retainer clip and unseat the grommet.
7. Remove the mirror from the door.
8. Pull the wiring harness through the hole in the mirror patch.

Installation Procedure

1. Route the mirror wiring harness through the hole in the mirror patch.
2. Install the mirror into the door frame.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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3. Install the mirror fasteners.

Tighten
Tighten the mirror fasteners to 9 N·m (80 lb in).

4. Install the grommet by gently pulling into place.

5. Connect the electrical connectors.
6. Install the mirror wire harness into retainer clip.
7. Install the sound barrier.
8. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .

9. Install the upper door trim panel (1).

9.1. Connect the wire harness to the tweeter.
9.2. Insert the tabs into the slots on the door trim.
9.3. Push the x-mas tree retainer into the door.

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Rear Door Energy Absorber Pad Replacement

Removal Procedure
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Peel the rear of the water deflector off far enough to access the energy absorbers. Refer to
Rear Side Door Water Deflector Replacement .

3. Cut the push pins that fasten the inner energy absorber to the door.
4. Remove the energy absorber.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the inner energy absorber to the door with new push pins.
2. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
3. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Door Frame Applique Replacement

Removal Procedure
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Remove the door module. Refer to Door Control Module Replacement .
3. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
4. Remove the door window inner belt molding. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
5. Remove the door window outer belt molding. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
6. Remove the rear door window. Refer to Rear Side Door Window Replacement .

7. Grasp the front, lower end of the window weatherstrip (3) and pull back to reveal door
applique fasteners.

© 2014 General Motors Corporation. All rights reserved.

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8. Remove the applique fasteners.

9. Slide the applique straight back to remove.

Installation Procedure

1. Slide the door applique forward over the door frame.

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2. Install the door applique fasteners.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

3. Reinstall the front portion of the door window weatherstrip.

4. Install the rear door window. Refer to Rear Side Door Window Replacement .
5. Install the door window outer belt molding. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
6. Install the door window inner belt molding. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
7. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
8. Install the door module. Refer to Door Control Module Replacement .
9. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Door Inner Filler Panel Replacement

Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover

Removal Procedure

1. Use the J 38778 in order to pry the upper edge of the filler panel away from the door frame.
2. Lift the filler panel upwards to remove.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Insert the tabs on the lower portion of the filler panel into the slots in the door.
2. Exert outboard pressure at the top of the filler panel to engage the push in fastener.

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Rear Door Opening Weatherstrip Replacement

Removal Procedure

1. Start at the joint at bottom of door opening and pull the weatherstrip away from the door
opening flange.
2. Work around the door opening and remove the weatherstrip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the paint dot in the upper corner of the center pillar.

Important: One paint dot on the weatherstrip indicates RH weatherstrip starting point, and
two paint dots on the weatherstrip indicates LH weatherstrip starting point.

2. Working downward along the front edge, install the weatherstrip on the door opening flange.
3. From the center pillar corner working rearward, install the weatherstrip along the roof rail
and the center-pillar flange.
4. With the palm of your hand ensure that the weatherstrip is seated on the entire door opening
flange.

5. Install both ends of the weatherstrip on the rocker flange, forcing both ends tightly against
each other.
6. Using a plastic trim stick or equivalent, position the close-out lip over the interior trim around

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the entire door opening, or use pull-string under closeout lip to reposition the lip.

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Rear Door Outer Filler Panel Replacement

Tools Required
J 38778 Door Trim Pad Clip Remover

Removal Procedure

1. Use the J 38778 in order to pry the front lower edge of the filler panel away from the door,
releasing the push in fastener.
2. Pull the filler panel forward to remove.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Insert the tabs at the rear of the filler panel into the slots in the door frame.
2. Align the push in fastener on the filler panel to the hole in the door.
3. Push the panel inboard to install.

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Rear Door Replacement

Tools Required
• J 38778 Door Trim Pad Clip Remover
• J 36796 Clip Zip Removal Tool
• J 39346-A Mini-Wedge Alignment Tool

Removal Procedure
1. Mark the location of the hinges (upper and lower) on the door.
2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the door module. Refer to Door Control Module Replacement .
4. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
5. Remove the inside door handle. Refer to Rear Side Door Inside Handle Replacement .
6. Remove the energy absorber pad. Refer to Rear Door Energy Absorber Pad Replacement .
7. Remove the window inner belt seal strip. Refer to Rear Door Window Belt Inner Sealing Strip
Replacement .
8. Remove the window outer belt seal strip. Refer to Rear Door Window Belt Outer Sealing Strip
Replacement .
9. Remove the door window. Refer to Rear Side Door Window Replacement .
10. Remove the window regulator. Refer to Rear Side Door Window Regulator Replacement .
11. Remove the window weatherstrip. Refer to Rear Side Door Window Weatherstrip
Replacement .
12. Remove the door frame applique. Refer to Rear Door Frame Applique Replacement .
13. Remove the door bottom auxiliary sealing strip. Refer to Rear Side Door Bottom Auxiliary
Sealing Strip Replacement .
14. Remove the front window run channel. Refer to Rear Side Door Window Front Channel
Replacement .
15. Remove the outside door handle. Refer to Rear Side Door Outside Handle Replacement .
16. Remove the door latch. Refer to Rear Side Door Latch Replacement .
17. Remove the upper auxiliary weatherstrip. Refer to Rear Side Door Upper Auxiliary
Weatherstrip Replacement .

© 2014 General Motors Corporation. All rights reserved.

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18. Insert a small flat bladed tool between the door wire harness conduit (2) and the hinge pillar
in order to depress and release the tab (3) on the door wiring harness connector.

19. Remove the door wire harness from the hinge pillar.
20. Disconnect the door wiring harness from the body wiring harness.

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21. Remove the rubber conduit and wiring harness (1) from the door.
22. Remove the door check link. Refer to Door Check Link Replacement .

23. Remove the intermediate hinge fasteners (1) from both hinges.
24. Lift the door to remove.
25. Remove the door hinges. Refer to Rear Side Door Hinge Replacement .

Installation Procedure
1. Install the door hinges to the pillar and the door. Refer to Rear Side Door Hinge
Replacement .
2. Align the door hinge halves.
3. Lower the door so the hinge halves mate together.

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Important: Use Loctite® Blue GM P/N 12345382 or equivalent prior to installing the
fasteners.

4. Install the intermediate door hinge fasteners (1).

Tighten
Tighten the fasteners to 33 N·m (24 lb ft).

5. Touch up any paint damage to the intermediate hinge fasteners with body color paint.
6. Install the door check link. Refer to Door Check Link Replacement .

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7. Route the wiring harness (1) and conduit into the door.

8. Connect the door wire harness to the body wire harness electrical connector.
9. Snap the wire harness connectors into the hinge pillar.
10. Install the upper auxiliary weatherstrip. Refer to Rear Side Door Upper Auxiliary Weatherstrip
Replacement .
11. Install the door latch. Refer to Rear Side Door Latch Replacement .
12. Install the outside door handle. Refer to Rear Side Door Outside Handle Replacement .
13. Install the front window run channel. Refer to Rear Side Door Window Front Channel
Replacement .
14. Install the door bottom auxiliary sealing strip. Refer to Rear Side Door Bottom Auxiliary
Sealing Strip Replacement .
15. Install the door frame applique. Refer to Rear Door Frame Applique Replacement .
16. Install the window weatherstrip. Refer to Rear Side Door Window Weatherstrip Replacement .
17. Install the window regulator. Refer to Rear Side Door Window Regulator Replacement .

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18. Install the door window. Refer to Rear Side Door Window Replacement .
19. Install the window outer belt seal strip. Refer to Rear Door Window Belt Outer Sealing Strip
Replacement .
20. Install the window inner belt seal strip. Refer to Rear Door Window Belt Inner Sealing Strip
Replacement .
21. Install the energy absorber pad. Refer to Rear Door Energy Absorber Pad Replacement .
22. Install the inside door handle. Refer to Rear Side Door Inside Handle Replacement .
23. Check the door for proper adjustment. Refer to Door Adjustment .
24. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
25. Install the door module. Refer to Door Control Module Replacement .
26. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
27. Check the door for proper adjustment. Refer to Door Adjustment .

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Rear Side Door Bottom Auxiliary Sealing Strip

Replacement
Removal Procedure

1. With the door open remove the rear door bottom sealing strip retainers.
2. Remove the rear door bottom sealing strip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear door bottom sealing strip on to the inside lower door edge.
2. Secure the rear door bottom sealing strip by inserting the retainers into the holes in the
lower door panel.

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Rear Side Door Inside Handle Replacement

4. Remove the fastener (2) from the inside door handle.

5. Slide the inside door handle forward to release the tabs (4) from the door.
6. Tilt the handle and remove
© 2014 the rods
General fromCorporation.
Motors the handleAllinrights
the reserved.
following sequence:

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6.1. Lock knob rod (1)

6.2. Handle lever rod (2)

Installation Procedure

1. Install the rods to the inside door handle in the following sequence:
1.1. Handle lever rod (2)
1.2. Lock knob rod (1)
2. Guide the tabs (4) on the inside door handle into the slots in the door.
3. Slide the inside door handle rearward to engage tabs.

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4. Install the inside door handle fastener (2).

Tighten
Tighten the fastener to 2 N·m (18 lb in).

5. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
6. Install the door module. Refer to Door Control Module Replacement .
7. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Latch Replacement

Removal Procedure
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Peel back the water deflector far enough to access the door latch. Refer to Rear Side Door
Water Deflector Replacement .
3. Remove the inside door handle. Refer to Rear Side Door Inside Handle Replacement .

4. Disconnect the outside door handle rod (1) from door latch by opening the clip (2).

5. Remove the door latch

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6. Remove the door latch (1) with the inside door handle and lock rods attached.
7. Disconnect the electrical connectors.

Installation Procedure

1. Install the electrical connectors.

2. Install the door latch (1), with inside door handle and lock rods attached, into the door.

3. Install the door latch fasteners.

Tighten
Tighten the fasteners to 10 N·m (89 lb in).

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4. Connect the door handle rod (1) to the door latch.

4.1. Push the rod (1) upwards.
4.2. Insert the rod into the clip (2) on the door latch assembly.
4.3. Close the clip.
5. Install the inside door handle. Refer to Rear Side Door Inside Handle Replacement .

Important: Inspect for the proper operation of the door handles before installing the water
deflector and the door trim panel.

6. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
7. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Lock Striker Anchor Plate Replacement

Removal Procedure

1. Remove the door striker. Refer to Door Striker Replacement .

2. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
3. Remove the anchor plate (1) from the rear pillar chute.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Load the anchor plate (1) into the rear pillar chute.
2. Install the door striker. Refer to Door Striker Replacement .
3. Install the seat back. Refer to Rear Seat Back Replacement in Seats.

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Rear Side Door Outside Handle Replacement

Removal Procedure
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Peel the water deflector forward just far enough to access the outside door handle.

3. Disconnect the outside door handle latch rod (1) by opening the retainer (2) on the door
latch.

4. Remove the outside door handle fasteners through the access holes (1).
© 2014 General Motors Corporation. All rights reserved.

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5. Remove the handle, with latch rod attached, by lifting up and out.
6. Remove the rod from the door handle.

Installation Procedure
1. Install the door handle rod into the door handle.

2. Install the door handle and rod into the door.

2.1. Rotate them into a horizontal position.
2.2. Insert the rods through cut out.
2.3. Rotate the handle into position.
2.4. Apply up and inward pressure.

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2.5. Slide the handle downward until the door metal engages into the two lower retaining
tabs on the handle.

3. Install the outside door handle fasteners through the access holes (1).

Tighten
Tighten the fasteners to 7 N·m (62 lb in).

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4. Connect the door handle rod to the door latch.

4.1. Insert the rod into the clip (2) on the door latch assembly.
4.2. Close the clip.

Important: Inspect for the proper operation of the door handle and lock cylinder
before installing the water deflector and the door trim panel.

5. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
6. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Trim Panel Replacement

Tools Required
J 38778 Door Trim Panel Clip Remover

Removal Procedure
1. Remove the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .
2. Use the J 38778 to pry out the retainers (3) around the outside edges of the door trim
panel (1).

3. Remove the door trim panel by pulling out at the bottom of the panel and lifting up.
4. Disconnect the door trim panel wire harness.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Remove the armrest pull cup retainers (1) from the door trim panel.
2. Install the retainers to the nylon nuts (2) on the inner door panel by sliding the retainers
down into the grooves in the nylon nuts.

3. Connect the door trim panel wiring harness electrical connector to the door wiring harness
electrical connector.
4. Align the armrest pull cup retainers to the door trim panel.
5. Push the center of the door trim panel outwards until two clicks are heard.
6. Pull on the armrest to assure proper attachment.

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7. Secure the outside edges of the door trim panel by pushing in the retainers (3).
8. Insert the top door trim panel retainer into the channel in the window inner belt seal strip by
exerting outward pressure just below the upper edge of the door trim panel.
9. Install the inside door handle bezel. Refer to Door Inside Handle Bezel Replacement .

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Rear Side Door Upper Auxiliary Weatherstrip

Replacement
Removal Procedure
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Remove the door control module. Refer to Door Control Module Replacement .
3. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
4. Remove the energy absorber pad. Refer to Rear Door Energy Absorber Pad Replacement .
5. Remove the window inner belt sealing strip. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
6. Remove the window outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
7. Remove the rear door window. Refer to Rear Side Door Window Replacement .
8. Remove the rear door window weatherstrip. Refer to Rear Side Door Window Weatherstrip
Replacement .

9. Remove the rear door upper auxiliary weatherstrip screws (1-7).

10. Carefully pull the auxiliary weatherstrip away from the door header.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Seat the top of the seal lip over the door header flange.
2. Align the front hole in the weatherstrip to the plastic nut in the door header.
3. Starting at the front, roll the weatherstrip over the flange on the door header while holding
the weatherstrip lip to prevent tucking under against door.
4. Install the door to door seal on to the forward flange of the door header starting at the top
and working towards the bottom.
5. Ensure the front screw hole is aligned with the plastic nut in the door header.

6. Install the auxiliary weatherstrip screws (1-7).

Tighten
Tighten the screws to 2 N·m (18 lb in).

7. Install the rear door window weatherstrip. Refer to Rear Side Door Window Weatherstrip
Replacement .
8. Install the rear door window. Refer to Rear Side Door Window Replacement .
9. Install the window outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
10. Install the window inner belt sealing strip. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
11. Install the energy absorber pad. Refer to Rear Door Energy Absorber Pad Replacement .
12. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
13. Install the door control module. Refer to Door Control Module Replacement .
14. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Upper Hinge and Lower Hinge

Replacement
Removal Procedure

1. Open the rear and the front doors.

2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
4. Remove the center pillar garnish molding. Refer to Center Pillar Garnish Molding Replacement
in Interior Trim.
5. Disconnect the door wire harness from the body wire harness.
6. Remove the door wire harness connector (3) from the center pillar.

© 2014 General Motors Corporation. All rights reserved.

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7. Remove the door check link fasteners from the pillar.

8. Remove the intermediate hinge fasteners (1) from both hinges.

9. Lift the door to remove, with the aid of an assistant.

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10. Mark the position of the hinge on the body with a grease pencil.
11. Remove the hinge to body fasteners.

Important: Be careful to secure the studplate within the door, when removing the hinge half
from the door . The studplate is not attached to the door and could fall into the door.

12. Mark the position of the hinge on the door with a grease pencil.
13. Remove the hinge to door fasteners (1).

Installation Procedure

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1. Align the body side half of the hinge to the marks made on the pillar during removal.
2. Install the hinge half to the body.

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3. Install the fasteners.

Tighten
Tighten the hinge to body fasteners to 35 N·m (26 lb ft).

4. Align the door half of the hinge to the marks made on the door during removal.
5. Install the fasteners (1).

Tighten
Tighten the hinge to door fasteners to 34 N·m (24 lb ft).

6. With the aid of an assistant, align the door hinge halves and lower the door so the hinge
halves mate together.

7. Apply Loctite® Blue GM P/N 12345382 or (Canadian P/N 10953489), or equivalent to the
intermediate hinge fasteners (1).
8. Install the intermediate door hinge fasteners (1).

Tighten
Tighten the fasteners to 24 N·m (18 lb ft).

9. Install the door check link. Refer to Door Check Link Replacement .

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10. Connect the door wire harness to the body wire harness.
11. Install the door wire harness connector to the hinge pillar.
12. Install the center pillar garnish molding. Refer to Center Pillar Garnish Molding Replacement
in Interior Trim.
13. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
14. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
15. Adjust the door for proper alignment. Refer to Door Adjustment .
16. Touch up any damage to the hinge. Compare the link fasteners with the body color paint.

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Rear Side Door Water Deflector Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Remove the door control module. Refer to Door Control Module Replacement .
3. Remove the nylon nuts (2).

4. Remove the retainers at the upper corners of the water deflector.

5. Push the wiring harness through
© 2014 the
General holeCorporation.
Motors in the water deflector.
All rights reserved.

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6. Carefully peel the water deflector away from the door, being careful not to damage the
sealer.
7. If removal of the auxiliary water deflector is required. Refer to Rear Door Window Belt Inner
Sealing Strip Replacement .

Installation Procedure
1. If the auxiliary water deflector was removed during disassembly. Refer to Rear Door Window
Belt Inner Sealing Strip Replacement .

2. Clean the water deflector to the inner door panel mating surface with denatured alcohol or
the equivalent.
3. Route the wiring harness through the hole in the water deflector.
4. Align the water deflector to the door assembly.
5. Install the retainers at both upper corners.
6. Seat the water deflector to the door using a rolling tool.

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7. Install the nylon nuts (2).

8. Install the door module. Refer to Door Control Module Replacement .
9. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Window Front Channel Replacement

Removal Procedure

1. Ensure that the window is fully closed.

2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the door module. Refer to Door Control Module Replacement .
4. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
5. Loosen the lower fastener (3).
6. Remove the upper fastener (1).
7. Rotate the top of the front window channel forward.
8. Lift upward on the front window channel in order to disengage the lower fastener from the
keyhole slot.
9. Remove the front window channel from the door.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front window channel into the door, top end first.
2. Insert the lower fastener (3) into the keyhole slot.
3. Rotate the top of the front window channel rearward and align on the lower edge of the
window.

4. Install the top fastener.

Tighten
Tighten the front window channel fasteners to 9 N·m (80 lb in).

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Rear Side Door Window Inner Sealing Strip

Replacement
Removal Procedure

1. Lower the window.

2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Starting at one end of the door window inner belt seal strip (1) pull upward in order to
release the seal strip.

© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure

1. If the auxiliary water deflector was removed during disassembly, install the deflector.
1.1. Insert the water deflector into the rear portion of the door, inboard of the window.
1.2. Fold the perforated part of the deflector over the door flange.
1.3. Press to secure the water deflector to the door flange.

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2. Work from one end of the seal strip to the other.

3. Position the door window belt seal strip over the flange of the door inner panel.
4. Position the notch in the belt seal strip to the rear stationary window frame.

Important: Do not distort the seal strip.

5. Press down in order engage the door window inner belt seal strip the entire length of the
door.
6. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Window Outer Sealing Strip

Replacement
Removal Procedure
1. Lower the rear door window.

2. Remove rear door outer belt sealing strip from the rear door pinchweld flange, by gently
pulling up, being careful not to distort the strip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the rear door outer belt sealing strip to the rear door pinchweld flange .
1.1. Align the sealing strip clips to the slots in the pinchweld flange of the door.
1.2. Push the sealing strip down to fully seat and secure the strip to the door.
2. Raise the rear door window.

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Rear Side Door Window Regulator Motor Replacement

Removal Procedure
1. Close the window.
2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .

4. Remove the window regulator. Refer to Rear Side Door Window Regulator Replacement .
5. Remove the fasteners (1,2,3) securing the power window motor to the window regulator.
6. Remove the power window motor from the regulator.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the power window motor (1) to the window regulator (3).

2. Install the power window motor to regulator fasteners.

Tighten
Tighten the power window motor fasteners to 4 N·m (62 lb in).

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3. Install the window regulator. Refer to Rear Side Door Window Regulator Replacement .
4. Check for proper operation of the window motor .
5. Reinstall the water deflector. Refer to Rear Side Door Water Deflector Replacement .
6. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Window Regulator Replacement

Removal Procedure

1. Lower the window half way down in order to gain access to the window retainer clamp
fasteners (1).
2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the door module. Refer to Door Control Module Replacement .
4. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
5. Loosen the window retainer clamp fasteners.

Important: You may need to use masking tape in order to hold the window in place while
removing the regulator.

6. Slide the window to the full up position.

7. Disconnect the electrical connector from the motor.
8. Remove the window regulator to inner door panel fasteners (1-3).
9. Remove the window regulator.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the window regulator into the door.

2. Install the window regulator fasteners.

Tighten
Tighten the fasteners in this order, (1, 3, 2), to 9 N·m (80 lb in).

3. Provide power to the window motor and run the motor to the fully closed position.

Tighten
Tighten the window retainer clamp fasteners to 11 N·m (95 lb in).

4. Connect the window motor electrical connector.

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Rear Side Door Window Replacement

6. Loosen the window regulator to window clamps.

7. Remove the window by lifting up and out.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the window down into the door assembly making sure the window is in the run
channels.
2. Locate the window into the two window regulator to window clamps.
3. Install the window inner belt sealing strip. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .

4. Connect a power source to the window motor and run the window to the full up position.

Tighten
Tighten the window clamp fasteners to 11 N·m (98 lb in).

5. Install water deflector. Refer to Rear Side Door Water Deflector Replacement .
6. Install the door module. Refer to Door Control Module Replacement .
7. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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Rear Side Door Window Switch Replacement

Removal Procedure

1. Place forefinger under the lower rear edge of the switch plate.
2. Place thumb at the upper rear end of the switch plate along the curved surface.
3. While pulling rearward with forefinger and holding pressure with thumb, flex and lift the rear
of the switch plate upwards.
4. Insert a small flat bladed tool under the forward edge of the switch plate.
5. Gently pry the forward edge of the switch plate upwards.
6. Lift the entire switch plate upwards to remove.
7. Disconnect the electrical connector.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the electrical connectors.

2. Slide the rear edge of the switch plate down into the slot in the door trim panel.
3. Snap the forward end of the switch plate down into the door trim panel.

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Rear Side Door Window Weatherstrip Replacement

Removal Procedure
1. Lower the window all the way down.
2. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
3. Remove the door module. Refer to Door Control Module Replacement .
4. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
5. Remove the window inner belt sealing strip. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
6. Remove the window outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
7. Remove the window. Refer to Rear Side Door Window Replacement .

8. Remove the rear door window weatherstrip fasteners.

9. Grasp the lower front edge of the window weatherstrip.
10. Pull the weatherstrip out of the door frame.
11. Remove the fastener from the run channel.
12. Slide the window weatherstrip forward until it clears the door frame.
13. Remove the weatherstrip.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Position the rear door stationary window and the weatherstrip into the door frame.
2. Install and fully seat the upper rear corner of the weatherstrip into the upper auxiliary
molding and over the pinch-weld flange.

3. Install the window weatherstrip fastener.

Tighten
Tighten the fastener to 6 N·m (53 lb in).

4. Position the remainder of the window weatherstrip into the door frame.
5. Install the window. Refer to Rear Side Door Window Replacement .
6. Install the window outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement .
7. Install the window inner belt sealing strip. Refer to Rear Door Window Belt Inner Sealing
Strip Replacement .
8. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
9. Install the door module. Refer to Door Control Module Replacement .
10. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

2002 ENGINE

Engine Mechanical - Aurora 3.5L

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Microsoft
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12:22:37 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 1: Fastener Tightening Specifications (1 Of 2)

Fig. 2: Fastener Tightening Specifications (2 Of 2)

ENGINE MECHANICAL SPECIFICATIONS

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 3: Engine Mechanical Specifications

SEALERS, ADHESIVES, AND LUBRICANTS

Fig. 4: Sealers, Adhesives, & Lubricants

Courtesy of GENERAL MOTORS CORP.

Microsoft
Friday, March 12, 2010 12:22:38 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL

Begin the system diagnosis by reviewing the DISASSEMBLED VIEWS, ENGINE COMPONENT
DESCRIPTION, Drive Belt System Description , LUBRICATION DESCRIPTION and NEW PRODUCT
INFORMATIONand . 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
- Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the
procedure is located.

SYMPTOMS - ENGINE MECHANICAL

Strategy Based Diagnostics

1. Perform a DIAGNOSTIC SYSTEM CHECKS in Engine Controls before using the symptom tables (if
applicable).
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
DISASSEMBLED VIEWS, ENGINE COMPONENT DESCRIPTION, Drive Belt System Description ,
LUBRICATION DESCRIPTION and NEW PRODUCT INFORMATION.

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for
repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The
diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to STRATEGY
BASED DIAGNOSIS in General Information.

Visual/Physical Inspection

 Inspect for aftermarket devices which could affect the operation of the Engine. Refer to CHECKING
AFTERMARKET ACCESSORIES in Wiring Systems.
 Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
 Check for the correct oil level, proper oil viscosity, and correct filter application.
 Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
 Compare the engine sounds (if applicable) to a known good engine and make sure you are not trying to
correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.

Symptom List

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:

 Base Engine Misfire without Internal Engine Noises

 Base Engine Misfire with Abnormal Internal Lower Engine Noises
 Base Engine Misfire with Abnormal Valve Train Noise
 Base Engine Misfire with Coolant Consumption
 Base Engine Misfire with Excessive Oil Consumption
 Engine Noise on Start-Up, but Only Lasting a Few Seconds
 Upper Engine Noise, Regardless of Engine Speed
 Lower Engine Noise, Regardless of Engine Speed
 Engine Noise Under Load
 Engine Will Not Crank - Crankshaft Will Not Rotate
 Oil Consumption Diagnosis
 Oil Pressure Diagnosis and Testing
 Oil Leak Diagnosis
 Engine Compression Test

BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 5: Base Engine Misfire without Internal Engine Noises (1 Of 2)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 6: Base Engine Misfire without Internal Engine Noises (2 Of 2)

BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES

Fig. 7: Base Engine Misfire with Abnormal Internal Lower Engine Noises

BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 8: Base Engine Misfire With Abnormal Valve Train Noise

BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION

Fig. 9: Base Engine Misfire with Coolant Consumption

BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION

Fig. 10: Base Engine Misfire with Excessive Oil Consumption

ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 11: Engine Noise on Start-Up, but Only Lasting a Few Seconds

UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Fig. 12: Upper Engine Noise, Regardless of Engine Speed (1 Of 2)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 13: Upper Engine Noise, Regardless of Engine Speed (2 Of 2)

LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED

Fig. 14: Lower Engine Noise, Regardless of Engine Speed (1 Of 2)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 15: Lower Engine Noise, Regardless of Engine Speed (2 Of 2)

ENGINE NOISE UNDER LOAD

Fig. 16: Engine Noise Under Load

ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 17: Engine Will Not Crank - Crankshaft Will Not Rotate (1 Of 2)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 18: Engine Will Not Crank - Crankshaft Will Not Rotate (2 Of 2)

OIL CONSUMPTION DIAGNOSIS

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 19: Oil Consumption Diagnosis

OIL PRESSURE DIAGNOSIS AND TESTING

Tools Required:

 J 21867 Pressure Gage and Hose Assembly

 J 43027 Oil Pressure Adapter

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time (2-
3 minutes) and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full
on the oil level indicator.
3. Run the engine briefly (10-15 seconds) and verify low or no oil pressure on the vehicle gauge or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following:
 Foamy oil

 Slow idle speed

 Plugged oil filter

 Oil diluted by the following:

 Water

 Engine coolant

 Unburned fuel mixtures

 Malfunctioning oil filter bypass valve

 Incorrect or faulty oil pressure gage

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Incorrect or faulty oil pressure gage sensor



 Improper engine oil viscosity for the expected temperature

6. Remove the oil pressure gage sensor.

7. Install the J 21867 with the J 43027.

Fig. 20: Installing Pressure Gauge Hose Assembly & Oil Pressure Adapter

8. Start the engine and then allow the engine to reach normal operation temperature.
9. Measure the engine oil pressure.
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

10. Compare the readings to the Engine Mechanical Specifications

11. If the engine oil pressure is below specifications, inspect the engine for one or more of the following:
 Worn or dirty oil pump

 Loose oil pump-to-engine block bolts

 Missing or damaged oil pump screen O-ring seal

 Damage or leak in the oil pump screen suction tube

 Damage or leak in the timing chain tensioner oil tube

 Malfunctioning oil pump pressure regulator valve

 Missing or incorrectly installed oil gallery plugs

 Excessive bearing clearance for the following:

 Connecting rod(s)

 Balance shaft

 Crankshaft

 Camshaft(s)

 Cracked, porous or restricted oil galleries

 Broken valve lifters

12. Repair or replace components as necessary.

OIL LEAK DIAGNOSIS

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 21: Oil Leak Diagnosis (1 Of 2)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 22: Oil Leak Diagnosis (2 Of 2)

CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS

Fig. 23: Crankcase Ventilation System Inspection/Diagnosis

DRIVE BELT CHIRPING DIAGNOSIS

Diagnostic Aids

The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to
spray a small amount of water on the drive belt(s) in order to duplicate the customers concern. If spraying water
on the drive belt(s) duplicates the symptom, cleaning the belt pulleys may be the probable solution.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the chirping noise.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the noise is related to the drive belt. When removing the drive belt(s) the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belt removed.
4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive
belt grooves from the accumulation of rubber dust.
6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a mis-aligned pulley using a straight edge in the pulley grooves
across two or three pulleys. If a mis-aligned pulley is found refer to that accessory drive component for
the proper installation procedure for that pulley.
10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 24: Drive Belt Chirping Diagnosis

DRIVE BELT SQUEAL DIAGNOSIS

Diagnostic Aids

A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the squeal noise.

If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are
operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose
or wrong fluid, or a generator failing are suggested items to inspect.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the squeal noise is the drive belt(s) or an accessory drive component. When removing
the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set
when the engine is operating with the drive belt removed.
4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt
remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory
drive components with the engine operating by varying the load on the components to verify that the
components operate properly.
5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner
from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction.
7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a mis-aligned pulley using a straight edge in the pulley grooves
across two or three pulleys. If a mis-aligned pulley is found refer to that accessory drive component for
the proper installation procedure for that pulley.
8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle
compare the pulley sizes.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 25: Drive Belt Squeal Diagnosis

DRIVE BELT WHINE DIAGNOSIS

Diagnostic Aids

The drive belt(s) will not cause the whine noise. If the whine noise is intermittent. Verify the accessory drive
components by varying their loads making sure they are operated to their maximum capacity. Such items but
not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or
the generator failing.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive
components. When removing the drive belt the water pump may not be operating and the engine may
overheat. Also DTCs may set when the engine is operating with the drive belt removed.
4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings.
The drive belt(s) may have to be installed and the accessory drive components operated separately by
varying their loads. Refer to the suspected accessory drive component for the proper inspection and
replacement procedure.
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Fig. 26: Drive Belt Whine Diagnosis

DRIVE BELT RUMBLING DIAGNOSIS

Diagnostic Aids

Vibration from the engine operating may cause a body component or another part of the vehicle to make
rumbling noise.

The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be
the only repair for the symptom.

If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s)
is installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom.
3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be
confused with an internal engine noise due to the similarity in the description. Remove only one drive belt
at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive
belt removed.
4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of
the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and
may be seen at the edge of the belt our felt as a lump in the belt.
5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
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Fig. 27: Drive Belt Rumbling Diagnosis

DRIVE BELT VIBRATION DIAGNOSIS

Diagnostic Aids

The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C
system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the
generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive
components.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom such as the exhaust system, or the drivetrain.
3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration.
When removing the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to
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inspect the condition of the belt.

6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
8. This step should only be performed if the water pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive
play. Compare the water pump with a known good water pump.
9. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.

Fig. 28: Drive Belt Vibration Diagnosis

DRIVE BELT FALLS OFF DIAGNOSIS

Diagnostic Aids

If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
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If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive
belt.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt
when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off.
Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a mis-aligned pulley using a straight edge in the pulley grooves
across two or three pulleys. If a mis-aligned pulley is found refer to that accessory drive component for
the proper installation procedure of that pulley.
5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.

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Fig. 29: Drive Belt Falls Off Diagnosis

DRIVE BELT EXCESSIVE WEAR DIAGNOSIS

Diagnostic Aids

Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the
application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt(s) to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s)
fall off.

Test Description

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The number(s) below refer to the step number(s) on the diagnostic table.

2. The inspection is to verify the drive belt(s) is correctly installed on 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.
3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The
drive belt ribs should match all of the grooves on all of the pulleys.
4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt(s) should not come in contact with an engine or a body component when
snapping the throttle.

Fig. 30: Drive Belt Excessive Wear Diagnosis

DRIVE BELT TENSIONER DIAGNOSIS

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Fig. 31: Drive Belt Tensioner Diagnosis

ENGINE COMPRESSION TEST

Tools Required

J 39313 Spark Plug Port Adapter

A compression pressure test of the engine cylinders determines the condition of the rings, the valves and the
head gasket.

1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge.
2. Turn the engine OFF.

Important: Remove the Powertrain Control Module (PCM) and the ignition fuse from the IP fuse block.

3. Disable the ignition.

4. Disable the fuel systems.
5. Remove the spark plugs from all cylinders.
6. Remove the air duct from the throttle body.
7. Block the throttle plate in open position.
8. Measure the engine compression, using the following procedure:
8.1. Install the compression gauge firmly to the spark plug hole.
8.2. Have an assistant crank the engine through, at least four compression strokes, in the testing
cylinder.
8.3. Check and record the readings on the gauge at each stroke.
8.4. Disconnect the gauge.
8.5. Repeat the compression test for each cylinder.
9. Record the compression readings from all of the cylinders.
 The lowest reading should not be less than 70 percent of the highest reading.

 No cylinder reading should be less than 965 kPa (140 psi).

10. The following are examples of measurement problems:

 When the compression measurement is normal, the compression builds up quickly and evenly to
specified compression on each cylinder
 When low compression is caused by the piston rings, compression is low on the first stroke and
tends to build up on the following strokes, but does not reach normal. Compression improves
considerably with the addition of oil. Use approximately three squirts of oil from a plunger-type
oiler.
 When low compression is caused by the valves, the measurement is low on the first stroke and does
not build up even with the addition of oil.
 Leaking head gaskets will provide the same results as worn valves but engine coolant may be
identified in the crankcase. In addition, a leaking head gasket will give low readings on paired
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2002 ENGINE Engine Mechanical - Aurora 3.5L

cylinders.
11. Remove the block from the throttle plate.
12. Install the air duct to the throttle body.
13. Install the spark plugs.
14. Install the Powertrain Control Module (PCM).
15. Install the ignition fuses to the IP fuse block.

REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT

Removal Procedure

1. Remove the drive belt tension by lifting or rotating the drive belt tensioner off of the drive belt, using a
3/8-inch or 1/2-inch breaker bar.
2. Remove the drive belt.
3. Inspect all the components and pulleys driven by the drive belt.

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Fig. 32: Identifying Drive Belt Routing

Installation Procedure

Important: Make sure that the drive belt is aligned into the proper grooves of the accessory drive belt pulleys.

1. Install the drive belt under the drive belt tensioner pulley by lifting or rotating the drive belt tensioner,
using a 3/8-inch or 1/2-inch breaker bar.
2. Inspect the drive belt and the drive belt system.
3. Make sure that the drive belt is properly routed.

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4. Inspect the drive belt length scale on the drive belt tensioner for the proper installed length.

Fig. 33: Identifying Drive Belt Routing

DRIVE BELT TENSIONER REPLACEMENT

Removal Procedure

1. Remove the drive belt. Refer to Drive Belt Replacement .

2. Remove the drive belt tensioner bolt from the cylinder head (1).

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3. Remove the drive belt tensioner.

Fig. 34: Installing Drive Belt Tensioner

Installation Procedure

1. Install the drive belt tensioner.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
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thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

2. Install the drive belt tensioner bolt to the cylinder head (1).

Tighten

Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

3. Install the drive belt. Refer to Drive Belt Replacement .

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Fig. 35: Installing Drive Belt Tensioner

DRIVE BELT IDLER PULLEY REPLACEMENT

Removal Procedure

1. Remove the drive belt. Refer to Drive Belt Replacement .

2. Remove the idler pulley bolt.
3. Remove the idler pulley.

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Fig. 36: Removing Drive Belt Idler Pulley

Installation Procedure

1. Install the idler pulley.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

2. Install the idler pulley bolt.

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Tighten

Tighten the idler pulley bolt to 50 N.m (37 lb ft).

3. Install the drive belt. Refer to Drive Belt Replacement .

Fig. 37: Installing Drive Belt Idler Pulley

ENGINE SUPPORT FIXTURE

Tools Required

 J 28467-B Universal Engine Support Fixture

 J 42478 Engine Support Fixture Adapters

Installation Procedure

1. Remove the air inlet grill. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.
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2. Remove the rearward strut bolts from the right and left strut towers.
3. Install the J 42478 (2) into the strut threads.
4. Place the strut adapters (J 28467-33A) (1) on top of the four remaining forward strut tower bolts.

Fig. 38: Locating Forward Strut Tower Bolts

5. Install the strut tower support assemblies (J 28467-5A) over the adapters J 42478 and (J 28467-33A).

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Fig. 39: Installing Strut Tower Support Assemblies

6. Install the T-Bolts to the J 42478 and (J 28467-33A).

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Fig. 40: Installing T-Bolts To Engine Support Fixture Adapters

7. Install the strut tower tube (J 28467-3) into the strut tower support assemblies (J 28467-5A).

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Fig. 41: Installing Strut Tower Tube

8. Install the 1/2 in. x 2.5 in. quick release pin (J 28467-10) (2) through the strut tower support assembly (J
28467-5A) (3) and the strut tower tube (J 28467-3) (1) on one side only.

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Fig. 42: Installing Quick Release Pin Through Strut Tower Support Assembly & Strut Tower Tube

9. Install the radiator shelf tube (J 28467-2A) on top of the strut tower tube (J 28467-3) over the front engine
lift bracket.

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Fig. 43: Installing Radiator Shelf Tube

10. Install the round tube of the front support assembly (J 28467-4A) through the large hole in the radiator
shelf tube (J 28467-2A). The hole used in the radiator shelf tube (J 28467-2A) depends on the vehicle
application.
11. Place the rubber padded foot of the front support assembly (J 28467-4A) on the upper tie bar.
12. Install the 7/16 in. x 2.0 in. quick release pin (J 28467-9) through the hole in the front support assembly (J
28467-4A) in order to level the radiator shelf tube (J 28467-2A).

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Fig. 44: Installing Front Support Assembly Through Radiator Shelf Tube

13. Install the passenger side cross bracket assembly (J 28467-1A).

14. Hand tighten the cross bracket assembly (J 28467-1A) wing nuts.

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Fig. 45: Installing Passenger Side Cross Bracket Assembly

15. Install the second radiator shelf tube (J 28467-2A) on the top of the strut tower tube (J 28467-3) over the
rear engine lift bracket.

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Fig. 46: Installing Second Radiator Shelf Tube

16. Install the round tube of the front support assembly (J 28467-4A) through the large hole in the radiator
shelf tube (J 28467-2A). The hole used in the radiator shelf tube (J 28467-2A) depends on the vehicle
application.
17. Place the rubber padded foot of the front support assembly (J 28467-4A) on the upper tie bar.
18. Install the 7/16 in. x 2.0 in. quick release pin (J 28467-9) through the hole in the front support assembly (J
28467-4A) in order to level the radiator shelf tube (J 28467-2A).

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Fig. 47: Installing Front Support Assembly Through Radiator Shelf Tube

19. Install the drivers side cross bracket assembly (J 28467-1A).

20. Hand tighten the cross bracket assembly (J 28467-1A) wing nuts.

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Fig. 48: Installing Driver Side Cross Bracket Assembly

21. Install the lift hook (J 28467-7A) through the lift hook bracket (J 28467-6A).
22. Install the 1/2 in. lift hook washer and lift hook wing nut (J 28467-34) onto the lift hook (J 28467-7A).

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Fig. 49: Installing Lift Hook Through Life Hook Bracket, Washer & Wing Nut

23. Install the assembled lift hook bracket (J 28467-6A) (1) over the passenger side radiator shelf tube (J
28467-2A) (2).
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Fig. 50: Installing Assembled Lift Hook Bracket Over Passenger Side Radiator Shelf Tube

24. Adjust the assembled lift hook bracket (J 28467-6A) in order to align the hook with the front engine lift
hook bracket.

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Fig. 51: Aligning Hook With Front Engine Lift Hook Bracket

25. Install the lift hook (J 28467-7A) through the front engine lift hook bracket. Ensure the hook does not
damage the surrounding components.

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Fig. 52: Installing Lift Hook Through Front Engine Lift Hook Bracket

26. Repeat steps 21 and 22.

27. Install the assembled lift hook bracket (J 28467-6A) (1) over the drivers side radiator shelf tube (J 28467-
2A) (2).

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Fig. 53: Installing Assembled Lift Hook Bracket Over Drivers Side Radiator Shelf Tube

28. Install the assembled lift hook bracket (J 28467-6A) over the drivers side radiator shelf tube (J 28467-
2A).
29. Adjust the assembled lift hook bracket (J 28467-6A) in order to align the hook with the rear engine lift
hook bracket.

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Fig. 54: Installing & Aligning Lift Hook Bracket

30. Install the lift hook (J 28467-7A) through the rear engine lift hook bracket. Ensure the hook does not
damage the surrounding components.

Fig. 55: Installing Lift Hook Through Rear Engine Lift Hook Bracket

31. Hand tighten the lift hook wing nuts (J 28467-34) securely to remove all slack from the engine support
fixture assembly.

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Fig. 56: Tightening Lift Hook Wing Nuts

Removal Procedure

1. Remove the J 28467-B.

2. Remove the J 42478.

CAUTION: Use the correct fastener in the correct location. Replacement

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3. Install the 2 rearward strut bolts to the right and left strut towers.

Tighten

Tighten the strut tower bolts to 45 N.m (33 lb ft).

4. Install the air inlet grill. Refer to AIR INLET GRILLE PANEL REPLACEMENT in Body Front End.

Fig. 57: Removing Universal Engine Support Fixture & Adapters

ENGINE MOUNT INSPECTION

Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is
the engine mount, not the engine or accessories.

1. Install the engine support fixture. Refer to Engine Support Fixture . Raising the engine removes the
weight from the engine mount and creates slight tension in the rubber.
2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount
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exhibits any of the following conditions:

 The hard rubber surface is covered with heat check cracks.

 The rubber is separated from the metal plate of the engine mount.

 The rubber is split through the center of the engine mount.

3. If there is movement between the metal plate of the engine mount and its attaching points, lower the
engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine
mount bracket. Refer to Engine Mount Replacement - Front or Engine Mount Replacement - Right .

ENGINE MOUNT REPLACEMENT - FRONT

Removal Procedure

1. Remove the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .
2. Raise and support the vehicle.
3. Remove the nut securing the front engine mount to the engine frame.
4. Lower the vehicle.
5. Remove the front engine mount from the vehicle.

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Fig. 58: Removing Front Engine Mount

Installation Procedure

1. Insert the front engine mount stud (long) through the hole in the engine frame.
2. Raise and support the vehicle.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
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affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

3. Install the nut securing the front engine mount to the engine frame.

Tighten

Tighten the front engine mount nut to 70 N.m (52 lb ft).

4. Lower the vehicle.

5. Install the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .

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Fig. 59: Installing Front Engine Mount

ENGINE MOUNT REPLACEMENT - RIGHT

Removal Procedure

1. Raise and support the vehicle.

2. Remove the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in
Tires and Wheels.
3. Support the engine assembly with a suitable jack.
4. Remove the nut securing the right engine mount to the right engine mount bracket.
5. Lower the jack allowing the engine to lower slightly.

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Fig. 60: Removing Right Engine Mount To Right Engine Mount Bracket Nut

6. Remove the nut (1) and bolt (4) securing the right engine mount (3) to the frame rail.
7. Remove the 2 nuts (2) securing the right engine mount (3) to the frame rail.
8. Remove the right engine mount (3).

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Fig. 61: Removing Right Engine Mount

Installation Procedure

1. Position the right engine mount (3) to the body rail.

2. Install the right engine mount attaching bolt (4) and nut (1) to the frame rail.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service

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procedure. Do not use paints, lubricants, or corrosion inhibitors on

fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

3. Install the 2 nuts (2) securing the right engine mount to the body rail.

Tighten

Tighten the right engine mount to body rail nuts (1, 2) to 70 N.m (52 lb ft).

4. Raise the engine into position.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 62: Installing Right Engine Mount

5. Install the nut securing the right engine mount to the right engine mount bracket.

Tighten

Tighten the right engine mount nut to 80 N.m (59 lb ft).

6. Remove the engine support jack.

7. Install the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires
and Wheels.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

8. Lower the vehicle.

Fig. 63: Installing Right Engine Mount To Right Engine Mount Bracket Nut

ENGINE MOUNT BRACKET REPLACEMENT - FRONT

Removal Procedure

1. Remove the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (LX5) or
EXHAUST MANIFOLD REPLACEMENT - LEFT (L47 in Engine Exhaust.
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2002 ENGINE Engine Mechanical - Aurora 3.5L

2. Install the engine support fixture. Refer to Engine Support Fixture .

3. Remove the nut (1) securing the front engine mount to the front engine mount bracket.

Fig. 64: Removing Front Engine Mount To Front Engine Mount Bracket Nut

4. Remove the 3 bolts securing the front engine mount bracket to the engine.
5. Remove the front engine mount bracket from the vehicle.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 65: Removing Front Engine Mount Bracket Bolts

Installation Procedure

1. Position the front engine mount bracket to the engine.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 66: Installing Front Engine Mount Bracket Bolts

CAUTION: Use the correct fastener in the correct location. Replacement

2. Install the front engine mount bracket bolts (1-3).

Tighten

Tighten the front engine mount bracket bolts in sequence (1-3) to 58 N.m (43 lb ft).
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2002 ENGINE Engine Mechanical - Aurora 3.5L

3. Install the nut (1) securing the front engine mount to the front engine mount bracket.

Tighten

Tighten the front engine mount to bracket nut to 55 N.m (41 lb ft).

4. Remove the engine support fixture. Refer to Engine Support Fixture .

5. Install the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (LX5) or
EXHAUST MANIFOLD REPLACEMENT - LEFT (L47 in Engine Exhaust.

Fig. 67: Installing Front Engine Mount To Front Engine Mount Bracket Nut

ENGINE MOUNT BRACKET REPLACEMENT - RIGHT

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Removal Procedure

1. Raise and support the vehicle.

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Fig. 68: Removing Front Engine Mount To Right Engine Mount Bracket Nut

6. Remove the 3 bolts securing the right engine mount bracket to the engine.
7. Remove the right engine mount bracket.

Fig. 69: Removing Right Engine Mount Bracket

Installation Procedure

 Position the right engine mount bracket to the engine.

CAUTION: Use the correct fastener in the correct location. Replacement

systems.

 Install the bolts securing the right engine mount bracket to the engine.

Tighten

Tighten the right engine mount bracket bolts to 60 N.m (44 lb ft).

 Raise the engine into position.

Fig. 70: Installing Right Engine Mount Bracket

 Install the nut securing the right engine mount to the right engine mount bracket.

Tighten

Tighten the right engine mount nut to 80 N.m (59 lb ft).

 Remove the engine support jack.

 Install the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires
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and Wheels.
 Lower the vehicle.

Fig. 71: Installing Front Engine Mount To Right Engine Mount Bracket Nut

BALANCE SHAFT OPENING COVER REPLACEMENT

Removal Procedure

1. Remove the intake manifold. Refer to Intake Manifold Replacement .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

2. Remove the balance shaft cover bolts.

3. Lift the balance shaft cover from the engine valley.
4. Remove the balance shaft cover gasket. Carefully scrape any remaining gasket material from the cylinder
block and cover plate.
5. Clean and inspect the balance shaft cover. Refer to BALANCE SHAFT CLEANING AND
INSPECTION in Engine Mechanical-3.5L Unit Repair.

Fig. 72: Removing Balance Shaft Opening Cover

Installation Procedure

1. Place the balance shaft cover gasket in position on the cylinder block. Make sure any remaining gasket
material is removed from the cylinder block and cover.
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2. Lower the balance shaft cover into the engine valley.

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the balance shaft cover bolts.

Tighten

Tighten the balance shaft cover bolts to 12 N.m (106 lb in).

4. Install the intake manifold. Refer to Intake Manifold Replacement .

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Fig. 73: Installing Balance Shaft Opening Cover

FUEL INJECTOR SIGHT SHIELD REPLACEMENT

Removal Procedure

1. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
2. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 74: Removing Fuel Injector Sight Shield

Installation Procedure

1. Insert the tab of the fuel injector sight shield under the engine bracket.
2. Lower the fuel injector sight shield.
3. Align the holes in the fuel injector sight shield with the studs.

CAUTION: Use the correct fastener in the correct location. Replacement

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2002 ENGINE Engine Mechanical - Aurora 3.5L

systems.

4. Install the 2 fuel injector sight shield nuts onto the studs.

Tighten

Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

Fig. 75: Installing Fuel Injector Sight Shield

POSITIVE CRANKCASE VENTILATION (PCV) VALVE REPLACEMENT

Removal Procedure

1. Remove the 2 nuts from the fuel injector sight shield.

2. Lift the sight shield from the front and pull forward to disengage the rear tab from the bracket.

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Fig. 76: Removing Fuel Injector Sight Shield

3. Pull the PCV valve (2) from the left camshaft cover (3).
4. Remove the PCV valve (2) from the PCV hose (1).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 77: Removing PCV Valve From PCV Hose

Installation Procedure

1. Install the PCV valve (2) into the PCV hose (1).
2. Push the PCV valve (2) into the left camshaft cover (3).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 78: Installing PCV Valve

3. Align the rear tab with the slot in the rear bracket and push the sight shield inward to engage.
4. Pull sight shield down and align the studs on the intake manifold with the holes in the sight shield.

CAUTION: Use the correct fastener in the correct location. Replacement

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systems.

5. Install the fuel injector sight shield nuts.

Tighten

Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

Fig. 79: Installing Fuel Injector Sight Shield

CRANKCASE VENTILATION HOSES/PIPES REPLACEMENT

Removal Procedure

1. Remove the 2 nuts from the fuel injector sight shield.

2. Lift the sight shield from the front and pull forward to disengage the rear tab from the bracket.

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Fig. 80: Removing Fuel Injector Sight Shield

3. Disconnect the PCV fresh air tube (2) from the right camshaft cover.
4. Remove the PCV fresh air tube (2) from the throttle body.
5. Remove the retaining clip securing the PCV dirty air tube (1).
6. Disconnect the PCV dirty air tube (1) from the PCV valve.
7. Remove the PCV dirty air tube (1) from the intake manifold.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 81: Removing Ventilation Hoses/Pipes

Installation Procedure

1. Connect the PCV dirty air tube (1) to the intake manifold fitting.
2. Connect the PCV dirty air tube (1) to the PCV valve.

Important: Ensure that the PCV dirty air tube is located between the tabs of the intake manifold.

3. Attach the retaining clip to the intake manifold.

4. Connect the PCV fresh air tube (2) to the left camshaft cover.
5. Connect the PCV fresh air tube (2) to the throttle body.

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Fig. 82: Ventilation Hoses/Pipes

6. Align the rear tab with the slot in the rear bracket and push the sight shield inward to engage.
7. Pull sight shield down and align the studs on the intake manifold with the holes in the sight shield.

CAUTION: Use the correct fastener in the correct location. Replacement

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2002 ENGINE Engine Mechanical - Aurora 3.5L

systems.

8. Install the fuel injector sight shield nuts.

Tighten

Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

Fig. 83: Installing Fuel Injector Sight Shield

INTAKE MANIFOLD REPLACEMENT

Removal Procedure

1. Disconnect the battery ground (negative) cable. Refer to BATTERY NEGATIVE CABLE
DISCONNECT/CONNECT PROCEDURE in Electrical.
2. Carefully disconnect the throttle body air inlet duct from the throttle body.

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3. Partially drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING
COOLING SYSTEM in Engine Cooling.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Fig. 84: Removing Fuel Injector Sight Shield

5. Disconnect the accelerator cable from the throttle body and accelerator cable bracket. Refer to
THROTTLE BODY in Engine Controls-3.5L and CRUISE CONTROL CABLE (3.5L V6) in Cruise
Control.
6. Disconnect the cruise control cable from the throttle body and accelerator cable bracket. Refer to
CRUISE CONTROL CABLE (3.5L V6) in Cruise Control.
7. Disconnect the throttle body coolant hoses from the throttle body.
8. Disconnect the fuel lines from the throttle body.

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Fig. 85: Disconnecting Fuel Lines From Throttle Body

9. Disconnect the fuel vapor line from the EVAP canister purge solenoid. Refer to EVAP CANISTER
PURGE SOLENOID in Engine Controls-3.5L.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 86: Disconnecting Fuel Vapor Line From EVAP Canister Purge Solenoid

10. Disconnect the brake booster vacuum hose from the brake booster.

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Fig. 87: Disconnecting Brake Booster Vacuum Hose From Brake Booster

11. Disconnect the A/C vacuum hose from the intake manifold.

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Fig. 88: Identifying A/C Vacuum Hose

12. Disconnect the surge tank inlet pipe retainer from the fuel injector rail.
13. Disconnect the fuel injector wiring harness connectors. Refer to COMPONENT LOCATIONS in Engine
Controls-3.5L.
14. Disconnect the engine wiring harness connectors from the following components:

Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.

Throttle position (TP) sensor



 Idle air control (IAC) valve

 EVAP canister purge solenoid

 Manifold absolute pressure (MAP) sensor

15. Remove the engine wiring harness channel bolts from the camshaft covers.

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16. Remove and set aside the engine wiring harness and channel. Refer to COMPONENT LOCATIONS in
Engine Controls-3.5L.
17. Disconnect the fuel pressure regulator vacuum tube (1) from the regulator (2) and the throttle body (3).

Fig. 89: Disconnect Fuel Pressure Regulator Vacuum Tube From Regulator And Throttle Body

18. Disconnect and remove both feed tubes (1, 2) from the camshaft covers and intake manifold.

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Fig. 90: Removing Feed Tubes From Camshaft Covers & Intake Manifold

Important: The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The
EGR valve outlet pipe must be replaced if disconnected from the water crossover.

19. Remove the EGR valve outlet pipe bolts from the intake manifold and the water crossover.
20. Remove the EGR outlet pipe and discard.

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Fig. 91: Removing EGR Outlet Pipe

21. Disconnect the 4 fuel rail snap-lock retainers by pushing toward the camshaft covers and lifting.
22. Remove the fuel rail (1) and fuel injectors (2) as an assembly and store in a clean, secure location away
from any heat sources.

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Fig. 92: Removing Fuel Rail & Fuel Injectors

23. Remove the intake manifold bolts.

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Fig. 93: Removing Intake Manifold Bolts

24. Disconnect the throttle body coolant hose from the water crossover feed tube (1).

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Fig. 94: Disconnecting Throttle Body Coolant Hose From Water Crossover Feed Tube

25. Remove the intake manifold.

26. Clean and inspect intake manifold. Refer to INTAKE MANIFOLD CLEANING AND INSPECTION in
Engine Mechanical-3.5L Unit Repair.

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Fig. 95: Removing Intake Manifold

Installation Procedure

Important: If you did NOT replace the intake manifold skip the intake manifold assembly.

1. If necessary, assemble the intake manifold. Refer to INTAKE MANIFOLD CLEANING AND
INSPECTION.
2. Install the intake manifold.

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Fig. 96: Installing Intake Manifold

3. Connect the throttle body heater hose to the water crossover feed tube (1).
4. Install the hose clamp.

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Fig. 97: Installing Hose Clamp

5. Loosely install the intake manifold bolts.

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Fig. 98: Installing Intake Manifold Bolts

CAUTION: Use the correct fastener in the correct location. Replacement

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6. Tighten the intake manifold bolts in sequence (1-8).

Tighten

Tighten the intake manifold bolts to 10 N.m (89 lb in).

Fig. 99: Identifying Intake Manifold Bolts Tightening Sequence

7. Inspect the fuel injector O-rings (2) for misalignment or damage. Replace the O-rings if necessary.

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8. Lubricate the intake manifold fuel injector bores with light mineral oil GM P/N 9981704, clean engine
oil, or equivalent.
9. Install the fuel rail (1) and fuel injectors (2) by aligning the fuel injectors with their respective ports and
pressing the 4 fuel rail snap-lock connectors into the intake manifold until they lock in place. DO NOT
apply excessive pressure to the fuel rail in place. The need for excessive pressure may be caused by
misalignment of a fuel injector and could cause damage to the seal or intake manifold.

Fig. 100: Installing Fuel Injector & Fuel Rail

Important: The EGR valve outlet pipe incorporates a crush seal connection at the water crossover. The
EGR valve outlet pipe must be replaced if disconnected from the water crossover.

10. Install the NEW EGR outlet pipe with NEW O-ring seal.
11. Install the EGR outlet pipe-to-intake manifold bolts.
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Tighten

Tighten the EGR outlet pipe-to-intake manifold bolts to 10 N.m (89 lb in).

12. Install the EGR outlet pipe-to-water crossover bolts.

Tighten

Tighten the EGR outlet pipe-to-water crossover bolts to 24 N.m (18 lb ft).

Fig. 101: Installing EGR Valve Outlet Pipe

13. Install the both feed tubes (1, 2) to the camshaft covers and intake manifold.

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Fig. 102: Installing Feed Tubes To Camshaft Covers & Intake Manifold

14. Connect the brake booster vacuum hose to the brake booster.

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Fig. 103: Connecting Brake Booster Vacuum Hose To Brake Booster

15. Connect the fuel pressure regulator vacuum tube (1) to the regulator (2) and the throttle body (3).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 104: Connecting Fuel Pressure Regulator Vacuum Tube To Regulator & Throttle Body

16. Connect the A/C vacuum hose to the intake manifold.

17. Install the engine wiring harness and channel. Refer to COMPONENT LOCATIONS in Engine Controls-
3.5L.
18. Install the engine wiring harness channel bolts to the camshaft covers. Refer to COMPONENT
LOCATIONS in Engine Controls-3.5L.

Tighten

Tighten the engine wiring harness channel bolts to 10 N.m (89 lb in).

19. Connect the surge tank inlet pipe retainer to the fuel injector rail.
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20. Connect the engine wiring harness connectors to the following components:

Refer to COMPONENT LOCATIONS in Engine Controls-3.5L.

 Throttle position (TP) sensor

 Idle air control (IAC) valve
 EVAP canister purge solenoid
 Manifold absolute pressure (MAP) sensor

Fig. 105: Identifying A/C Vacuum Hose

21. Connect the fuel injector wiring harness connectors. Refer to COMPONENT LOCATIONS in Engine
Controls-3.5L.
22. Connect the throttle body coolant hoses to the throttle body.

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23. Connect the accelerator cable to the throttle body and accelerator cable bracket. Refer to THROTTLE
BODY in Engine Controls-3.5L.
24. Connect the cruise control cable to the throttle body. Refer to CRUISE CONTROL CABLE (3.5L V6)
in Cruise Control.
25. Connect the fuel lines to the throttle body.

Fig. 106: Connecting Fuel Lines To Throttle Body

26. Connect the fuel vapor line to the EVAP canister purge solenoid. Refer to EVAP CANISTER PURGE
SOLENOID in Engine Controls-3.5L.

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Fig. 107: Connecting Fuel Vapor Line To EVAP Canister Purge Solenoid

27. Install the fuel injector sight shield (3). Refer to Fuel Injector Sight Shield Replacement .
28. Carefully connect the throttle body air inlet duct to the throttle body.
29. Fill the cooling system with engine coolant. Refer to DRAINING AND FILLING COOLING SYSTEM
in Engine Cooling.
30. Connect the battery ground (negative) cable. Refer to BATTERY NEGATIVE CABLE
DISCONNECT/CONNECT PROCEDURE in Engine Electrical.

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Fig. 108: Installing Fuel Injector Sight Shield

OIL LEVEL INDICATOR AND TUBE REPLACEMENT

Removal Procedure

1. Remove the oil level indicator.

2. Remove the oil level indicator tube bracket bolt from the oil level indicator tube bracket.
3. Remove the oil level indicator tube.
4. Remove the oil level indicator tube seal, and discard.

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Fig. 109: Removing Oil Level Indicator Tube

Installation Procedure

1. Clean the oil level indicator tube.

2. Install a NEW oil level indicator tube seal.
3. Install the oil level indicator tube into the engine block.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
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2002 ENGINE Engine Mechanical - Aurora 3.5L

fastener. Use the correct tightening sequence and specifications

when installing fasteners in order to avoid damage to parts and
systems.

4. Install the bolt to the oil level indicator tube bracket.

Tighten

Tighten the oil level indicator tube bracket bolt to 9 N.m (80 lb in).

5. Install the oil level indicator.

Fig. 110: Installing Oil Level Indicator Tube

CRANKSHAFT BALANCER REPLACEMENT

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Tools Required

 J 36660-A Electronic Torque Angle Meter

 J 41816 Crankshaft Balancer Remover
 J 42041 Front Crankshaft Seal Installer
 J 43010 Crankshaft Balancer Puller Adapter
 J 43442 Flywheel Holder

Removal Procedure

1. Remove the drive belt. Refer to Drive Belt Replacement .

2. Raise and support the vehicle.
3. Remove the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in
Tires and Wheels.
4. Remove the right front fascia extension. Refer to FASCIA EXTENSION REPLACEMENT in Bumpers.
5. Remove the right engine mount bracket. Refer to Engine Mount Bracket Replacement - Right in order
to gain clearance between the J 41816 and the frame rail.
6. Remove the torque converter cover. Refer to 4T65-E TRANSAXLE .
7. Install the J 43442 as shown.

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Fig. 111: Installing Flywheel Holder J43442

8. Loosen the crankshaft balancer bolt.

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Fig. 112: Loosening Crankshaft Balancer Bolt

9. Remove the crankshaft balancer bolt.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 113: Removing Crankshaft Balancer Bolt

10. Place the J 43010 for the J 41816 in position on the nose of the crankshaft.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 114: Placing J 43010 For J 41816 In Position On Crankshaft Nose

11. Mount the legs of the J 41816 into the recesses cast into the backside of the balancer inner hub.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 115: Mounting J41816 Legs Into Recesses Cast Into Backside Of Balancer Inner Hub

12. Tighten the center screw on the puller until the balancer pulls clear of the crankshaft end.
13. Remove the crankshaft balancer.
14. Clean and inspect the crankshaft balancer. Refer to CRANKSHAFT BALANCER CLEANING AND
INSPECTION in Engine Mechanical-3.5L Unit Repair.

Installation Procedure

1. Remove the front crankshaft seal mandrel J 42041-1 from the J 42041. The J 42041 consists of J 42041-2
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and J 42041.

Fig. 116: Removing Front Crankshaft Seal Mandrels From J42041

Important: Do not lubricate the crankshaft front oil seal or the crankshaft balancer sealing surfaces. The
crankshaft balancer is installed into a dry seal.

2. Place the balancer in position on the crankshaft.

3. Thread the J 42041 in the crankshaft. Make sure you engage at least ten threads of the J 42041 before
pressing the crankshaft balancer in place.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 117: Threading J 42041 In Crankshaft

4. Push the balancer into position by tightening the nut on the J 42041 until the large washer bottoms out on
the crankshaft end.
5. Remove the J 42041.

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Fig. 118: Removing J 42041

6. Install the crankshaft balancer retaining bolt.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 119: Installing Crankshaft Balancer Retaining Bolt

CAUTION: Use the correct fastener in the correct location. Replacement

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2002 ENGINE Engine Mechanical - Aurora 3.5L

systems.

7. Tighten the crankshaft balancer bolt.

Tighten

Tighten the crankshaft balancer bolt to 50 N.m +120 degrees (37 lb ft + 120 degrees) using the J 36660-
A.

Fig. 120: Tightening Crankshaft Balancer Bolt

8. Remove the J 43442.

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Fig. 121: Removing J 43442

9. Install the torque converter cover. Refer to 4T65-E TRANSAXLE .

10. Install the right engine mount bracket. Refer to Engine Mount Bracket Replacement - Right .
11. Install the right front fascia extension. Refer to FASCIA EXTENSION REPLACEMENT in Bumpers.
12. Install the right front wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires
and Wheels.
13. Lower the vehicle.
14. Install the drive belt. Refer to Drive Belt Replacement .

CRANKSHAFT FRONT OIL SEAL REPLACEMENT

Tools Required: J 42041 Front Crankshaft Seal Installer

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Removal Procedure

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

2. Do not gouge the front cover when prying out the front cover seal. The seal will remove easily.

Remove the front cover seal with a small pry bar or a flat-bladed tool.

Fig. 122: Removing Front Cover Seal

Installation Procedure

1. Place the front seal (1) onto the mandrel of the installation tool.

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Fig. 123: Identifying Front Seal

2. Slide the mandrel onto the screw of the installation tool.

3. Thread the J 42041 in the crankshaft. Make sure you engage at least ten threads of the J 42041 before
pressing the seal in place.

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Fig. 124: Identifying J 42041

4. Push the seal into position by tightening the nut on the installation tool until the mandrel bottoms out on
the crankshaft sprocket.

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Fig. 125: Installing Front Oil Seal

Important: The seal should NOT be flush with the front cover.

5. Check the installed depth of the seal (1). The seal should protrude 1-2 mm (0.039-0.078 in) from the front
cover.
6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 126: Checking Installed Seal Depth

ENGINE FRONT COVER REPLACEMENT

Removal Procedure

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

2. Remove the surge tank. Refer to SURGE TANK REPLACEMENT in Engine Cooling.
3. Remove the water pump. Refer to WATER PUMP REPLACEMENT (LX5) in Engine Cooling.
4. Remove the engine front cover coolant drain plug and drain the remaining coolant from the engine.

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Fig. 127: Removing Engine Front Cover Coolant Drain Plug

5. Remove the 10 front cover perimeter bolts.

6. Remove the front cover and the gasket. Make sure you do not damage the sealing surface. Some of the
gasket material may remain on the engine block.
7. Remove the remaining gasket material from the front cover and engine block using a plastic scraper.
8. Clean and inspect the engine front cover. Refer to ENGINE FRONT COVER CLEANING AND
INSPECTION in Engine Mechanical-3.5L Unit Repair.

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Fig. 128: Removing Engine Front Cover & Gasket

Installation Procedure

1. Install the new water pump gasket.

2. Place the water pump in position on the front cover.

CAUTION: Use the correct fastener in the correct location. Replacement

systems.

3. Install the short water pump bolts.

Tighten

Tighten the short water pump bolts in the sequence shown to 14 N.m (124 lb in).

Fig. 129: Identifying Water Pump Tightening Sequence

4. Place a short bead of RTV sealant, GM P/N 12345739 or equivalent, on the cylinder block in the
locations shown (1).

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Fig. 130: Identifying Sealant Locations

5. Align the front cover gasket to the front cover bolt holes and insert 2 bolts to hold the gasket in place.
6. Install the front cover and gasket on the cylinder block.

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Fig. 131: Installing Engine Front Cover & Gasket

7. Hand start all the front cover retaining bolts.

Tighten

Tighten the front cover retaining bolts in the sequence shown to 14 N.m (124 lb in).

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Fig. 132: Identifying Engine Front Cover Tightening Sequence

8. Install the engine front cover coolant drain plug.

Tighten

Tighten the front cover coolant drain plug to 10 N.m (89 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 133: Installing Front Cover Coolant Drain Plug

9. Install the water pump pulley and retaining bolts

Tighten

Tighten the water pump pulley bolts to 12 N.m (106 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 134: Installing Water Pump Pulley & Bolts

10. Install the drive belt idler pulley.

11. Install the drive belt idler pulley bolt.

Tighten

Tighten the drive belt idler pulley bolt to 50 N.m (37 lb ft).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 135: Installing Drive Belt Idler Pulley

12. Install the drive belt. Refer to Drive Belt Replacement .

13. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
14. Install the surge tank. Refer to SURGE TANK REPLACEMENT in Engine Cooling.
15. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.

OIL PUMP REPLACEMENT

Tools Required: J 42038 Camshaft Holding Fixtures

Removal Procedure

1. Remove the engine front cover. Refer to Engine Front Cover Replacement .
2. Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left and Camshaft Cover
Replacement - Right .

Important: You must install the J 42038 immediately after cam cover removal. The fixtures prevent
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unexpected camshaft rotation caused by valve spring pressure.

3. Install the camshaft holding fixture J 42038 onto the ends of the camshaft. Rotate the engine to align the
camshafts with the tool using the hex in the camshaft and an open wrench.

Fig. 136: Installing Camshaft Holding Fixture J 42038

4. When installed properly, the J 42038 will be fully seated on the camshaft ends with the camshaft flats
parallel to the cam cover sealing surface.
5. Remove the oil pan. Refer to Oil Pan Replacement .
6. Remove the oil pump pipe and screen. Refer to Oil Pump Pipe and Screen Assembly Replacement .

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Fig. 137: Identifying J 42038 Installation Position

7. Remove the camshaft drive chain tensioner (1) in order to remove the primary camshaft drive chain from
the drive sprocket. Refer to Primary Camshaft Drive Chain Tensioner Replacement .

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Fig. 138: Removing Camshaft Drive Chain Tensioner

8. Remove the 4 oil pump assembly retaining bolts identified by the larger head size.
9. Slide the oil pump assembly off the nose of the crankshaft with the drive sprocket in place.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 139: Removing Oil Pump Assembly

10. Remove the crankshaft sprocket from the oil pump assembly.

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Fig. 140: Removing Crankshaft Sprocket From Oil Pump Assembly

11. If necessary, disassemble the oil pump. Refer to OIL PUMP DISASSEMBLE.
12. Clean and inspect the oil pump. Refer to OIL PUMP CLEANING AND INSPECTION in Engine
Mechanical-3.5L Unit Repair.

Installation Procedure

1. If necessary, assemble the oil pump. Refer to OIL PUMP DISASSEMBLE.

2. Align the crankshaft sprocket splines with the oil pump gerotor and install the sprocket in the oil pump.

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Fig. 141: Installing Crankshaft Sprocket In Oil Pump

3. Place the pump and sprocket assembly in position by rotating the crankshaft sprocket until the machined
slot (2) is indexed with the drive pin (1) in the crankshaft.

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Fig. 142: Identifying Sprocket Installation Position

4. Slide the pump and sprocket onto the crankshaft until a positive stop is felt. Make sure the crankshaft
sprocket is aligned with the drive pin in the crankshaft.
5. Install the oil pump pipe and screen. Refer to Oil Pump Pipe and Screen Assembly Replacement .
6. Install the oil pan. Refer to Oil Pan Replacement .

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Fig. 143: Installing Oil Pump & Sprocket

7. When properly installed, the crankshaft sprocket will protrude from the oil pump but the face of the
sprocket will be located behind the machined step in the crankshaft as shown.
8. Align the pump body with the mounting holes in the cylinder block.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
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fastener. Use the correct tightening sequence and specifications

when installing fasteners in order to avoid damage to parts and
systems.

9. Install the oil pump retaining bolts.

Tighten

Tighten the oil pump retaining bolts to 25 N.m (18 lb ft).

10. Install the primary camshaft drive chain over the drive sprocket. Refer to Primary Camshaft Drive
Chain Tensioner Replacement .

Important: Make sure correct primary and secondary camshaft drive chain timing are maintained.

Fig. 144: Identifying Crankshaft Sprocket Installation Position

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11. Install the camshaft drive chain tensioner (1).

Fig. 145: Installing Camshaft Drive Chain Tensioner

12. Remove the J 42038 from the cylinder heads.

13. Install the camshaft covers. Refer to Camshaft Cover Replacement - Left and Camshaft Cover
Replacement - Right .
14. Install the engine front cover. Refer to Engine Front Cover Replacement .

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Fig. 146: Locating J 42038

CAMSHAFT COVER REPLACEMENT - LEFT

NOTE: Tools Required: J 43094 Spark Plug Boot Puller

Removal Procedure

1. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
2. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
3. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

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Fig. 147: Removing Fuel Injector Sight Shield

4. Disconnect the PCV dirty air tube (1) from the left camshaft cover.
5. Remove the left ignition coil assembly from the left camshaft cover. Refer to IGNITION SYSTEMS in
Engine Controls-3.5L.

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Fig. 148: Removing PCV Dirty Air Tube

CAUTION: Use only the spark plug boot special removal tool to remove the
spark plug boots. Prying or using regular pliers could damage the
boots.

6. Remove the spark plug boots using the J 43094.

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Fig. 149: Removing Spark Pug Boots

7. Disconnect and set aside the engine wiring harness and fuel injector harness from the left camshaft cover
retainers.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 150: Locating Engine Wiring Harness & Fuel Injector Harness

8. Remove the left camshaft cover retaining bolts.

Important: The left camshaft cover seals (perimeter and spark plug) should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

9. Lift the left camshaft cover off the left cylinder head evenly.
10. If necessary, disassemble the camshaft cover. Refer to CAMSHAFT COVER DISASSEMBLE in Engine
Mechanical-3.5L Unit Repair.
11. Clean and inspect the camshaft cover. Refer to CAMSHAFT COVER CLEANING AND INSPECTION
in Engine Mechanical-3.5L Unit Repair.

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Fig. 151: Removing Left Camshaft Cover & Bolts

Installation Procedure

1. If necessary, assemble the camshaft cover. Refer to CAMSHAFT COVER DISASSEMBLE in Engine
Mechanical-3.5L Unit Repair.
2. Wipe the left cylinder head sealing surface with a clean, lint-free cloth.
3. Inspect the left camshaft cover seals (perimeter and spark plug) for damage. Check to make sure the
perimeter seal is not pulled from its groove. Replace the seals if they are damaged or pulled from the
groove.
4. Place the left camshaft cover in position on the cylinder head.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
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Fasteners requiring replacement or fasteners requiring the use of

thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

5. Install the left camshaft cover retaining bolts.

Tighten

Tighten the left camshaft cover retaining bolts to 9 N.m (80 lb in).

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Fig. 152: Installing Left Camshaft Cover & Bolts

6. Connect the engine wiring harness and fuel injector harness to the left camshaft cover retainers.

Fig. 153: Locating Engine Wiring Harness & Fuel Injector Harness

7. Push the spark plug boots onto the ignition coil assembly.
8. Install the left ignition coil assembly to the left camshaft cover. Refer to IGNITION SYSTEMS in
Engine Controls-3.5L.

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Fig. 154: Installing Spark Plug Boots

9. Connect the PCV dirty air tube (1) to the left camshaft cover.
10. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

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Fig. 155: Installing PCV Dirty Air Tube

11. Insert the tab of the fuel injector sight shield under the engine bracket.
12. Lower the fuel injector sight shield.
13. Align the holes in the fuel injector sight shield with the studs.
14. Install the 2 fuel injector sight shield nuts onto the studs.

Tighten

Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

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Fig. 156: Installing Fuel Injector Sight Shield

CAMSHAFT COVER REPLACEMENT - RIGHT

Tools Required: J 43094 Spark Plug Boot Puller

Removal Procedure

1. Remove the automatic transaxle filler tube. Refer to 4T65-E TRANSAXLE .

2. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
3. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.

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Fig. 157: Removing Fuel Injector Sight Shield

4. Remove the fuel injector sight shield bracket bolts.

5. Remove the fuel injector sight shield bracket.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 158: Removing Fuel Injector Sight Shield Bracket

6. Disconnect the PCV fresh air tube (2) from the right camshaft cover.
7. Disconnect the engine wiring harness clips at the front of the right camshaft cover and position aside.
8. Disconnect the oxygen sensor electrical connector and remove the connector end from the right camshaft
cover.
9. Remove the right ignition coil assembly from the right camshaft cover. Refer to IGNITION SYSTEMS
in Engine Controls-3.5L.

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Fig. 159: Removing PCV Fresh Air Tube

CAUTION: Use only the spark plug boot special removal tool to remove the
spark plug boots. Prying or using regular pliers could damage the
boots.

10. Remove the spark plug boots using the J 43094.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 160: Removing Spark Plug Boots

11. Remove the right camshaft cover retaining bolts.

Important: The right camshaft cover perimeter and spark plug seals should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

12. Lift the right camshaft cover off the right cylinder head evenly.
13. If necessary, disassemble the camshaft cover. Refer to CAMSHAFT COVER DISASSEMBLE.
14. Clean and inspect the camshaft cover. Refer to CAMSHAFT COVER CLEANING AND INSPECTION
in Engine Mechanical-3.5L Unit Repair.

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Fig. 161: Removing Camshaft Cover

Installation Procedure

1. If necessary, assemble the camshaft cover. Refer to CAMSHAFT COVER DISASSEMBLE in Engine
Mechanical 3.5L Unit Repair Manual.
2. Wipe the right cylinder head sealing surface with a clean, lint-free cloth.
3. Inspect the right camshaft cover perimeter and spark plug seals for damage. Check to make sure the
perimeter seal is not pulled from its groove. Replace the seals if they are damaged or pulled from the
groove.
4. Place the right camshaft cover in position on the cylinder head.

CAUTION: Use the correct fastener in the correct location. Replacement

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fasteners must be the correct part number for that application.

Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

5. Install the right camshaft cover retaining bolts.

Tighten

Tighten the right camshaft cover retaining bolts to 9 N.m (80 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 162: Installing Camshaft Cover

6. Push the spark plug boots onto the ignition coil assembly.
7. Install the right ignition coil assembly to the right camshaft cover. Refer to IGNITION COIL(S)
REPLACEMENT in Engine Controls-3.5L.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 163: Installing Spark Plug Boots

8. Connect the PCV fresh air tube (2) to the right camshaft cover.

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Fig. 164: Connecting PCV Fresh Air Tube

9. Connect the oxygen sensor electrical connector and install the connector end to the right camshaft cover.
10. Connect the engine wiring harness clips at the front of the right camshaft cover.
11. Install the fuel injector sight shield bracket.
12. Install the fuel injector sight shield bracket bolts.

Tighten

Tighten the fuel injector sight shield bracket bolts to 8 N.m (71 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 165: Installing Fuel Injector Sight Shield Bracket

13. Insert the tab of the fuel injector sight shield under the engine bracket.
14. Lower the fuel injector sight shield.
15. Align the holes in the fuel injector sight shield with the studs.
16. Install the 2 fuel injector sight shield nuts onto the studs.

Tighten

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Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

Fig. 166: Installing Fuel Injector Sight Shield

17. Install the automatic transaxle filler tube. Refer to 4T65-E TRANSAXLE .

SECONDARY CAMSHAFT DRIVE CHAIN REPLACEMENT - LEFT

Tools Required

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture
 J 42042 Primary Drive Timing Chain/Sprocket Holding Fixture

Removal Procedure

1. Remove the left secondary camshaft drive chain tensioner. Refer to Secondary Camshaft Drive Chain
Tensioner Replacement - Left .
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2. Remove the intake camshaft sprocket bolt.

Fig. 167: Removing Intake Camshaft Sprocket Bolt

3. Remove the 2 chain guide access plugs (3, 4) located in the cylinder head. Note the O-ring seals on the
access plugs.
4. Loosen the primary camshaft drive chain guide upper bolts ONLY 2 full turns.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 168: Removing Chain Guide Access Plugs

5. Install the J 42042 on to the left cylinder head.

6. Slide the intake camshaft sprocket off of the camshaft and onto the pin of the J 42042.
7. Secure the intake camshaft sprocket in place using a wire tie.

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Fig. 169: Locating J 42042 On Left Cylinder Head

Important: DO NOT rotate the camshafts more than 10 degrees.

8. Remove the J 42038.

Allow the camshaft lobes to find a neutral position by rotating each camshaft, if necessary.

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Fig. 170: Removing J 42038

9. Alternately loosen the camshaft bearing cap bolts a few turns at a time until all valve spring pressure has
been released.
10. Remove the camshaft bearing caps.
11. Lift the left intake camshaft out of the cylinder head.
12. Remove the left secondary camshaft drive chain from the left intake camshaft sprocket.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 171: Removing Camshaft Bearing Caps

Installation Procedure

Important: Make sure the darkened chain links on the left secondary camshaft drive chain are facing inward.

1. Position the left secondary camshaft drive chain to the left intake camshaft sprocket.
2. Place the left intake camshaft (1) in position in the cylinder head.
3. Position the camshaft lobes in a neutral position with the front notch for the camshaft sprocket drive pins
near the top of their rotation and the flats machined into the camshaft parallel and facing the cylinder
head.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 172: Installing Left Intake Camshaft

4. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.
The markings have the following meanings:
 The raised feature must always be oriented toward the outboard side of the engine.

 The "I" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

5. Apply a liberal amount of lubricant GM P/N 12345501 or equivalent to the camshaft bearing caps.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 173: Identifying Markings On Bearing Caps

6. Install the camshaft bearing cap bolts according to the identification marks.

CAUTION: Use the correct fastener in the correct location. Replacement

7. Tighten the camshaft bearing caps.

Tighten

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2002 ENGINE Engine Mechanical - Aurora 3.5L

7.1. Alternately hand tighten the camshaft bearing cap bolts a few turns at a time until all caps are
fully seated.
7.2. Tighten the camshaft bearing cap bolts to 8 N.m (71 lb in).
7.3. Tighten the camshaft bearing cap bolts an additional 22 degrees using the J 36660-A.

Fig. 174: Installing Camshaft Bearing Caps

WARNING: The camshaft holding tools must be installed on the camshafts to

prevent camshaft rotation. When performing service to the valve
train and/or timing components, valve spring pressure can cause the
camshafts to rotate unexpectedly and can cause personal injury.

Important: There should be no need to rotate the camshaft more then 10 degrees.

8. Using the hex cast into the camshaft, rotate the camshaft so the rear camshaft flat is facing the cylinder
head in order to install the J 42038
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9. Install the J 42038 to the rear of the camshafts on the left cylinder head.

Fig. 175: Installing J 42038

10. Slide the intake camshaft sprocket off of the J 42042 and onto the camshaft, aligning the drive pin into
the camshaft notch.
11. Remove the J 42042 from the left cylinder head.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 176: Locating J 42042

12. Tighten the primary camshaft drive chain guide upper bolts.

Tighten

Tighten the primary camshaft drive chain guide bolts to 25 N.m (18 lb ft).

Important: Ensure that each chain guide access plug has an O-ring installed.

13. Install the 2 chain guide access plugs (3, 4).

Tighten

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten the chain guide access plugs to 5 N.m (44 lb in).

Fig. 177: Installing Chain Guide Access Plugs

14. Install the intake camshaft sprocket bolt.

Tighten

14.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

14.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
15. Install the left secondary camshaft drive chain tensioner. Refer to Secondary Camshaft Drive Chain
Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Tensioner Replacement - Left .

Fig. 178: Installing Intake Camshaft Sprocket Bolt

SECONDARY CAMSHAFT DRIVE CHAIN REPLACEMENT - RIGHT

Tools Required:

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture
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2002 ENGINE Engine Mechanical - Aurora 3.5L

 J 42042 Primary Drive Timing Chain/Sprocket Holding Fixture

Removal Procedure

1. Remove the right secondary camshaft drive chain tensioner. Refer to Secondary Camshaft Drive Chain
Tensioner Replacement - Right .
2. Remove the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine
Controls-3.5L.
3. Remove the intake camshaft sprocket bolt.

Fig. 179: Removing Intake Camshaft Sprocket Bolt

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4. Remove the 2 chain guide access plugs (1, 2) located in the cylinder head. Note the O-ring seals on the
access plugs.
5. Loosen the primary camshaft drive chain guide upper bolts ONLY 2 full turns.

Fig. 180: Removing Chain Guide Access Plugs

6. Install the J 42042 on to the right cylinder head.

7. Slide the intake camshaft sprocket off of the camshaft and onto the pin of the J 42042.
8. Secure the intake camshaft sprocket in place using a wire tie.

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Fig. 181: Installing J 42042

Important: DO NOT rotate the camshafts more than 10 degrees.

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9. Remove the J 42038.

Allow the camshaft lobes to find a neutral position by rotating each camshaft, if necessary.

Fig. 182: Removing J 42038

10. Alternately loosen the camshaft bearing cap bolts a few turns at a time until all valve spring pressure has
been released.
11. Remove the camshaft bearing caps.
12. Lift the right intake camshaft out of the cylinder head.
13. Remove the right secondary camshaft drive chain from the right intake camshaft sprocket.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 183: Removing Camshaft Bearing Caps

Installation Procedure

Important: Make sure the darkened chain links on the right secondary camshaft drive chain are facing inward.

1. Position the right secondary camshaft drive chain to the right intake camshaft sprocket.
2. Place the right intake camshaft (1) in position in the cylinder head.
3. Position the camshaft lobes in a neutral position with the front notch for the camshaft sprocket drive pins
near the top of their rotation and the flats machined into the camshaft parallel and facing the cylinder
head.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 184: Installing Right Intake Camshaft

 The "I" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

5. Apply a liberal amount of lubricant GM P/N 12345501 or equivalent to the camshaft bearing caps.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 185: Identifying Bearing Caps Markings

6. Install the camshaft bearing cap bolts according to the identification marks.

CAUTION: Use the correct fastener in the correct location. Replacement

7. Tighten the camshaft bearing caps.

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Tighten

7.1. Alternately hand tighten the camshaft bearing cap bolts a few turns at a time until all caps are
fully seated.
7.2. Tighten the camshaft bearing cap bolts to 8 N.m (7 lb in).
7.3. Tighten the camshaft bearing cap bolts an additional 22 degrees using the J 36660-A.

Fig. 186: Installing Camshaft Bearing Caps

WARNING: The camshaft holding tools must be installed on the camshafts to

prevent camshaft rotation. When performing service to the valve
train and/or timing components, valve spring pressure can cause the
camshafts to rotate unexpectedly and can cause personal injury.

Important: There should be no need to rotate the camshaft more then 10 degrees.

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8. Using the hex cast into the camshaft, rotate the camshaft so the rear camshaft flat is facing the cylinder
head in order to install the J 42038
9. Install the J 42038 to the rear of the camshafts on the right cylinder head.

Fig. 187: Installing J 42038

10. Slide the intake camshaft sprocket off of the J 42042 and onto the camshaft, aligning the drive pin into
the camshaft notch.
11. Remove the J 42042 from the right cylinder head.

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Fig. 188: Removing J 42042

12. Tighten the primary camshaft drive chain guide upper bolts.
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Tighten

Tighten the primary camshaft drive chain guide bolts to 25 N.m (18 lb ft).

Important: Ensure that each chain guide access plug has an O-ring installed.

13. Install the 2 chain guide access plugs (1, 2).

Tighten

Tighten the chain guide access plugs to 5 N.m (44 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 189: Installing Chain Guide Access Plugs

14. Install the intake camshaft sprocket bolt.

Tighten

14.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

14.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
15. Install the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls-
3.5L.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

16. Install the right secondary camshaft drive chain tensioner. Refer to Secondary Camshaft Drive Chain
Tensioner Replacement - Right .

Fig. 190: Installing Intake Camshaft Sprocket Bolt

SECONDARY CAMSHAFT TIMING SPROCKET REPLACEMENT - LEFT EXHAUST

Tools Required:

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture

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 J 43032 Crankshaft Rotation Socket

Removal Procedure

1. Remove the left camshaft cover. Refer to Camshaft Cover Replacement - Left .
2. Rotate the crankshaft to TDC of the # 1 cylinder compression stroke using the J 43032 the flats machined
into the rear of the camshafts should be parallel and facing the cylinder head.
3. Use an open end wrench on the hex cast into the camshaft to aid in the installation of the J 42038.

Fig. 191: Using Open End Wrench On Hex Cast Into Camshaft

WARNING: The camshaft holding tools must be installed on the camshafts to

prevent camshaft rotation. When performing service to the valve
train and /or timing components, valve spring pressure can cause
the camshafts to rotate unexpectedly and can cause personal injury

4. Install the J 42038 to the rear of the camshafts on the left cylinder head.

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Fig. 192: Installing J 42038

5. Compress the left secondary drive chain tensioner shoes with your hand.
6. Lock the left secondary drive chain tensioner by inserting a piece of wire (2) into the access hole in the
side of the tensioner (1).
7. Slowly release the pressure from the left secondary drive chain tensioner shoes. The tensioner should
remain closed.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 193: Inserting Wire Into Tensioner Side Access Hole

8. Remove the exhaust camshaft sprocket bolt.

9. Remove the left exhaust secondary camshaft timing sprocket from the camshaft.

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Fig. 194: Removing Exhaust Camshaft Sprocket Bolt

Installation Procedure

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Fig. 195: Identifying Left Secondary Camshaft Timing Components Position

CAUTION: Use the correct fastener in the correct location. Replacement

2. Install the exhaust camshaft sprocket bolt.

Tighten

2.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

2.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 196: Installing Exhaust Camshaft Sprocket Bolt

3. Remove the locking wire (2) from the left secondary drive chain tensioner (1) allowing the tensioner
shoes to expand and apply pressure to the drive chain.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 197: Removing Locking Wire From Left Secondary Drive Chain Tensioner

4. Remove the J 42038 from the left camshafts.

5. Install the left camshaft cover. Refer to Camshaft Cover Replacement - Left .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 198: Removing J 42038

SECONDARY CAMSHAFT TIMING SPROCKET REPLACEMENT - LEFT INTAKE

Tools Required: J 36660-A Electronic Torque Angle Meter

Removal Procedure

1. Remove the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain
Tensioner Replacement .
2. Compress the left secondary drive chain tensioner shoes with your hand.
3. Lock the left secondary drive chain tensioner by inserting a piece of wire (2) into the access hole in the
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side of the tensioner (1).

4. Slowly release the pressure from the left secondary drive chain tensioner shoes. The tensioner should
remain closed.

Fig. 199: Locking Left Secondary Drive Chain Tensioner

5. Remove the intake camshaft sprocket bolt.

6. Remove the left intake secondary camshaft timing sprocket from the following:
 The left intake camshaft.

 The left secondary camshaft drive chain.

 The primary camshaft drive chain.

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Fig. 200: Removing Intake Camshaft Sprocket Bolt

Installation Procedure

1. Position the left secondary camshaft timing components in the following order:
1.1. Align the intake sprocket drive pin (4) with the single darkened link (3).
1.2. Align the exhaust sprocket drive pin (1) between the two darkened links (2).
1.3. Slide the intake camshaft sprocket onto the camshaft aligning the drive pin into the camshaft
notch.
2. Position the primary camshaft drive chain to the intake sprocket.
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Fig. 201: Identifying Left Secondary Camshaft Timing Components Position

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the intake camshaft sprocket bolt.

Tighten

3.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

3.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
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Fig. 202: Installing Intake Camshaft Sprocket Bolt

4. Remove the locking wire (2) from the left secondary drive chain tensioner (1) allowing the tensioner
shoes to expand and apply pressure to the drive chain.
5. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 203: Removing Locking Wire From Left Secondary Drive Chain Tensioner

SECONDARY CAMSHAFT TIMING SPROCKET REPLACEMENT - RIGHT EXHAUST

Tools Required:

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture
 J 43032 Crankshaft Rotation Socket

Removal Procedure

1. Remove the right camshaft cover. Refer to Camshaft Cover Replacement - Right .
2. Rotate the crankshaft to TDC of the # 1 cylinder compression stroke using the J 43032 the flats machined
into the rear of the camshafts should be parallel and facing the cylinder head.
3. Use an open end wrench on the hex cast into the camshaft to aid in the installation of the J 42038.

Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 204: Using Open End Wrench On Hex Cast Into Camshaft

WARNING: The camshaft holding tools must be installed on the camshafts to

prevent camshaft rotation. When performing service to the valve
train and /or timing components, valve spring pressure can cause
the camshafts to rotate unexpectedly and can cause personal injury

4. Install the J 42038 to the rear of the camshafts on the right cylinder head.

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Fig. 205: Installing J 42038

5. Compress the right secondary drive chain tensioner shoes with your hand.
6. Lock the right secondary drive chain tensioner by inserting a piece of wire (2) into the access hole in the
side of the tensioner (1).
7. Slowly release the pressure from the right secondary drive chain tensioner shoes. The tensioner should
remain closed.

Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 206: Locking Right Secondary Drive Chain Tensioner

8. Remove the exhaust camshaft sprocket bolt.

9. Remove the right exhaust secondary camshaft timing sprocket from the camshaft.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 207: Removing Exhaust Camshaft Sprocket Bolt

Installation Procedure

1. Position the right secondary camshaft timing components in the following order:
1.1. Align the intake sprocket drive pin (1) between the two darkened links (2).
1.2. Align the exhaust sprocket drive pin (4) with the single darkened link (3).
1.3. Slide the exhaust camshaft sprocket onto the camshaft aligning the drive pin into the camshaft
notch.

Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 208: Identifying Right Secondary Camshaft Timing Components Position

CAUTION: Use the correct fastener in the correct location. Replacement

2. Install the exhaust camshaft sprocket bolt.

Tighten

2.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

2.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 209: Installing Exhaust Camshaft Sprocket Bolt

3. Remove the locking wire (2) from the right secondary drive chain tensioner (1) allowing the tensioner
shoes to expand and apply pressure to the drive chain.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 210: Removing Locking Wire From Right Secondary Drive Chain Tensioner

4. Remove the J 42038 from the right camshafts.

5. Install the right camshaft cover. Refer to Camshaft Cover Replacement - Right .

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 211: Removing J 42083

SECONDARY CAMSHAFT TIMING SPROCKET REPLACEMENT - RIGHT INTAKE

Tools Required: J 36660-A Electronic Torque Angle Meter

Removal Procedure

1. Remove the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain
Tensioner Replacement .
2. Remove the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls
- 3.5L.
3. Compress the right secondary drive chain tensioner shoes with your hand.
4. Lock the right secondary drive chain tensioner by inserting a piece of wire (2) into the access hole in the
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2002 ENGINE Engine Mechanical - Aurora 3.5L

side of the tensioner (1).

Fig. 212: Locking Right Secondary Drive Chain Tensioner

5. Slowly release the pressure from the right secondary drive chain tensioner shoes. The tensioner should
remain closed.
6. Remove the intake camshaft sprocket bolt.
7. Remove the right intake secondary camshaft timing sprocket from the following:
 The right intake camshaft.

 The right secondary camshaft drive chain.

 The primary camshaft drive chain.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 213: Removing Intake Camshaft Sprocket Bolt

Installation Procedure

1. Position the right secondary camshaft timing components in the following order:
1.1. Align the intake sprocket drive pin (1) between the two darkened links (2).
1.2. Align the exhaust sprocket drive pin (4) with the single darkened link (3).
1.3. Slide the intake camshaft sprocket onto the camshaft aligning the drive pin into the camshaft
notch.
2. Position the primary camshaft drive chain to the intake sprocket.

Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 214: Identifying Right Secondary Camshaft Timing Components Position

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the intake camshaft sprocket bolt.

Tighten

3.1. Tighten the camshaft sprocket bolt to 25 N.m (18 lb ft).

3.2. Use the J 36660-A in order to tighten the camshaft sprocket bolt an additional 45 degrees.
Microsoft
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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 215: Installing Intake Camshaft Sprocket Bolt

4. Remove the locking wire (2) from the right secondary drive chain tensioner (1) allowing the tensioner
shoes to expand and apply pressure to the drive chain.
5. Install the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls-
3.5L.
6. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 216: Removing Locking Wire From Right Secondary Drive Chain Tensioner

SECONDARY CAMSHAFT DRIVE CHAIN TENSIONER REPLACEMENT - LEFT

Removal Procedure

1. Remove the left exhaust secondary camshaft timing sprocket. Refer to Secondary Camshaft Timing
Sprocket Replacement - Left Exhaust .
2. Remove the secondary drive chain tensioner retaining bolts.
3. Remove the secondary drive tensioner.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 217: Removing Secondary Drive Tensioner

Installation Procedure

1. Ensure that the left secondary timing chain tensioner (1) is being installed.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 218: Identifying Left Secondary Timing Chain Tensioner

2. Position the secondary timing chain tensioner between the camshafts.

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the secondary timing chain tensioner bolts.

Tighten

Tighten the secondary timing chain tensioner bolts to 12 N.m (106 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 219: Installing Secondary Timing Chain Tensioner

4. Once mounted, compress the left secondary timing chain tensioner shoes with your hand.
5. Lock the left secondary timing chain tensioner by inserting a piece of wire (2) into the access hole in the
side of the tensioner (1).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 220: Locking Left Secondary Timing Chain Tensioner

6. Slowly release the pressure from the left secondary timing chain tensioner shoes. The tensioner should
remain compressed.
7. Install the left exhaust secondary camshaft timing sprocket. Refer to Secondary Camshaft Timing
Sprocket Replacement - Left Exhaust .

SECONDARY CAMSHAFT DRIVE CHAIN TENSIONER REPLACEMENT - RIGHT

Removal Procedure

1. Remove the right exhaust secondary camshaft timing sprocket. Refer to Secondary Camshaft Timing
Sprocket Replacement - Right Exhaust .
2. Remove the secondary drive chain tensioner retaining bolts.
3. Remove the secondary drive tensioner.

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Fig. 221: Removing Secondary Drive Chain Tensioner

Installation Procedure

1. Ensure that the right secondary timing chain tensioner (1) is being installed.

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Fig. 222: Identifying Right Secondary Timing Chain Tensioner

2. Position the secondary timing chain tensioner between the camshafts.

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the secondary timing chain tensioner bolts.

Tighten

Tighten the secondary timing chain tensioner bolts to 12 N.m (106 lb in).

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Fig. 223: Installing Secondary Timing Chain Tensioner

4. Once mounted, compress the right secondary timing chain tensioner shoes with your hand.
5. Lock the right secondary timing chain tensioner by inserting a piece of wire (2) into the access hole in the
side of the tensioner (1).
6. Slowly release the pressure from the right secondary timing chain tensioner shoes. The tensioner should
remain compressed.
7. Install the right exhaust secondary camshaft timing sprocket. Refer to Secondary Camshaft Timing
Sprocket Replacement - Right Exhaust .

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Fig. 224: Locking Right Secondary Timing Chain Tensioner

PRIMARY CAMSHAFT DRIVE CHAIN TENSIONER REPLACEMENT

Tools Required:

 J 42038 Camshaft Holding Fixture

 J 43032 Crankshaft Rotation Socket

Removal Procedure

1. Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left and Camshaft Cover
Replacement - Right .
2. Rotate the crankshaft to TDC of the # 1 cylinders compression stroke using the J 43032, the flats
machined into the rear of the camshafts should be parallel and facing the cylinder head.

WARNING: The camshaft holding tools must be installed on the camshafts to

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prevent camshaft rotation. When performing service to the valve

train and /or timing components, valve spring pressure can cause
the camshafts to rotate unexpectedly and can cause personal injury

3. Install the J 42038 to the rear of the camshafts on the left and right cylinder heads.
4. Remove the engine front cover. Refer to Engine Front Cover Replacement .

Fig. 225: Identifying J 42038

5. Loosen both primary timing chain tensioner bolts.

6. Remove the lower primary timing chain tensioner bolt allowing the tensioner to swing downward and
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expand. This will release tension on the primary drive chain.

7. Remove the upper tensioner bolt.
8. Remove the primary drive chain tensioner (1).

Fig. 226: Removing Primary Drive Chain Tensioner

Installation Procedure

1. Collapse the primary timing chain tensioner using the following procedure:
1.1. Rotate the ratchet release lever (2) clockwise and hold.
1.2. Collapse the tensioner shoe (1) and hold.
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1.3. Release the ratchet lever.

2. Slowly release the pressure on the shoe, until the ratchet lever moves to the first detent and a "click" is
heard and felt.
3. Collapse the tensioner shoe and hold.

Fig. 227: Collapsing Priming Timing Chain Tensioner

4. Insert a pin through the hole in the release lever in order to lock the tensioner shoe in the collapsed
position.

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Fig. 228: Locking Tensioner Shoe In Collapsed Position

CAUTION: Use the correct fastener in the correct location. Replacement

Important: Ensure the tensioner release lever is facing outward.

5. Install the primary timing chain tensioner (1) and retaining bolts.

Tighten

Tighten the primary timing chain tensioner bolts to 25 N.m (18 lb ft).

6. Ensure the crankshaft is at TDC of the # 1 cylinders compression stroke.

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Fig. 229: Installing Primary Timing Chain Tensioner

7. Remove the pin holding the tensioner to tighten any slack in the timing chain.
8. Verify correct timing chain and timing mark alignments. Refer to Setting Camshaft Timing .
9. Install the engine front cover. Refer to Engine Front Cover Replacement .

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Fig. 230: Removing Locking Pin From Tensioner

10. Remove the J 42038 from the camshafts on the left and right cylinder heads.
11. Install the camshaft covers. Refer to Camshaft Cover Replacement - Left and Camshaft Cover
Replacement - Right .

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Fig. 231: Identifying J 42038

PRIMARY CAMSHAFT DRIVE CHAIN TENSIONER SHOE REPLACEMENT

Removal Procedure

1. Remove the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain
Tensioner Replacement .
2. Remove the chain guide access plug (2) located in the cylinder head. Note the O-ring seal on the access
plug.

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Fig. 232: Removing Chain Guide Access Plugs

3. Remove the primary drive chain tensioner shoe bolt using the access hole in the cylinder head.
4. Remove the primary camshaft drive chain tensioner shoe (1) by pulling the shoe downward through the
front cover area.

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Fig. 233: Removing Primary Camshaft Drive Chain Tensioner Shoe

Installation Procedure

1. Install the primary camshaft drive chain tensioner shoe (1) upward through the front cover area, aligning
the shoe to the threaded hole in the cylinder head.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners or fastener joint surfaces unless specified. These coatings

2. Install the primary camshaft drive chain tensioner shoe bolt using the access hole in the cylinder head.

Tighten

Tighten the primary camshaft drive chain tensioner shoe bolt to 25 N.m (18 lb ft).

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Fig. 234: Installing Primary Camshaft Drive Chain Tensioner Shoe

Important: Ensure that the chain guide access plug has an O-ring installed.

3. Install the chain guide access plug (2).

Tighten

Tighten the chain guide access plug to 5 N.m (44 lb in).

4. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .

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Fig. 235: Installing Chain Guide Access Plugs

PRIMARY CAMSHAFT DRIVE CHAIN GUIDE REPLACEMENT - LOWER

Removal Procedure

1. Remove the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain
Tensioner Replacement .
2. Transfer the chain slack from the primary camshaft drive chain tensioner area to the primary camshaft
drive chain lower guide area by moving the chain links counterclockwise around the crankshaft sprocket.
3. Remove the chain guide access plug (4) located in the cylinder head. Note the O-ring seal on the access
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plug.

Fig. 236: Removing Chain Guide Access Plugs

4. Remove the primary camshaft drive chain lower guide bolts.

5. Remove the primary camshaft drive chain lower guide in the following order:
5.1. Rotate the guide clockwise.
5.2. Pull the guide downward through the front cover area.

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Fig. 237: Removing Primary Camshaft Drive Chain Lower Guide

Installation Procedure

1. Install the primary camshaft drive chain lower guide in the following order:
1.1. Position the guide upward through the front cover area.
1.2. Rotate the guide counter-clockwise around the drive chain.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of

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thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

2. Install the primary camshaft drive chain lower guide bolts.

Tighten

Tighten the primary camshaft drive chain guide bolts to 25 N.m (18 lb ft).

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Fig. 238: Installing Primary Camshaft Drive Chain Lower Guide

Important: Ensure that the chain guide access plug has an O-ring installed.

3. Install the chain guide access plug (4).

Tighten

Tighten the chain guide access plug to 5 N.m (44 lb in).

4. Rotate the crankshaft clockwise only enough to transfer the chain slack to the primary drive chain
tensioner side.
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5. Transfer the chain slack from the primary camshaft drive chain lower guide area to the primary camshaft
drive chain tensioner area by moving the chain links clockwise around the crankshaft sprocket.
6. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .

Fig. 239: Installing Chain Guide Access Plugs

PRIMARY CAMSHAFT DRIVE CHAIN GUIDE REPLACEMENT - LEFT UPPER

Removal Procedure

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Fig. 240: Locating Chain Links Around Right Intake Sprocket

Important: Ensure the relationship between the primary camshaft drive chain and balance shaft sprocket
remain in a timed sequence.

3. Rotate the balance shaft counterclockwise in order to transfer the chain slack from the right upper guide
to the left upper guide.

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Fig. 241: Locating Balance Shaft

4. Remove the chain guide access plug (3) located in the cylinder head. Note the O-ring seal on the access
plug.

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Fig. 242: Removing Chain Guide Access Plugs

5. Remove the primary camshaft drive chain left upper guide bolts.
6. Remove the primary camshaft drive chain left upper guide by pulling the guide downward through the
front cover area.

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Fig. 243: Removing Primary Camshaft Drive Chain Left Upper Guide

Installation Procedure

1. Install the primary camshaft drive chain left upper guide upward through the front cover area, aligning the
guide to the threaded holes in the cylinder head and block.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

2. Install the primary camshaft drive chain left upper guide bolts.

Tighten

Tighten the primary camshaft drive chain guide bolts to 25 N.m (18 lb ft).

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Fig. 244: Installing Primary Camshaft Drive Chain Left Upper Guide

Important: Ensure that the chain guide access plug has an O-ring installed.

3. Install the chain guide access plug (3).

Tighten

Tighten the chain guide access plug to 5 N.m (44 lb in).

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Fig. 245: Installing Chain Guide Access Plug

Important: Ensure the relationship between the primary camshaft drive chain and balance shaft sprocket
remain in a timed sequence.

4. Rotate the balance shaft clockwise in order to transfer the chain slack from the left upper guide to the
right upper guide.

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Fig. 246: Locating Balance Shaft

5. Transfer the chain slack from the primary camshaft drive chain upper guide area to the primary camshaft
drive chain tensioner area by moving the chain links counter-clockwise around the right intake sprocket.
6. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .

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Fig. 247: Locating Chain Links Around Right Intake Sprocket

PRIMARY CAMSHAFT DRIVE CHAIN GUIDE REPLACEMENT - RIGHT UPPER

Removal Procedure

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Fig. 248: Locating Chain Links Around Right Intake Sprocket

3. Remove the front engine lift bracket bolts.

4. Remove the front engine lift bracket.

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Fig. 249: Removing Front Engine Lift Bracket

5. Remove the chain guide access plug (1) located in the cylinder head. Note the O-ring seal on the access
plug.

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Fig. 250: Removing Chain Guide Access Plug

6. Remove the primary camshaft drive chain right upper guide bolts.
7. Remove the primary camshaft drive chain right upper guide by pulling the guide downward through the
front cover area.

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Fig. 251: Removing Primary Camshaft Drive Chain Right Upper Guide

Installation Procedure

1. Install the primary camshaft drive chain right upper guide upward through the front cover area, aligning
the guide to the threaded holes in the cylinder head and block.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

2. Install the primary camshaft drive chain right upper guide bolts.

Tighten

Tighten the primary camshaft drive chain guide bolts to 25 N.m (18 lb ft).

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Fig. 252: Installing Primary Camshaft Drive Chain Right Upper Guide

Important: Ensure that the chain guide access plug has an O-ring installed.

3. Install the chain guide access plug (1).

Tighten

Tighten the chain guide access plug to 5 N.m (44 lb in).

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Fig. 253: Installing Chain Guide Access Plug

4. Install the front engine lift bracket retaining bolts.

Tighten

 Tighten the front lift bracket hex head bolt to 50 N.m (37 lb ft).
 Tighten the front lift bracket TORX (r) bolt to 25 N.m (18 lb ft).

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Fig. 254: Installing Front Engine Lift Bracket

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Fig. 255: Locating Chain Links Around Right Intake Sprocket

PRIMARY CAMSHAFT DRIVE CHAIN REPLACEMENT

Removal Procedure

1. Remove the primary camshaft drive chain tensioner shoe. Refer to Primary Camshaft Drive Chain
Tensioner Shoe Replacement .
2. Remove the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls
-3.5L.

Important: Do not allow the primary camshaft drive chain to fall into the crankcase.

3. Remove the primary camshaft drive chain from the following:

 The crankshaft sprocket.

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The right intake sprocket.



 The left intake sprocket.

4. Remove the primary camshaft drive chain from the front cover area.

Fig. 256: Removing Primary Camshaft Drive Chain

Installation Procedure

Important: Do not allow the primary camshaft drive chain to fall into the crankcase.

1. Install the primary camshaft drive chain into the front cover area.
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2. Set the camshaft timing. Refer to Setting Camshaft Timing .

3. Install the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls -
3.5L.
4. Install the primary camshaft drive chain tensioner shoe. Refer to Primary Camshaft Drive Chain
Tensioner Shoe Replacement .

Fig. 257: Installing Primary Camshaft Drive Chain

SETTING CAMSHAFT TIMING

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Tools Required:

 J 36660-A Torque Angle Meter

 J 42038 Camshaft Holding Fixture
 J 43032 Crankshaft Rotation Socket

Setting the camshaft timing is necessary whenever the camshaft drive system has been disturbed such that the
relationship between any chain and sprocket has been lost. Even when only one sprocket is involved the
following procedure should be observed since one crankshaft rotation will not provide conditions where correct
timing can be confirmed.

The camshafts, crankshaft and balance shaft events are correctly timed when the relationships shown exist. The
following procedure explains how to establish this condition.

1. Remove the following components for access:

 The left camshaft cover, Refer to Camshaft Cover Replacement - Left .

 The right camshaft cover. Refer to Camshaft Cover Replacement - Right .

 The primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .
 The primary camshaft drive chain tensioner shoe. Refer to Primary Camshaft Drive Chain
Tensioner Shoe Replacement .
 The camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls -
3.5L
2. Ensure the following components are positioned accordingly:
 The crankshaft is at TDC of the # 1 cylinder compression stroke.

 The 4 camshaft drive pin notches upward.

3. Use an open end wrench on the hex cast into the camshaft to aid in the installation of the J 42038.

WARNING: The camshaft holding tools must be installed on the camshafts to

prevent camshaft rotation. When performing service to the valve
train and /or timing components, valve spring pressure can cause
the camshafts to rotate unexpectedly and can cause personal injury

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Fig. 258: Using Open End Wrench On Hex Cast Into Camshaft

4. Install the J 42038 to the rear of the camshafts on the left and right cylinder heads.

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Fig. 259: Identifying J 42038

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Fig. 260: Locking Left Secondary Drive Chain Tensioner

8. Wrap the left secondary timing chain around both secondary drive sprockets.
9. Align the exhaust sprocket drive pin (1) between the 2 darkened links (2).
10. Align the intake sprocket drive pin (4) with the single darkened link (3).

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Fig. 261: Identifying Right Secondary Camshaft Timing Components Position

11. Fit the intake and exhaust camshaft sprockets with the secondary timing chain onto their respective
camshafts and align the drive pins in the camshafts.

CAUTION: Use the correct fastener in the correct location. Replacement

12. Install the camshaft sprocket bolts.

Tighten
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12.1. Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).

12.2. Tighten the camshaft sprocket bolts an additional 45 degrees using the J 36660-A.
13. Remove the locking wire from the left secondary drive chain tensioner allowing the tensioner shoes to
expand and apply pressure to the drive chain.

Fig. 262: Installing Camshaft Sprocket Bolts

14. Compress the right secondary drive chain tensioner shoes with your hand.
15. Lock the right secondary drive chain tensioner by inserting a piece of wire (2) into the access hole in the
side of the tensioner (1).
16. Slowly release the pressure from the right secondary drive chain tensioner shoes. The tensioner should
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remain closed.

Fig. 263: Locking Right Secondary Drive Chain Tensioner

17. Wrap the right secondary timing chain around both secondary drive sprockets.
18. Align the intake sprocket drive pin (1) between the 2 darkened links (2).
19. Align the exhaust sprocket drive pin (4) with the single darkened link (3)

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Fig. 264: Identifying Right Secondary Camshaft Timing Components Position

20. Fit the intake and exhaust camshaft sprockets with the secondary timing chain onto their respective
camshafts and align the drive pins in the camshafts.
21. Install the camshaft sprocket bolts.

Tighten

21.1. Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).

21.2. Tighten the camshaft sprocket bolts an additional 45 degrees using the J 36660-A.
22. Remove the locking wire from the right secondary drive chain tensioner allowing the tensioner shoes to
expand and apply pressure to the drive chain.

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Fig. 265: Installing Intake & Exhaust Camshaft Sprockets & Bolts

Important: Do not allow the primary camshaft drive chain to fall into the crankcase.

23. Install the primary camshaft drive chain into the front cover area.

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Fig. 266: Installing Primary Camshaft Drive Chain

Important: Do not remove the J 42038.

24. To assist in primary camshaft drive chain installation, use an open end wrench on the hex cast into the
camshaft to provide minor adjustments to the secondary sprocket position.

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Fig. 267: Using Open End Wrench On Hex Cast Into Camshaft

25. When installing the primary camshaft drive chain you must set the base engine timing. Base engine
timing is set with cylinder number one at top dead center (TDC) starting the intake stroke and with the
correct camshaft to balance shaft to crankshaft relationship. To set the correct base engine timing proceed
as follows:
25.1. Rotate the crankshaft until cylinder number one is at top dead center and the crankshaft
sprocket timing mark (6) is at the 4 o'clock position using the J 43032.
25.2. Rotate the balance shaft until its timing mark (7) is at the 5 o'clock position.
26. Make sure the darkened chain links on the primary camshaft drive chain are facing outward.

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Fig. 268: Identifying Drive Chain Markings

27. Center the timing mark (1) on the left hand intake camshaft between the paired darkened timing links (2)
and wrap the chain around the sprocket. Allow the remainder of the primary camshaft drive chain to drop
into the crankcase area once the timing mark is aligned.
28. Fabricate a hook out of wire and feed it down through the right cylinder head. Use the hook to pull the
remainder of the primary camshaft drive chain up to the right intake camshaft sprocket.
29. While pulling the timing chain up to the right cylinder head, align the darkened chain links with the
balance shaft (7) and crankshaft (6) sprockets.
30. Wrap the primary camshaft drive chain around the right intake camshaft sprocket and align the darkened
link (8) with the sprocket's timing mark (9).
31. Install the primary camshaft drive chain tensioner shoe. Refer to Primary Camshaft Drive Chain
Tensioner Shoe Replacement .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

32. Install the primary camshaft drive chain tensioner. Refer to Primary Camshaft Drive Chain Tensioner
Replacement .
33. Remove the J 42038 from the rear of the camshafts on the left and right cylinder heads.

Fig. 269: Identifying J 42038

34. Make sure all the timing marks (1,6,7,9) are properly aligned with the darkened chain links (2,3,5,8).
35. Install the following components:
 The left camshaft cover. Refer to Camshaft Cover Replacement - Left .

 The right camshaft cover. Refer to Camshaft Cover Replacement - Right .

 The camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine Controls-
Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

3.5L.

Fig. 270: Identifying Drive Chain Markings

CAMSHAFT REPLACEMENT- LEFT

Tools Required:

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture
 J 42042 Timing Chain/Sprocket Holding Fixture
 J 43032 Crankshaft Rotation Socket

Removal Procedure
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

1. Remove the left camshaft cover. Refer to Camshaft Cover Replacement - Left .

Important: You must install the J 42038 immediately after can cover removal. The J 42038 prevents
unexpected camshaft rotation caused by valve spring pressure.

2. Install the J 42038 on to the left camshafts. When installed properly the J 42038 will be fully seated on
the camshaft ends with the camshaft flats parallel to the cam cover sealing surface.
3. Remove the camshaft sprocket bolts.

Fig. 271: Identifying J 42038

4. Install the J 42042 on to the left cylinder head.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

5. Evenly slide the secondary drive chain and camshaft sprockets off the camshafts on to the J 42042.

Fig. 272: Installing J 42042 On Left Cylinder Head

6. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.
The markings have the following meanings:
 The raised feature must always be oriented toward the outboard of the engine.

 The "l" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 273: Identifying Bearing Cap Markings

7. Remove the camshaft bearing cap retaining bolts.

8. Remove the camshaft bearing caps. The cap closest to the front of the engine is the thrust cap and must
not be installed in another location.
9. Remove the J 42038 from the left camshafts. Allow the camshaft lobes to find a neutral position by
rotating each camshaft, if necessary. DO NOT rotate the camshafts more than 10 degrees.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 274: Removing Camshaft Bearing Caps

10. Lift the camshaft (1 or 2) out of the cylinder head.

11. Clean and inspect the camshaft. Refer to CAMSHAFT CLEANING AND INSPECTION in Engine
Mechanical-3.5L Unit Repair.
12. Cover the camshaft with an oil soaked towel in order to prevent corrosion

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 275: Removing Camshafts

Installation Procedure

1. Apply a liberal amount of clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent to
the roller (2), lash adjuster and valve tip areas (1) of the camshaft followers.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 276: Locating Camshaft Followers Lubrication Areas

Important: The follower must be positioned squarely on the valve tip so that the full width of the roller
will completely contact the camshaft lobe. If the followers are being reused you must put them back in
their original location.

2. Place the camshaft followers in position on the valve tip and lifter. The rounded head end of the follower
goes on the lash adjuster while the flat end goes on the valve tip.
3. Clean the camshaft journals and carriers with a clean, lint-free cloth.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 277: Installing Camshaft Followers

Important: Use the J 43032 in order to make sure that the crankshaft is in the TDC position.

4. Select the proper camshaft for the particular installation location. The left cylinder head camshafts (1,2)
are longer than those for the right cylinder head (3,4). However, both sets of camshafts share the same
placement of identification rings. The ring placement is defined as follows:
4.1. The identification ring for the intake camshafts (1,3) is located between the first and second
sets of lobes.
4.2. The identification ring for the exhaust camshafts (2,4) is located between the second and third
sets of lobes.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 278: Identifying Camshaft Identification Rings

5. Apply a liberal amount of clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent to
the camshaft journals and the cylinder head camshaft carriers.
6. Place the intake (1) and exhaust (2) camshafts in position in the cylinder head.
7. Position the camshaft lobes in a neutral position with the front notch for the camshaft sprocket drive pins
near the top of their rotation and the rear flats of the camshaft near the installation position of the J 42038.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 279: Installing Camshafts

8. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.
The markings have the following meanings:
 The raised feature must always be oriented toward the outboard of the engine.

 The "l" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 280: Identifying Camshaft Markings

9. Install the camshaft bearing thrust caps in the first journal of each camshaft. The thrust caps are wider
than the others and have machined undercuts not present on the other caps. Make sure the orientation
marking is closest to the engine valley.
10. Install the remaining bearing caps with their orientation mark closest to the engine valley.
11. Hand start all the camshaft bearing cap bolts.

CAUTION: Use the correct fastener in the correct location. Replacement

12. Tighten the camshaft bearing caps.

Tighten

12.1. Tighten the camshaft bearing cap bolts to 8 N.m (71 lb in).
12.2. Use the J 36660-A in order to tighten the camshaft bearing cap bolts an additional 22 degrees.

Fig. 281: Installing Camshaft Bearing Thrust Caps

Important: There should be no need to rotate the camshaft more than 10 degrees.

13. Using the hex cast into the camshaft, rotate the camshaft so the rear camshaft flat is facing the cylinder
head.
14. Install the J 42038 at the rear of the cylinder head.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 282: Installing J 42038

Important: The camshafts must be locked in place using the J 42038 before installation of the secondary
timing chain.

15. Make sure the locking tool is fully seated and locked onto the camshafts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 283: Identifying J 42038

16. Compress the secondary timing chain tensioner shoes with your hand.
17. Lock the tensioner by inserting a piece of wire (2) into the access hole in the side of the tensioner (1).
18. Slowly release pressure on the tensioner shoes. The tensioner should remain compressed.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 284: Locking Secondary Timing Chain Tensioner

19. Slide the intake and exhaust camshaft sprockets off of the J 42042 and onto their respective camshafts
and align the drive pins (1) in the camshafts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 285: Identifying Right Secondary Camshaft Timing Components Position

20. Remove the J 42042 from the left cylinder head.

21. Install the intake camshaft sprocket bolts and exhaust camshaft sprocket bolt.

Tighten

21.1. Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).

21.2. Use the J 36660-A in order to tighten the camshaft bearing cap bolts an additional 45 degrees.
22. Remove the locking wire from the secondary timing chain tensioner allowing the tensioner shoes to
expand and apply pressure to the timing chain.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 286: Removing J 42042

23. Remove the J 42038 from the left camshafts.

24. Install the left camshaft cover. Refer to Camshaft Cover Replacement - Left .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 287: Identifying J 42038

CAMSHAFT REPLACEMENT - RIGHT

Tools Required:

 J 42038 Camshaft Holding Fixture

 J 43032 Crankshaft Rotation Socket
 J 36660-A Electronic Torque Angle Meter
 J 42042 Timing Chain/Sprocket Holding Fixture

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Removal Procedure

1. Remove the right camshaft cover. Refer to Camshaft Cover Replacement - Right .

Important: You must install the J 42038 immediately after cam cover removal. The J 42038 prevents
unexpected camshaft rotation caused by valve spring pressure.

2. Install the J 42038 on to the right camshafts. When installed properly the J 42038 will be fully seated on
the camshaft ends with the camshaft flats parallel to the cam cover sealing surface.

Fig. 288: Identifying J 42038

3. Remove the camshaft position sensor. Refer to CRANKSHAFT POSITION SENSOR in Engine
Controls-3.5L.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

4. Remove the camshaft sprocket bolts.

5. Install the J 42042 on to the right cylinder head.
6. Evenly slide the secondary drive chain and camshaft sprockets off the camshafts on to the J 42042.
7. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its location.
The markings have the following meanings:
 The raised feature must always be oriented toward the outboard of the engine.

 The "I" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

Fig. 289: Identifying Camshaft Markings

8. Remove the camshaft bearing cap retaining bolts.

9. Remove the camshaft bearing caps. The cap closest to the front of the engine is the thrust cap and must
not be installed in another location.
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10. Remove the J 42038 from the right camshafts.

Fig. 290: Removing Camshaft Bearing Caps

11. Lift the camshaft (1 or 2) out of the cylinder head.

12. Clean and inspect the camshaft. Refer to CAMSHAFT CLEANING AND INSPECTION in Engine
Mechanical-3.5L Unit Repair.
13. Cover the camshaft with an oil soaked towel in order to prevent corrosion.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 291: Removing Camshafts

Installation Procedure

1. Apply a liberal amount of clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent to
the roller (2), lash adjuster and valve tip areas (1) of the camshaft followers.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 292: Identifying Camshaft Followers Lubrication Areas

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 293: Installing Camshaft Followers

Important: Use the J 43032 in order to make sure that the crankshaft is in the TDC position.

4. Select the proper camshaft for the particular installation location. The left cylinder head camshafts (1, 2)
are longer than those for the right cylinder head (3, 4). However, both sets of camshafts share the same
placement of identification rings. The ring placement is defined as follows:
4.1. The identification ring for the intake camshafts (1, 3) is located between the first and second
sets of lobes.
4.2. The identification ring for the exhaust camshafts (2, 4) is located between the second and third
sets of lobes.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 294: Identifying Camshaft Identification Rings

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 295: Installing Camshafts

 The "I" indicates the intake camshaft.

 The "E" indicates the exhaust camshaft.

 The number indicates the journal position from the front of the engine.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 296: Identifying Camshaft Markings

CAUTION: Use the correct fastener in the correct location. Replacement

systems.

12. Tighten the camshaft bearing caps.

Tighten

12.1. Tighten the camshaft bearing cap bolts to 8 N.m (71 Ib. in).
12.2. Use the J 36660-A in order to tighten the camshaft bearing cap bolts an additional 22 degrees.

Fig. 297: Installing Camshaft Bearing Thrust Caps

Important: There should be no need to rotate the camshaft more than 10 degrees.

13. Using the hex cast into the camshaft, rotate the camshaft so the rear camshaft flat is facing the cylinder
head.
14. Install the J 42038 at the rear of the cylinder head.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 298: Installing J 42038

Important: The camshafts must be locked in place using the J 42038 before installation of the secondary
timing chain.

15. Make sure the locking tool is fully seated and locked onto the camshafts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 299: Identifying J 42038

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 300: Locking Secondary Timing Chain Tensioner

19. Slide the intake and exhaust camshaft sprockets off of the J 42042 and onto their respective camshafts
and align the drive pins (1) in the camshafts.
20. Remove the J 42042 from the right cylinder head.
21. Install the intake camshaft sprocket bolt and exhaust camshaft sprocket bolt.

Tighten

21.1. Tighten the camshaft sprocket bolts to 25 N.m (18 lb ft).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 301: Identifying Right Secondary Camshaft Timing Components Position

24. Remove the J 42038 from the right camshafts.

25. Install the right camshaft cover. Refer to Camshaft Cover Replacement - Right .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 302: Identifying J 42038

VALVE ROCKER ARM REPLACEMENT- LEFT

Removal Procedure

1. Remove the left (front) camshafts. Refer to Camshaft Cover Replacement - Left .
2. Remove the camshaft followers from the cylinder head. Keep the followers in the order they were
removed.
3. Clean and inspect the valve rocker arms. Refer to VALVE ROCKER ARMS CLEANING AND
INSPECTION in Engine Mechanical-3.5L Unit Repair.
4. Store the camshaft and followers in a clean, secure location.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 303: Removing Camshaft Followers

Installation Procedure

1. Apply a liberal amount of clean engine oil to the roller (2), lash adjuster and valve tip areas (1) of the
camshaft followers.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 304: Identifying Camshaft Followers Lubrication Areas

2. Place the camshaft followers in position on the valve tip and lifter. The rounded head end of the follower
goes on the lash adjuster while the flat end goes on the valve tip.

3. Clean the camshaft journals and carriers with a clean, lint-free cloth.
4. Install the left (front) camshafts. Refer to Camshaft Cover Replacement - Left .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 305: Installing Camshaft Followers

VALVE ROCKER ARM REPLACEMENT- RIGHT

Removal Procedure

1. Remove the right (rear) camshafts. Camshaft Cover Replacement - Right .

2. Remove the camshaft followers from the cylinder head. Keep the followers in the order they were
removed.
3. Clean and inspect the valve rocker arms. Refer to VALVE ROCKER ARMS CLEANING AND
INSPECTION in Engine Mechanical-3.5L Unit Repair.
4. Store the camshaft and followers in a clean, secure location.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 306: Removing Camshaft Followers

Installation Procedure

1. Apply a liberal amount of clean engine oil to the roller (2), lash adjuster and valve tip areas (1) of the
camshaft followers.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 307: Identifying Camshaft Followers Lubrication Areas

2. Place the camshaft followers in position on the valve tip and lifter. The rounded head end of the follower
goes on the lash adjuster while the flat end goes on the valve tip.

3. Clean the camshaft journals and carriers with a clean, lint-free cloth.
4. Install the right (rear) camshafts. Refer to Camshaft Cover Replacement - Right .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 308: Installing Camshaft Followers

VALVE LIFTER REPLACEMENT- LEFT

Removal Procedure

1. Remove the left (front) valve rocker arm(s). Valve Rocker Arm Replacement- Left .
2. Remove the stationary hydraulic lash adjuster (SHLA) from the cylinder head bore.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 309: Removing Stationary Hydraulic Lash Adjuster

3. Clean and inspect the valve lifters. Refer to CAMSHAFT COVER CLEANING AND INSPECTION in
Engine Mechanical-3.5L Unit Repair.
4. Store the lifter(s) in a clean, secure location

Installation Procedure

1. Fill the stationary hydraulic lash adjuster (SHLA) with clean engine oil and lubricate the all outer
surfaces. Take precautions to prevent scratching the head area (1) of the adjuster.
2. Lubricate the lash adjuster bore in the cylinder head with clean engine oil.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 310: Identifying Stationary Hydraulic Lash Adjuster Head

3. Install the lash adjuster in the cylinder head.

4. Install the left (front) valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Left .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 311: Installing Stationary Hydraulic Lash Adjuster

VALVE LIFTER REPLACEMENT- RIGHT

Removal Procedure

1. Remove the right (rear) valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Right .
2. Remove the stationary hydraulic lash adjuster (SHLA) from the cylinder head bore.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 312: Removing Stationary Hydraulic Lash Adjuster

3. Clean and inspect the valve lifters. Refer to VALVE LIFTERS CLEANING AND INSPECTION in
Engine Mechanical-3.5L Unit Repair.
4. Store the lifter(s) in a clean, secure location.

Installation Procedure

1. Fill the stationary hydraulic lash adjuster (SHLA) with clean engine oil and lubricate the all outer
surfaces. Take precautions to prevent scratching the head area (1) of the adjuster.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 313: Identifying Stationary Hydraulic Lash Adjuster Head

2. Lubricate the lash adjuster bore in the cylinder head with clean engine oil.
3. Install the lash adjuster in the cylinder head.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 314: Install The Lash Adjuster

4. Install the right (rear) valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Right .

VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT - LEFT

Tools Required:

 J 43059 Valve Retainer Remover/Installer

 J 38820 Valve Stem Seal Installer
 J 39313 Spark Plug Port Adapter
 J 42039 Valve Spring Compressor

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Removal Procedure

1. Remove the valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Left .
2. Remove the spark plug.
3. Install the J 39313 and apply air pressure to the cylinder in order to keep the valve from dropping into the
cylinder.
4. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer to
loosen the valve keepers.

WARNING: Compressed valve springs have high tension against the valve
spring compressor. Valve springs that are not properly compressed
by or released from the valve spring compressor can be ejected
from the valve spring compressor with intense force. Use care when
compressing or releasing the valve spring with the valve spring
compressor and when removing or installing the valve stem keys.
Failing to use care may cause personal injury.

5. Compress the valve spring with the J 42039.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 315: Identifying J 42039

6. Use the magnetic end of the J 43059 in order to remove the valve keepers (1).
7. Remove the J 42039.
8. Remove the valve spring retainer (2).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 316: Removing Valve Spring Retainer

9. Remove the valve spring.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 317: Removing Valve Spring

10. Remove the valve seal using the J 38820.

11. Inspect and measure the valve spring. Refer to VALVE SPRING INSPECTION AND MEASUREMENT
in Engine Mechanical-3.5L Unit Repair.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 318: Removing Valve Seal

Installation Procedure

1. Lubricate the valve stem, valve seal and guide with engine oil.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 319: Locating Valve Stems

2. Using the J 38820 , install the valve seal using the following procedure:
2.1. Mount the valve seal in the J 38820.
2.2. Push and twist the valve seal into position on the valve guide until the seal positively locks on
the guide.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 320: Installing Valve Seal

3. Position the valve spring on the spring seat.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 321: Installing Valve Spring

4. Place the valve spring retainer (2) onto the valve spring.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 322: Installing Valve Spring Retainer

5. Compress the valve spring using the J 42039.

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Fig. 323: Identifying J 42039

6. With the spring compressed, install the valve keepers into the J 43059.
7. Place the keepers (1) into position by pushing the tool downward.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 324: Installing Valve Keepers

8. Release the tension on the spring compressor and remove the J 42039.
9. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-
blow hammer. The valve keepers and the spring should remain in place.
10. Relieve the air pressure from the cylinder and remove the J 39313.
11. Install the spark plug.
12. Install the left (front) valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Left .

VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT - RIGHT

Tools Required

 J 43059 Valve Retainer Remover/Installer

 J 38820 Valve Stem Seal Installer

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2002 ENGINE Engine Mechanical - Aurora 3.5L

 J 39313 Spark Plug Port Adapter

 J 42039 Valve Spring Compressor

Removal Procedure

1. Remove the valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Right .
2. Remove the spark plug.
3. Install the J 39313 and apply air pressure to the cylinder in order to keep the valve from dropping into the
cylinder.
4. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve spring retainer to
loosen the valve keepers.

5. Compress the valve spring with the J 42039.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 325: Identifying J 42039

6. Use the magnetic end of the J 43059 in order to remove the valve keepers (1).
7. Remove the J 42039.
8. Remove the valve spring retainer (2).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 326: Removing Valve Keepers

9. Remove the valve spring.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 327: Removing Valve Spring

10. Remove the valve seal using the J 38820.

11. Inspect and measure the valve spring. Refer to VALVE SPRING INSPECTION AND MEASUREMENT
in Engine Mechanical-3.5L Unit Repair.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 328: Removing Valve Seal

Installation Procedure

1. Lubricate the valve stem, valve seal and guide with engine oil.

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Fig. 329: Locating Valve Stems

2. Using the J 38820 , install the valve seal using the following procedure:
1. 2.1. Mount the valve seal in the J 38820.
2. 2.2. Push and twist the valve seal into position on the valve guide until the seal positively locks on
the guide.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 330: Installing Valve Seal

3. Position the valve spring on the spring seat.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 331: Installing Valve Spring

4. Place the valve spring retainer (2) onto the valve spring.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 332: Installing Valve Spring Retainer

5. Compress the valve spring using the J 42039.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 333: Identifying G 42039

6. With the spring compressed, install the valve keepers into the J 43059.
7. Place the keepers (1) into position by pushing the tool downward.
8. Release the tension on the spring compressor and remove the J 42039.
9. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping with a dead-
blow hammer. The valve keepers and the spring should remain in place.
10. Relieve the air pressure from the cylinder and remove the J 39313.
11. Install the spark plug.
12. Install the left (front) valve rocker arm(s). Refer to Valve Rocker Arm Replacement- Right .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 334: Installing Valve Keepers

CYLINDER HEAD REPLACEMENT - LEFT

Tools Required

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture

Removal Procedure

1. Remove the intake manifold. Refer to Intake Manifold Replacement .

2. Remove the water housing crossover. Refer to WATER CROSSOVER REPLACEMENT (LX5) in
Engine Cooling.
3. Remove the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (LX5) in
Engine Exhaust.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

4. Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left .

5. Install the J 42038 on the camshafts.
6. Remove the primary camshaft drive chain. Refer to Primary Camshaft Drive Chain Replacement .
7. Remove the left cylinder head camshafts. Refer to Camshaft Replacement- Left .

Important: Place the valve train parts in a rack in order to make sure that they are installed in the same
location from which they were removed.

Fig. 335: Removing Cylinder Head & Bolts

8. Remove the valve rocker arms.

9. Remove the lifters.
10. Remove the M6 external drive bolts (1, 3) from the front portion of the cylinder head. Note the location
of the longer M6 bolt (1).
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11. Remove and discard the M11 internal drive cylinder head bolts (2). DO NOT reuse the cylinder head
bolts.
12. Remove the cylinder head. Make sure that no dowel guide pins are stuck in the cylinder head.
13. Remove the cylinder head gasket. Make sure all of the gasket material is removed.
14. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in order to prevent
damage to the deck face.
15. If necessary, disassemble the cylinder head. Refer to CYLINDER HEAD DISASSEMBLE in Engine
Mechanical-3.5L Unit Repair.
16. Clean and inspect the cylinder head. Refer to CYLINDER HEAD CLEANING AND INSPECTION in
Engine Mechanical-3.5L Unit Repair.

Fig. 336: Removing Cylinder Head Gasket

Installation Procedure

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1. If necessary, assemble the cylinder head. Refer to CYLINDER HEAD DISASSEMBLE in Engine
Mechanical-3.5L Unit Repair.
2. Make sure all the cylinder head locating pins are securely mounted in the cylinder block deck face.
3. Install a new cylinder head gasket using the deck face locating pins for retention.

Fig. 337: Installing Cylinder Head Gasket

4. Align the cylinder head with the deck face locating pins.
5. Place the cylinder head in position on the deck face.

Important: DO NOT reuse the old M11 cylinder head bolts.

6. Install new M11 cylinder head bolts (2).

7. Install the M6 bolts at the front of the cylinder head. Install the longer M6 bolt (1) in the outboard
location as shown. Install the 2 shorter M6 bolts (3) in the locations shown.
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Fig. 338: Installing Cylinder Head & Bolts

CAUTION: Use the correct fastener in the correct location. Replacement

8. Tighten the M11 bolts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten

7.1. Tighten the M11 cylinder head bolts to 40 N.m (30 lb ft) in the sequence shown.
7.2. Repeat the sequence turning each bolt an additional 100 degrees using the J 36660-A.
7.3. Repeat the sequence again turning each bolt an additional 100 degrees (total 200 degrees)
using the J 36660-A.

Fig. 339: Identifying Cylinder Head Bolt Tightening Sequence

9. Tighten the long M6 bolt (1).

Tighten

Tighten the long M6 cylinder head bolt to 12 N.m (106 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

10. Tighten the 2 shorter M6 bolts (2).

Tighten

Tighten the 2 shorter M6 cylinder head bolts to 12 N.m (106 lb in).

11. Install the lifters.

12. Install the rocker arms.
13. Install the left cylinder head camshafts. Refer to Camshaft Replacement- Left .
14. Install the primary camshaft drive chain. Refer to Primary Camshaft Drive Chain Replacement .
15. Remove the J 42038 from the camshafts.
16. Install the camshaft covers. Refer to Camshaft Cover Replacement - Left .
17. Install the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (LX5) in
Engine Exhaust.
18. Install the water housing crossover. Refer to WATER CROSSOVER REPLACEMENT (LX5) in Engine
Cooling.
19. Install the intake manifold. Refer to Intake Manifold Replacement .

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Fig. 340: Locating Cylinder Head Bolts

CYLINDER HEAD REPLACEMENT - RIGHT

Tools Required

 J 36660-A Electronic Torque Angle Meter

 J 42038 Camshaft Holding Fixture

Removal Procedure

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2002 ENGINE Engine Mechanical - Aurora 3.5L

1. Remove the intake manifold. Refer to Intake Manifold Replacement .

Important: Do NOT remove the right exhaust manifold. Disconnect from the right cylinder head and
connection at the left exhaust manifold and move aside.

2. Disconnect the right exhaust manifold from the cylinder head. Refer to EXHAUST MANIFOLD
REPLACEMENT - RIGHT (LX5) in Engine Exhaust.
3. Adjust the water crossover pipe for access. Refer to WATER CROSSOVER REPLACEMENT (LX5) in
Engine Cooling.
4. Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left and Camshaft Cover
Replacement - Right .

Fig. 341: Removing Cylinder Head

5. Install the J 42038 on the camshafts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

6. Remove the primary camshaft drive chain. Refer to Primary Camshaft Drive Chain Replacement .
7. Remove the right cylinder head camshafts. Refer to Camshaft Replacement -Right .

Important: Place the valve train parts in a rack in order to make sure that they are installed in the same
location from which they were removed.

8. Remove the valve rocker arms.

9. Remove the lifters.
10. Remove the coolant temperature sensor from the right cylinder head. Refer to ENGINE COOLANT
TEMPERATURE SENSOR in Engine Controls-3.5L.
11. Remove the M6 external drive bolts (1, 3) from the front portion of the cylinder head. Note the location
of the longer M6 bolt (1).
12. Remove and discard the M11 internal drive cylinder head bolts (2). DO NOT reuse the cylinder head
bolts.
13. Remove the cylinder head. Make sure that no dowel guide pins are stuck in the cylinder head.
14. Remove the cylinder head gasket. Make sure all of the gasket material is removed.
15. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in order to prevent
damage to the deck face.
16. If necessary, disassemble the cylinder head. Refer to CYLINDER HEAD DISASSEMBLE in Engine
Mechanical-3.5L Unit Repair.
17. Clean and inspect the cylinder head. Refer to CYLINDER HEAD CLEANING AND INSPECTION in
Engine Mechanical-3.5L Unit Repair.

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Fig. 342: Removing Cylinder Head Gasket

Installation Procedure

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Fig. 343: Installing Cylinder Head Gasket

4. Align the cylinder head with the deck face locating pins.
5. Place the cylinder head in position on the deck face.

Important: DO NOT reuse the old M11 cylinder head bolts.

6. Install new M11 cylinder head bolts (2).

7. Install the M6 bolts at the front of the cylinder head. Install the longer M6 bolt (1) in the outboard
location as shown. Install the 2 shorter M6 bolts (3) in the locations shown.

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Fig. 344: Installing Cylinder Head

CAUTION: Use the correct fastener in the correct location. Replacement

8. Tighten the M11 bolts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten

Fig. 345: Identifying Cylinder Head Bolt Tightening Sequence

9. Tighten the long M6 bolt (2).

Tighten

Tighten the long M6 cylinder head bolt to 12 N.m (106 lb in).

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2002 ENGINE Engine Mechanical - Aurora 3.5L

10. Tighten the 2 shorter M6 bolts (1).

Tighten

Tighten the 2 shorter M6 cylinder head bolts to 12 N.m (106 lb in).

11. Install the coolant temperature sensor into the right cylinder head. Refer to ENGINE COOLANT
TEMPERATURE SENSOR in Engine Controls-3.5L.
12. Install the lifters.
13. Install the rocker arms.
14. Install the right cylinder head camshafts. Refer to Camshaft Replacement -Right .
15. Install the primary camshaft drive chain. Refer to Primary Camshaft Drive Chain Replacement .
16. Remove the J 42038 from the camshaft.
17. Install the camshaft cover. Refer to Camshaft Replacement -Right .
18. Install the water crossover pipe. Refer to WATER CROSSOVER REPLACEMENT (LX5) in Engine
Cooling.
19. Connect the right exhaust manifold to the cylinder head. Refer to EXHAUST MANIFOLD
REPLACEMENT - RIGHT (LX5) in Engine Exhaust.
20. Install the intake manifold. Refer to Intake Manifold Replacement .

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Fig. 346: Locating Cylinder Head Bolts

ENGINE FLYWHEEL REPLACEMENT

Tools Required

 J 43442 Flywheel Holder

 J 36660-A Electronic Torque Angle Meter

Removal Procedure
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1. Remove the transmission. Refer to 4T65-E TRANSAXLE in Automatic Transaxle - 4T65-E

2. Install the J 43442 in order to prevent flywheel rotation.

Fig. 347: Identifying J 43442

3. Loosen the 8 engine flywheel mounting bolts.

4. Remove 7 of the 8 engine flywheel mounting bolts leaving 1 bolt at the top of the crankshaft rotation.
5. Remove the J 43442.
6. Grip the engine flywheel and remove the remaining bolt. Do not drop the engine flywheel when removing
the final bolt.
7. Remove the engine flywheel.
8. Clean and inspect the engine flywheel. Refer to ENGINE FLYWHEEL CLEANING AND INSPECTION
in Engine Mechanical-3.5L Unit Repair.

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Fig. 348: Removing Engine Flywheel

Installation Procedure

1. Apply sealant, GM P/N 12346004 or equivalent, to engine flywheel retaining bolts.

2. Place the engine flywheel in position on the crankshaft.
3. Slip one bolt into the engine flywheel washer.
4. Install the washer and a bolt in a location at the top of the engine flywheel rotation allowing the engine
flywheel to hang in position. Install a bolt at the bottom of the engine flywheel rotation allowing the
engine flywheel to hang in position.

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Fig. 349: Installing Engine Flywheel

5. Install the J 43442 in order to prevent flywheel rotation.

CAUTION: Use the correct fastener in the correct location. Replacement

6. Install the remaining engine flywheel bolts.

Tighten

Tighten the engine flywheel retaining bolts to 15 N.m + 50 degrees (11 Ib. ft + 50 degrees) using the J
36660-A .

7. Remove the J 43442.

8. Install the transmission. Refer to 4T65-E TRANSAXLE in Automatic Transaxle - 4T65-E.

Fig. 350: Identifying J 43442

CRANKSHAFT REAR OIL SEAL REPLACEMENT

Tools Required

 J 42841 Crankshaft Rear Oil Seal Remover

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2002 ENGINE Engine Mechanical - Aurora 3.5L

 J 42842 Crankshaft Rear Oil Seal Installer

Removal Procedure

1. Remove the engine flywheel. Refer to Engine Flywheel Replacement .

Important: Rear crankshaft seal removal cannot be performed on an engine stand. If the engine is out of
the vehicle, properly support the engine on a bench or on the floor. If the engine is in the vehicle the seal
can be removed after the transaxle and engine flywheel are removed.

2. Place the J 42841 onto the crankshaft.

3. Install the J 42841 retaining bolts.

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Fig. 351: Identifying J 42841

4. Using a drill motor (variable speed preferred) with a socket adapter, install 8 one-inch self-drilling screws
into the seal using the guide holes in the removal tool. When drilling, make sure you reduce the drill
speed when the screw begins threading into the seal.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 352: Installing J 42841

5. With all 8 removal screws installed, remove the J 42841 retaining bolts.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 353: Removing J 42841 Retaining Bolts

6. Install the center forcing screw.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 354: Installing Center Forcing Screw

7. Tighten the center screw on the removal tool to pull the seal assembly off the end of the crankshaft.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 355: Removing Rear Oil Seal Assembly

Installation Procedure

1. Clean any debris from the crankshaft rear oil seal drain (1) using wire or an unbound plastic tie-wrap (2).

Important: Make sure the drain is clear before installing the new crankshaft rear oil seal. Failure to clear
the drain could cause the crankshaft rear oil seal to leak.

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2. Place a small amount of Gasket Maker, GM P/N 1052942 or equivalent, at the crankcase split line across
the end of the upper/lower crankcase seal.
3. Coat the outer diameter of the cylinder block crankshaft rear oil seal area with clean engine oil GM P/N
12345501 or equivalent.

Fig. 356: Cleaning Crankshaft Rear Oil Seal Drain

Important: DO NOT allow any engine oil on the area where the crankshaft rear oil seal is to be pressed
onto the crankshaft. The green coating pre-applied to the inner diameter of the crankshaft rear oil seal
must not be contaminated.

4. Wipe the outer diameter of the flywheel flange clean with a lint-free cloth.

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Important: DO NOT put any engine oil on the green coating pre-applied to the inner diameter of the
crankshaft rear oil seal. This coating is a sealant that must not be contaminated.

5. Lubricate the outer rubber surface (1) of the crankshaft rear oil seal with clean engine oil GM P/N
12345501 or equivalent.

Important: It is not necessary to completely unthread the center bolt and separate the 2 pieces of the J
42842.

Fig. 357: Identifying Crankshaft Rear Oil Seal Lubrication Area

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6. Loosen the center bolt of the J 42842 until the center hub protrudes approximately 13 mm (0.50 in)
beyond the outer plate.
7. Install the J 42842 to the rear of the crankshaft.

Fig. 358: Installing J 42842

8. Thread the 3 mounting bolts into the crankshaft flange.

9. Tighten the bolts until the J 42842 is firmly mounted on the crankshaft.

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Fig. 359: Tightening J 42842 On Crankshaft

10. Install the crankshaft rear oil seal by tightening the center bolt until the J 42842 bottoms against the
crankcase.
11. Loosen the center bolt to release pressure on the crankcase.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 360: Loosening Center Bolt On J 42842

12. Loosen the 3 mounting bolts.

13. Remove the J 42842 from the crankshaft flange.
14. Inspect to ensure the installation depth is equal around the crankshaft rear oil seal's circumference. If the
depth is not equal reinstall the J 42842 and repeat the installation procedure.
15. Install the engine flywheel. Refer to Engine Flywheel Replacement .

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Fig. 361: Loosening J 42842 Off Crankshaft

OIL PAN REPLACEMENT

Removal Procedure

1. Remove the oil filter cap and drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
2. Disconnect the electrical connector from engine oil level switch.
3. Remove the transaxle brace.

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Fig. 362: Removing Transaxle Brace

4. Remove the oil pan retaining bolts.

5. Remove the oil pan (2) from the lower crankcase.

Important: DO NOT damage the sealing surface.

6. Remove the oil pan gasket. Scrape any remaining gasket material from the pan rail surfaces.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 363: Removing Oil Pan

7. Remove the engine oil level switch from the oil pan.
8. Clean and inspect the oil pan. Refer to OIL PAN CLEANING AND INSPECTION in Engine
Mechanical-3.5L Unit Repair.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 364: Removing Engine Oil Level Switch From Oil Pan

Installation Procedure

1. Install the engine oil level switch into the oil pan.

CAUTION: Use the correct fastener in the correct location. Replacement

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

fastener. Use the correct tightening sequence and specifications

when installing fasteners in order to avoid damage to parts and
systems.

Fig. 365: Installing Engine Oil Level Switch

2. Install the engine oil level switch bolt.

Tighten

Tighten the engine oil level switch bolt to 9 N.m (80 Ib. in).

3. Install a new oil pan gasket.

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4. Install the oil pan (2) to the lower crankcase.

Fig. 366: Installing Oil Pan

5. Loosely install the oil pan retaining bolts.

Important: DO NOT install the transaxle brace-to-oil pan bolts.

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6. Install the transaxle brace and the two brace-to-cylinder block bolts.

Tighten

Tighten the transaxle brace bolts to 50 N.m (37 Ib. ft).

7. Loosely install the transaxle brace-to-oil pan bolts (4).

8. To ensure proper mounting of the transaxle, align the cast boss on the rear of the oil pan so it is flush with
the rear of the cylinder block face. Use a straight edge in order to check the pan alignment from the rear
of the block face to the bolt boss on the oil pan.
9. Press the forward part of the oil pan against the transaxle brace. Be sure to keep the rear of the oil pan
flush with the rear face of the cylinder block.

Tighten

Tighten the transaxle brace bolts to 50 N.m (37 Ib. ft).

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Fig. 367: Tightening Transaxle Brace Bolts

10. Keep the rear of the oil pan flush with the rear cylinder block and tighten the oil pan retaining bolts.

Tighten

Tighten the oil pan retaining bolts in sequence shown to 25 N.m (18 lb ft).

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Fig. 368: Identifying Oil Pan Bolts Tightening Sequence

11. Tighten the remaining transaxle brace bolts to the transaxle.

Tighten

Tighten the transaxle brace bolts to 50 N.m (37 lb ft).

12. Connect the electrical connector to engine oil level switch.

13. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement .
14. Inspect for oil leaks after engine start up.

OIL PUMP PIPE AND SCREEN ASSEMBLY REPLACEMENT

Removal Procedure
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

1. Remove the oil pan. Refer to Oil Pan Replacement .

2. Remove the oil pump pick-up tube nut (2) from the main bearing stud.
3. Remove the oil pump pick-up tube bolt (4) from the oil pump.
4. Remove the oil pump pipe and screen (1).

Fig. 369: Removing Oil Pump Pipe & Screen

Installation Procedure

1. Make sure the new O-ring seal on the tube end is in place.
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

2. Press the tube end into the oil pump.

CAUTION: Use the correct fastener in the correct location. Replacement

3. Install the oil pump pick-up tube bolt (4) into the oil pump.

Tighten

Tighten the oil pump pick-up tube bolt to 10 N.m (89 lb in).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 370: Installing Oil Pump Pipe & Screen

4. Place the tab on the stud end main bearing bolt.

5. Install the oil pump pick-up tube nut (2) on the stud.

Tighten

Tighten the oil pump pick-up tube nut to 10 N.m (89 lb in).

6. Install the oil pan. Refer to Oil Pan Replacement .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

ENGINE REPLACEMENT

Tools Required

 J 38185 Hose Clamp Pliers

 J 39580 Universal Engine Support Table
 J 41623-B Cooler Quick Connect Tool
 J 42640 Steering Column Lock Pin

Removal Procedure

1. Disconnect the battery negative cable. Refer to BATTERY NEGATIVE CABLE

DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
2. Recover the A/C refrigerant system. Refer to GENERAL MOTORS in Heating, Ventilation and Air
Conditioning.
3. Disconnect the vacuum brake booster hose from the vacuum brake booster and secure to the top of the
engine.
4. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 371: Disconnecting Vacuum Brake Booster Hose

5. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure to the air inlet
grille.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 372: Disconnecting Evaporative Emission Canister Purge Valve Hose

6. Remove the air cleaner assembly.

7. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield.
8. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 373: Removing Fuel Injector Sight Shield

9. Remove the nut (1) securing the battery positive cable to the remote positive terminal and secure to the
top of the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 374: Removing Battery Positive Cable To Remote Positive Terminal Nut

10. Disconnect the secondary AIR relay (1) from the relay bracket and secure to the top of the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 375: Disconnecting Secondary AIR Relay

11. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
 The PCM. Refer to POWERTRAIN CONTROL MODULE .

 The C101 (2)

 The engine electrical harness. Refer to UNDERHOOD ELECTRICAL CENTER OR JUNCTION

BLOCK in Wiring Systems.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 376: Identifying C101 Wiring Harness Electrical Connector

12. Remove the bolt (1) securing the engine ground cable (2) from the right side body frame rail.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 377: Removing Engine Ground Cable Bolt

WARNING: In order to avoid 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.

13. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever.
14. Remove the accelerator control cable from the throttle body. Refer to THROTTLE BODY .

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 378: Removing Cruise Control Cable

15. Set the park brake and chock the wheels.

16. Fully lift the retainer from the transaxle range selector cable mechanism.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 379: Lifting Transaxle Range Selector Cable Mechanism Retainer

17. Disconnect the transaxle range selector cable terminal from the transaxle manual shift lever pin.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 380: Disconnecting Transaxle Range Selector Cable Terminal

18. Press the locking tabs inward in order to release the transaxle range selector cable from the bracket.
19. Remove the transaxle range selector cable and position aside.
20. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
21. Position the J 38185 to the clamp in order to remove the radiator inlet hose (2) from the water housing
crossover and position aside.
22. Position the J 38185 to the clamp in order to remove the radiator outlet hose (1) from the thermostat
housing and position aside.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 381: Clamping Radiator Outlet & Inlet Hoses

23. Disconnect the surge tank inlet hose (2) from the surge tank (1).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 382: Disconnecting Surge Tank Inlet Hose From Surge Tank

24. Position the J 38185 to the clamp in order to remove the heater outlet hose from the thermostat housing.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 383: Clamping Heater Outlet Hose

25. Position the J 38185 to the clamp in order to remove the heater inlet hose from the water crossover.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 384: Removing Heater Inlet Hose

WARNING: Brake fluid may irritate eyes and skin. In case of contact, take the
following actions:

 Eye contact-rinse thoroughly with water.

 Skin contact-wash with soap and water.
 If ingested-consult a physician immediately.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Important: Record the location of the brake pipes to the brake pressure modulator valve (BPMV) for use
as an aid during installation.

26. Remove the two master cylinder brake pipes (1) from the BPMV (2).

Plug the open outlet ports to prevent fluid loss and contamination.

Fig. 385: Removing Master Cylinder Brake Pipes

27. Remove the transaxle oil cooler pipe bracket bolt from the fan shroud.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 386: Removing Transaxle Oil Cooler Pipe Bracket Bolt From Fan Shroud

28. Slide the plastic cap off the transaxle oil cooler pipe quick connect fittings.
29. Disconnect the upper (1) and lower (2) transaxle oil cooler pipes from the radiator using the J 41623-B.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 387: Disconnecting Upper & Lower Transaxle Oil Cooler Pipes From Radiator

CAUTION: The wheels of the vehicle must be straight ahead and the steering
column in the LOCK position before disconnecting the steering
column or intermediate shaft from the steering gear. Failure to do so
will cause the SIR coil assembly to become uncentered, which may
cause damage to the coil assembly.

30. Lock the steering column by installing the J 42640 into the underside of the steering column.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 388: Locking steering Column

31. Remove the right and left side strut tower bolts.
32. Raise and support the vehicle.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 389: Removing Strut Tower Bolts

33. Remove the transaxle oil cooler pipe bracket bolt from the lower tie bar.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 390: Removing Transaxle Oil Cooler Pipe Bracket Bolt From Lower Tie Bar

34. Remove the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (LX5) in
Engine Exhaust.
35. Remove the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires
and Wheels.
36. Disconnect the front wheel speed sensor electrical leads (2) from the body frame rail.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 391: Disconnecting Front Wheel Speed Sensor Electrical Leads

37. Remove the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT in Body Front End.
38. Remove the wheelhouse extensions. Refer to WHEELHOUSE EXTENSION REPLACEMENT in Body
Front End.
39. Disconnect the secondary AIR inlet hose from the secondary AIR pump.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 392: Disconnecting Secondary AIR Inlet Hose

40. Loosen the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
41. Disconnect the front brake pipes from the retainers at the body frame rails.
42. Carefully pull the front brake pipes away from the body frame rails.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 393: Locating Front Brake Pipe Frame Bracket Nuts

43. Disconnect the 2 rear brake pipes at the rear of the engine frame.

Plug the open outlet ports to prevent fluid loss and contamination.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 394: Locating Rear Brake Pipes At Rear Of Engine Frame

44. Disconnect the A/C pressure sensor (1).

45. Disconnect the A/C discharge hose (3) from the compressor and secure to the cooling fan assembly.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 395: Disconnecting A/C Pressure Sensor & Discharge Hose

46. Disconnect the A/C suction hose from the compressor and secure to the cooling fan assembly.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 396: Disconnecting A/C Suction Hose From Compressor

WARNING: Failure to disconnect the intermediate shaft from the rack and pinion
stub shaft can result in damage to the steering gear and/or damage
to the intermediate shaft. This damage may cause loss of steering
control which could result in personal injury.

47. Remove the intermediate shaft pinch bolt.

48. Remove the steering gear from the intermediate shaft.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 397: Removing Steering Gear From Intermediate Shaft

49. Disconnect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS
HEAT SHIELD REPLACEMENT in Engine Exhaust.
50. Remove the torque converter cover. Refer to 4T65-E TRANSAXLE .

Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

51. Remove the torque converter to the flywheel bolts.

52. Position the J 39580 powertrain support dolly under the engine frame.
53. Lower the vehicle on to the J 39580.

Fig. 398: Identifying J 39580

54. If the powertrain support dolly is unavailable. Support the powertrain with 4 suitable jackstands.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 399: Supporting Powertrain Using Jackstands

55. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
56. Remove the nut securing the right engine mount to the engine mount bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 400: Removing Nut Securing Right Engine Mount To Engine Mount Bracket

57. Remove the nut (1) securing the left transaxle mount to the transaxle mount bracket.

WARNING: 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.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 401: Removing Nut Securing Left Engine Mount To Engine Mount Bracket

58. Secure the front hoist pads to the vehicle.

59. Remove the 6 frame to body mounting bolts (3).

Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:

 The A/C accumulator hose

 The A/C compressor hose
 The brake pipes
 The heater hoses
 The radiator hoses
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

 The wheel speed sensor leads

 The wiring harnesses

Fig. 402: Removing Frame To Body Mounting Bolts

60. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
61. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
62. Remove the secondary air injection crossover pipe/hose.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 403: Removing Secondary Air Injector Crossover Pipe/Hose

63. Disconnect the engine wiring harness from the engine. Refer to COMPONENT LOCATIONS in Engine
Controls-3.5 L.
64. Remove the power steering pump from the engine and lay the pump aside. Refer to POWER
STEERING PUMP .
65. If the vehicle is equipped, remove the secondary air injection check valve/pipe. Refer to SECONDARY
AIR INJECTION (AIR) SHUT-OFF VALVE REPLACEMENT - BANK 2 in Engine Controls - 3.5L.
66. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
67. Remove the exhaust manifolds and crossover pipe. Refer to Exhaust Manifold Replacement - Left and to
Exhaust Manifold Replacement - Right in Engine Exhaust.
68. Install the engine lifting device to the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

69. Remove the bolts which secure the engine mount bracket to the engine. Refer to Engine Mount Bracket
Replacement - Front .
70. Remove the transaxle brace. Refer to 4T65-E TRANSAXLE in Automatic Transaxle - 4T65-E.
71. Disconnect the power steering return hose from the power steering pump reservoir.
72. Remove the power steering return hose retaining bolt from the cylinder head.

Fig. 404: Removing Power Steering Return Hose Retaining Bolt

73. Remove the power steering pressure hose (1) from the power steering pump.
74. Remove the bolt (2) securing the power steering pressure hose to the secondary AIR valve bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 405: Removing Power steering Pressure Hose Securing Bolt

75. Remove the 3 bolts securing the right engine mount bracket to the engine.
76. Remove the right engine mount bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 406: Removing Right Engine Mount Bracket

77. Remove the bolts securing the transaxle brace to the engine and transaxle.
78. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 407: Removing Transaxle Brace Bolts

79. Remove the nut (1) securing the front engine mount to the front engine mount bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 408: Removing Front Engine Mount Nut

80. Remove the bolts attaching the engine to the transaxle.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 409: Removing Transaxle To Engine Bolts

81. Raise the engine from the supported frame and transaxle assembly.
82. Remove the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .

Installation Procedure

1. Install the front engine mount bracket. Refer to Engine Mount Bracket Replacement - Front .
2. Carefully position the engine to the supported frame and transaxle assembly, aligning the engine dowels
to the transaxle cover.

CAUTION: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

thread locking compound or sealant are identified in the service

procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.

Important: The bolt installed in position (5) is two millimeters shorter than the other engine-to-transaxle
bolts and requires the use of thread sealant.

3. Install the bolts attaching the engine to the transaxle.

Tighten

Tighten the engine to transaxle mounting bolts to 75 N.m (55 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 410: Installing Transaxle To Engine Bolts

4. Install the transaxle brace. Refer to 4T65-E TRANSAXLE in Automatic Transaxle - 4T65-E.
5. Install the bolts which secure the engine mount bracket to the engine. Refer to Engine Mount Bracket
Replacement - Front .
6. Remove the engine lifting device from the engine.
7. Install the crossover pipe and the exhaust manifolds. Refer to Exhaust Manifold Replacement - Left and
to Exhaust Manifold Replacement - Right.
8. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
9. If the vehicle is equipped, install the AIR check valve/pipe. Refer to SECONDARY AIR INJECTION
(AIR) SHUT-OFF VALVE REPLACEMENT - BANK 2 in Engine Controls - 3.5L.
10. Install the power steering pump to the engine. Refer to POWER STEERING PUMP in Power Steering
System.
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

11. Install the nut (1) securing the front engine mount to the front engine mount bracket.

Tighten

Tighten the front engine mount to bracket nut to 55 N.m (41 lb ft).

Fig. 411: Installing Front Engine Mount Nut

12. Place a block of wood between the front of the engine oil pan and the engine frame.
13. Remove the engine lift chain from the engine lift brackets.
14. Install the bolts securing the transaxle brace to the engine and transaxle.

Tighten
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten the transaxle brace bolts to 50 N.m (37 lb ft).

Fig. 412: Installing Transaxle Brace Bolts

15. Position the right engine mount bracket to the engine.

16. Install the 3 bolts securing the right engine mount bracket to the engine.

Tighten

Tighten the right engine mount bracket bolts to 60 N.m (44 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 413: Installing Right Engine Mount Bracket

17. Install the power steering pressure hose (1) to the power steering pump.

Tighten

Tighten the power steering pressure hose to power steering pump to 30 N.m (22 lb ft).

18. Install the bolt (2) securing the power steering pressure hose to the secondary AIR valve bracket.

Tighten

Tighten the power steering pressure hose retaining bolt to 9 N.m (80 lb in).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 414: Installing Power steering Pressure Hose Securing Bolt

19. Connect the power steering return hose to the power steering pump reservoir.
20. Install the power steering return hose retaining bolt to the cylinder head.

Tighten

Tighten the power steering return hose retaining bolt to 17 N.m (13 lb ft).

21. Install the secondary air injection crossover pipe/hose.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 415: Removing Secondary Air Injector Crossover Pipe/Hose

22. Connect the engine wiring harness to the engine. Refer to COMPONENT LOCATIONS in Engine
Controls-3.5 L.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 416: Installing Power Steering Return Hose Retaining Bolt

23. Position the engine/transaxle assembly under the vehicle.

Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:

 The A/C accumulator hose

 The A/C compressor hose
 The brake pipes
 The heater hoses
 The radiator hoses
 The wheel speed sensor leads
 The wiring harnesses

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 417: Installing Frame To Body Mounting Bolts

24. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
25. Install the 6 frame mounting bolts (3) retaining the frame (2) to the vehicle.

Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

Tighten

Tighten the frame mounting bolts to 191 N.m (141 lb ft).

26. Install the nut securing the right engine mount to the engine mount bracket.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 418: Installing Nut Securing Right Engine Mount To Engine Mount Bracket

Tighten

Tighten the right engine mount nut to 80 N.m (59 lb ft).

27. Remove the block of wood between the front of the engine oil pan and the engine frame.
28. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.

Tighten
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten the left transaxle mount nut to 80 N.m (59 lb ft).

29. Raise and support the vehicle.

Fig. 419: Removing Nut Securing Left Engine Mount To Engine Mount Bracket

30. Remove the J 39580 powertrain support dolly from under the engine frame.

Important: Line up the flywheel and converter, using the alignment marks made during disassembly.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 420: Identifying J 39580

31. Install the bolts securing the flywheel to the torque converter.

Tighten

Tighten the flywheel to torque converter bolts to 65 N.m (48 lb ft).

32. Install the torque converter cover. Refer to 4T65-E TRANSAXLE .

33. Connect the post HO2S at the sensor pigtail. Refer to OXYGEN SENSOR WIRING HARNESS HEAT
SHIELD REPLACEMENT in Engine Exhaust.

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2002 ENGINE Engine Mechanical - Aurora 3.5L

disengage. Disengagement of the two mating shafts will cause loss

of steering control which could result in personal injury.

34. Connect the intermediate shaft to the steering gear.

35. Install the pinch bolt.

Tighten

Tighten the intermediate shaft to steering gear pinch bolt to 45 N.m (33 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 421: Connecting Intermediate Shaft To Steering Gear

36. Connect the A/C suction hose to the compressor.

Tighten

Tighten the A/C suction hose nut to 20 N.m (15 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 422: Connecting A/C Suction Hose From Compressor

37. Connect the A/C discharge hose (3) to the compressor.

Tighten

Tighten the A/C discharge hose nut to 20 N.m (15 lb ft).

38. Connect the A/C pressure sensor (1).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 423: Connecting A/C Pressure Sensor & Discharge Hose

39. Connect the 2 rear brake pipes at the rear of the engine frame.

Tighten

Tighten the brake pipes to 15 N.m (11 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 424: Locating Rear Brake Pipes At Rear Of Engine Frame

40. Connect the front brake pipes to the retainers at the body frame rails.
41. Install the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.

Tighten

Tighten the brake pipe frame bracket nuts to 15 N.m (11 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 425: Locating Front Brake Pipe Frame Bracket Nuts

42. Connect the secondary AIR inlet hose to the secondary AIR pump.
43. Install the front fascia extensions. Refer to FASCIA EXTENSION REPLACEMENT in Bumpers.
44. Install the front air deflector. Refer to AIR DEFLECTOR REPLACEMENT in Body Front End.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 426: Connecting Secondary AIR Inlet Hose

45. Attach the front wheel speed sensor electrical leads (2) to the body frame rail.
46. Install the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (LX5) in
Engine Exhaust.
47. Install the front wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and
Wheels.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 427: Connecting Front Wheel Speed Sensor Electrical Leads

48. Install the transaxle oil cooler pipe bracket bolt to the lower tie bar.

Tighten

Tighten the transaxle oil cooler pipe bracket to lower tie bar bolt to 9 N.m (80 lb in).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 428: Installing Transaxle Oil Cooler Pipe Bracket Bolt To Lower Tie Bar

49. Lower the vehicle ONLY enough to allow the threaded holes in the strut to align with the holes in the
strut towers.
50. Install the right and left side strut tower bolts.

Tighten

Tighten the strut tower bolts to 45 N.m (33 lb ft).

51. Lower the vehicle.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 429: Installing Strut Tower Bolts

52. Remove the J 42640 from the steering column.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 430: Unlocking steering Column

53. Push the upper (1) and lower (2) transaxle oil cooler pipes into the radiator quick connect fitting, until a
click is heard.
54. Tug gently on the cooler pipe to ensure proper retention.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 431: Connecting Upper & Lower Transaxle Oil Cooler Pipes From Radiator

55. Slide the plastic caps (1) over the quick connect joints.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 432: Sliding Plastic Caps Over Quick Connect Joints

56. Align the transaxle oil cooler pipes with the routing features (1, 2) on the fan shroud.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 433: Aligning Transaxle Oil Cooler Pipes With Routing Features On The Shroud

57. Install the transaxle oil cooler pipe bracket bolt to the fan shroud.

Tighten

Tighten the transaxle oil cooler pipe bracket to fan shroud bolt to 6 N.m (53 lb in).

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 434: Installing Transaxle Oil Cooler Pipe Bracket Bolt From Fan Shroud

58. Install the 2 master cylinder brake pipes (1) to the BPMV (2) using the location recorded during the
removal procedure.

Tighten
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Tighten the brake pipes to 15 N.m (11 lb ft).

Fig. 435: Installing Master Cylinder Brake Pipes

59. Position the J 38185 to the clamp in order to connect the heater inlet hose to the water crossover.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 436: Installing Heater Inlet Hose

60. Position the J 38185 to the clamp in order to connect the heater outlet hose to the thermostat housing.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 437: Unclamping Heater Outlet Hose

61. Connect the surge tank inlet hose (2) to the surge tank (1).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 438: Connecting Surge Tank Inlet Hose From Surge Tank

62. Position the J 38185 to the clamp in order to connect the radiator outlet hose (1) to the thermostat
housing.
63. Position the J 38185 to the clamp in order to connect the radiator inlet hose (2) to the engine.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 439: Connecting Radiator Outlet & Inlet Hoses

64. Insert the transaxle range selector cable into the bracket.
65. Connect the transaxle range selector cable terminal to the transaxle manual shift lever pin.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 440: Connecting Transaxle Range Selector Cable Terminal

66. Install the retainer to the transaxle range selector cable mechanism.
67. Adjust the transaxle range selector cable. Refer to SHIFT CABLE in Automatic Transaxle - 4T65-E.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 441: Installing Transaxle Range Selector Cable Mechanism Retainer

WARNING: In order to avoid possible injury or vehicle damage, always replace

68. Install a NEW accelerator control cable to the throttle body. Refer to THROTTLE BODY in Engine
Controls-3.5 L.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

69. Slide the cruise control cable (2) fully into the throttle body bracket until it snaps into place.
70. Install the cruise control cable (1) to the throttle body lever.

Fig. 442: Installing Cruise Control Cable

71. Install the bolt (1) securing the engine ground cable (2) to the right side body frame rail.

Tighten

Tighten the engine ground cable bolt to 36 N.m (27 lb ft).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 443: Installing Engine Ground Cable Bolt

72. Connect the wiring harness electrical connectors to the following components:
 The PCM. Refer to POWERTRAIN CONTROL MODULE in Engine Controls-3.5 L.

 The C101 (2)

 The engine electrical harness. Refer to UNDERHOOD ELECTRICAL CENTER OR JUNCTION

BLOCK in Wiring Systems.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 444: Identifying C101 Wiring Harness Electrical Connector

73. Install the nut (1) securing the battery positive cable to the remote positive terminal.

Tighten

Tighten the battery positive cable to remote positive terminal nut to 12 N.m (106 lb in).

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 445: Install Nut Securing Battery Positive Cable To Remote Positive Terminal

74. Attach the secondary AIR relay (1) to the relay bracket.
75. Install the air cleaner assembly.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 446: Connecting Secondary AIR Relay

76. Connect the hose (4) to the evaporative emission canister purge valve (3).
77. Connect the fuel inlet and return quick-connect fittings at the fuel rail.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 447: Connecting Evaporative Emission Canister Purge Valve Hose

78. Connect the vacuum brake booster hose to the vacuum brake booster.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 448: Connecting Vacuum Brake Booster Hose

79. Insert the tab of the fuel injector sight shield under the engine bracket.
80. Lower the fuel injector sight shield, aligning the holes with the studs.
81. Install the 2 fuel injector sight shield nuts onto the studs.

Tighten

Tighten the fuel injector sight shield nuts to 3 N.m (27 lb in).

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 449: Installing Fuel Injector Sight Shield

82. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE
DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
83. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
84. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
85. Bleed the hydraulic brake system. Refer to BLEEDING PROCEDURE in Hydraulic Brakes.
86. Recharge the A/C refrigerant system. Refer to GENERAL MOTORS in Heating, Ventilation and Air
Conditioning.
87. Bleed the power steering system. Refer to HYDRAULIC SYSTEM BLEEDING in Power Steering
System.
88. Measure the wheel alignment. Refer to WHEEL ALIGNMENT PROCEDURES in Wheel Alignment.

Engine Final Test and Inspection

Complete the following procedure after the engine is installed in the vehicle.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or
evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR
SYSTEM VARIATION L in Engine Controls-3.5 L.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.

ENGINE OIL AND OIL FILTER REPLACEMENT

Tools Required:

J 29142 Oil Filter Wrench

Removal Procedure

1. Raise and support the vehicle.

2. Position an oil drain pan under the engine oil filter cap and the oil drain plug.
3. Loosen the oil pan drain plug.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 450: Loosening Oil Pan Drain Plug

4. Remove the oil pan drain plug.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 451: Removing Oil Pan Drain Plug

5. Clean and inspect the oil pan drain plug, repair or replace if necessary.
6. Clean and inspect the oil pan drain plug sealing surface on the oil pan, repair or replace oil pan if
necessary.
7. Use the J 29142 in order to loosen the engine oil filter cap.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 452: Identifying J 29142

8. Remove the oil filter cartridge and engine oil filter cap.
9. Clean and inspect the engine oil filter cap, repair or replace if necessary.
10. Clean and inspect the engine oil filter cap sealing surface on the oil pan, repair or replace oil pan if
necessary.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 453: Removing Oil Filter Cartridge & Oil Filter Cap

Installation Procedure

1. Install the new oil filter cartridge and engine oil filter cap.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 454: Installing Oil Filter Cartridge & Oil Filter Cap

CAUTION: Use the correct fastener in the correct location. Replacement

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

2. Use the J 29142 in order to tighten the engine oil filter cap.

Tighten

Tighten the engine oil filter cap to 25 N.m (18 lb ft).

Fig. 455: Identifying J 29142

3. Install the oil pan drain plug.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 456: Installing Oil Pan Drain Plug

4. Tighten the oil pan drain plug.

Tighten

Tighten the oil pan drain plug to 20 N.m (15 lb ft).

5. Remove the oil drain pan from under the vehicle.

6. Lower the vehicle.
7. Fill the engine with new engine oil.
8. Inspect for leaks.
9. Verify oil level.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 457: Tightening Oil Pan Drain Plug

DESCRIPTION AND OPERATION

CRANKCASE VENTILATION SYSTEM INSPECTION/DESCRIPTION

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 458: Identifying PCV Valve

A crankcase ventilation system is used to consume crankcase vapors created during the combustion process
instead of venting them to atmosphere.

Fresh air is supplied through a filter to the crankcase, the crankcase mixes the fresh air with the blow-by gases
and then passed through a positive crankcase ventilation (PCV) valve into the intake manifold.

The PCV valve controls the flow rate of the blow-by gases based on intake manifold vacuum. To maintain idle
quality, the PCV valve (1) restricts the flow when inlet vacuum is high. If abnormal operating conditions arise,
the system is designed to allow excessive amounts of blow-by gases to back flow through the crankcase vent
tube into the throttle body in order to be consumed by normal combustion.

DRIVE BELT SYSTEM DESCRIPTION

The drive belt system consists of the following components:

 The drive belt

 The drive belt tensioner
 The drive belt idler pulley

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2002 ENGINE Engine Mechanical - Aurora 3.5L

 The crankshaft balancer pulley

 The accessory drive component mounting brackets
 The accessory drive components
 The power steering pump, if belt driven

 The generator

 The A/C compressor, if equipped

 The engine cooling fan, if belt driven

 The water pump, if belt driven

 The vacuum pump, if equipped

 The air compressor, if equipped

The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has
several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain
accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM -
and have different layers or plys containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side
of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The
spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from
slipping. The drive belt tensioner arm will 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.

TOOLS AND EQUIPMENT

 Special tools are listed and illustrated throughout this section with a complete listing at the end of the
section. These tools (or their equivalents) are specially designed to quickly and safely accomplish the
operations for which they are intended. The use of these special tools will also minimize possible damage
to engine components. Some precision measuring tools are required for inspection of certain critical
components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various
fasteners.
 To properly service the engine assembly, the following items should be readily available:
 Approved eye protection and safety gloves

 A clean, well-lit, work area

 A suitable parts cleaning tank

 A compressed air supply

 Trays or storage containers to keep parts and fasteners organized

 An adequate set of hand tools

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

 Approved engine repair stand

 An approved engine lifting device that will adequately support the weight of the components

SPECIAL TOOLS AND EQUIPMENT

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 459: Special Tools & Equipment (1 Of 6)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 460: Special Tools & Equipment (2 Of 6)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 461: Special Tools & Equipment (3 Of 6)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 462: Special Tools & Equipment (4 Of 6)

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 463: Special Tools & Equipment (5 Of 6)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 464: Special Tools & Equipment (6 Of 6)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs (N.m)
A/C Discharge Hose Nut 15 (20)
A/C Suction Hose Nut 15 (20)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Brake Pipe 11 (15)

Brake Pipe Frame Bracket Nut 11 (15)
Camshaft Sprocket Bolt
First Tightening Pass 18 (25)
Final Tightening Pass 45 Degrees
Crankshaft Balancer Bolt
First Tightening Pass 37 (50)
Final Tightening Pass 120 Degrees
Cylinder Head Bolt (M11)
First Tightening Pass 30 (40)
Second Tightening Pass 100 Degrees
Final Tightening Pass 100 Degrees
Drive Belt Idler Pulley/Generator Bolt 37 (50)
Drive Belt Tensioner Bolt 37 (50)
EGR Pipe Water Crossover Bolt (Same for Both Pipes) 18 (24)
Engine Ground Cable Bolt 27 (36)
Engine-To-Transaxle Mounting Bolt 55 (75)
Frame Mounting Bolt 141 (191)
Front Engine Mount Bracket Bolt 43 (58)
Front Engine Mount Nut 52 (70)
Front Engine Mount-To-Bracket Nut (1) 41 (55)
Front Lift Bracket
Hex Head Bolt 37 (50)
Torx(R) Head Bolt 18 (25)
Flywheel Bolt
First Tightening Pass 11 (15)
Final Tightening Pass 50 Degrees
Flywheel to Torque Converter Bolt 48 (65)
Intermediate Shaft-To-Steering Gear Pinch Bolt 33 (45)
Left Transaxle Mount Nut 59 (80)
Oil Filter Cap 18 (25)
Oil Pan Bolt (2) 18 (25)
Oil Pan Drain Plug 15 (20)
Oil Pump Retaining Bolt 18 (25)
Power Steering Pressure Hose-To-Power Steering Pump 22 (30)
Power Steering Return Hose Retaining Bolt 13 (17)
Primary Camshaft Drive Chain
Guide Bolt 18 (25)
Tensioner Bolt 18 (25)
Tensioner Shoe Bolt 18 (25)

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Right Engine Mount Bracket Bolt 44 (60)

Right Engine Mount Nut 59 (80)
Right Engine Mount-To-Body Rail Nut 52 (70)
Strut Tower Bolt 33 (45)
Transaxle Brace Bolt 37 (50)
INCH Lbs. (N.m)
Balance Shaft Cover Bolt 106 (12)
Battery Cable-To-Remote Positive Terminal Nut 106 (12)
Camshaft Bearing Cap Bolt
First Tightening Pass 71 (8)
Final Tightening Pass 22 Degrees
Camshaft Cover Bolt 80 (9)
Cylinder Head Bolt (M6) (3)
Long Bolt 106 (12)
Short Bolt 106 (12)
EGR Pipe Intake Manifold Bolt 89 (10)
Engine Front Cover Bolt (4) 124 (14)
Engine Front Cover Coolant Drain Plug 89 (10)
Engine Oil Level Switch Bolt 80 (10)
Engine Oil Pressure Switch 89 (10)
Engine Wiring Harness Channel Bolt 89 (10)
Fuel Injector Sight Shield Bracket Bolt 71 (8)
Fuel Injector Sight Shield Nut 27 (3)
Intake Manifold Bolt (5) 89 (10)
Oil Level Indicator Tube Bolt 80 (9)
Oil Level Sensor 80 (9)
Oil Pump Pick-Up Tube Bolt 89 (10)
Oil Pump Pick-Up Tube Nut 89 (10)
Power Steering Pressure Hose Retaining Bolt 80 (9)
Primary Camshaft Drive Chain Guide Access Plug 44 (5)
Secondary Timing Chain Tensioner Bolt 106 (12)
Transaxle Oil Cooler Pipe Bracket-To-Fan Shroud Bolt 53 (6)
Transaxle Oil Cooler Pipe Bracket-To-Lower Tie Bar Bolt 80 (9)
Water Pump Bolt (6) 124 (14)
Water Pump Pulley Bolt 106 (12)
(1) Tighten bolts according to sequence shown, see Fig. 465 .

(2) Tighten bolts according to sequence shown, see Fig. 466 .

(3) Tighten bolts according to sequence shown, see Fig. 467 .

Tighten bolts according to sequence shown, see Fig. 468 .

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2002 ENGINE Engine Mechanical - Aurora 3.5L

(4)

(5) Tighten bolts according to sequence shown, see Fig. 469 .

(6) Tighten bolts according to sequence shown, see Fig. 470 .

Fig. 465: Identifying Engine Mount-To-Engine Mount Bracket Nuts Tightening Sequence
Courtesy of GENERAL MOTORS CORP.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 466: Identifying Oil Pan Retaining Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 467: Identifying Cylinder Head Bolts (M6) Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

Microsoft
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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 468: Identifying Front Cover Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 469: Identifying Intake Manifold Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

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2001 Oldsmobile Aurora
2002 ENGINE Engine Mechanical - Aurora 3.5L

Fig. 470: Identifying Water Pump Bolts Tightening Sequence

Courtesy of GENERAL MOTORS CORP.

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Document ID: 55757 Page 1 of 3

Fastener Tightening Specifications

Specification
Application Metric English
Air Conditioning Compressor Bracket to Lower Crankcase
30 N·m 22 lb ft
Lock Nut
Air Conditioning Compressor Bracket to Lower Crankcase
25 N·m 18 lb ft
Stud
Air Conditioning Compressor to Block and Bracket 50 N·m 37 lb ft
Air Conditioning Compressor Mounting Bracket to
25 N·m 18 lb ft
Compressor
Brace--Left Bank (Long) 75 N·m 55 lb ft
Brace--Left Bank (Short) 50 N·m 37 lb ft
Braces--Right Bank 50 N·m 37 lb ft
Camshaft Bearing Cap 12 N·m 106 lb in
Camshaft Chain Guide Access Plug 4.5 N·m 39 lb in
Camshaft Cover 10 N·m 89 lb in
Camshaft Drive Chain Guide Bolts 25 N·m 18 lb ft
Camshaft Drive Chain Tensioner to Block 25 N·m 18 lb ft
Camshaft Seal Retainer to Cam Cover (Left Hand Head) 3 N·m 27 lb in
Camshaft Sprocket 120 N·m 89 lb ft
Catalytic Converter to Exhaust Manifold Rear Pipe 50 N·m 37 lb ft
Connecting Rod Bolt
l First Pass 30 N·m 22 lb ft
l Second Pass Back off to zero
l Third Pass 25 N·m 18 lb ft
l Final Pass +110 degrees
Coolant Temperature Sensor 20 N·m 15 lb ft
Crankshaft Balancer Bolt
l First Pass 50 N·m 37 lb ft
l Final Pass +150 degrees
Crankshaft Position Sensor 10 N·m 89 lb in
Cruise Control Bracket to Throttle Body Bracket 12 N·m 106 lb in
Cylinder Block Coolant Heater - Right & Left 10 N·m 89 lb in
Cylinder Head Bolt (M11)
l First Pass 40 N·m 30 lb ft
l Second Pass +70 degrees
l Third Pass +60 degrees
l Final Pass +60 degrees (190 degrees
Total)
© 2010 General Motors Corporation. All rights reserved.

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Cylinder Head Bolt (M6) 12 N·m 106 lb in

Cylinder Head Plug 80 N·m 59 lb ft
Cylinder Head Plug (Oil Gallery) 12 N·m 106 lb in
Cylinder Head Plug (Soc Hex) 5.5 N·m 49 lb in
Drive Belt Idler Pulley 50 N·m 37 lb ft
Drive Belt Tensioner 50 N·m 37 lb ft
EGR Pipe (to Intake Manifold) 25 N·m 18 lb ft
EGR Tube to Intermediate Pipe Nut 60 N·m 44 lb ft
EGR Valve 25 N·m 18 lb ft
Engine Flywheel Bolt
l First Pass 15 N·m 11 lb ft
l Final Pass +50 degrees
Exhaust Manifold Pipe to Cylinder Head 25 N·m 18 lb ft
Exhaust Manifold Pipe to EGR Tube 60 N·m 44 lb ft
Exhaust Manifold Pipe to Exhaust Manifold Rear Pipe 25 N·m 18 lb ft
Exhaust Manifold Pipe to Lower Crankcase 25 N·m 18 lb ft
Exhaust Manifold Rear Pipe to Right Manifold 40 N·m 30 lb ft
Exhaust Manifold to Cylinder Head Lock Nut 25 N·m 18 lb ft
Exhaust Manifold to Cylinder Head Bolt 25 N·m 18 lb ft
Flywheel Housing Cover Bolt 9 N·m 80 lb in
Front Cover Bolt 10 N·m 89 lb in
Generator and Air Conditioning Bracket to Block Bolt 50 N·m 37 lb ft
Generator Bracket to Block (Rear Bolt) 47 N·m 35 lb ft
Generator Bracket to Block (Rear Nut) 38 N·m 28 lb ft
Generator to Bracket (Front Lower Bolt) 50 N·m 37 lb ft
Generator to Bracket (Front Upper Bolt) 50 N·m 37 lb ft
Generator to Bracket (Rear Bolt) 50 N·m 37 lb ft
Ignition Module Bolt (to Cam Cover) 12 N·m 106 lb in
Intake Manifold Bolt 10 N·m 89 lb in
Intermediate Sprocket Retaining Bolt 60 N·m 44 lb ft
Intermediate Sprocket Shaft Bolt 10 N·m 89 lb in
Knock Sensor 20 N·m 15 lb ft
Lift Bracket--Right Rear 50 N·m 37 lb ft
Lower Crankcase to Block (M8 x 1.25) 30 N·m 22 lb ft
Lower Crankcase Bolt/Stud (In Sequence) (M10 x 1.5)
l First Pass 20 N·m 15 lb ft
l Final Pass +65 degrees
Oil Cooler lines to Oil Cooler 18 N·m 13 lb ft
Oil Cooler Lines to Oil Filter Adapter 18 N·m 13 lb ft
Oil Filter Adapter 16 N·m 12 lb ft

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Oil Filter Adapter Plug w/Oil Cooler 20 N·m 15 lb ft

Oil Filter Adapter Plug w/o Oil Cooler 18 N·m 13 lb ft
Oil Level Indicator Tube 10 N·m 89 lb in
Oil Level Sensor 30 N·m 22 lb ft
Oil Manifold Plate to Lower Crankcase 10 N·m 89 lb in
Oil Pan Bolt
l First Pass 8 N·m 71 lb in
l Final Pass 12 N·m 106 lb in
Oil Pan Brace 50 N·m 37 lb ft
Oil Pan Drain Plug 20 N·m 15 lb ft
Oil Pump Suction Pipe (Lock Nut) 25 N·m 18 lb ft
Oil Pump to Lower Crankcase
l First Pass 10 N·m 89 lb in
l Final Pass +35 degrees
Oxygen Sensor 40 N·m 30 lb ft
Power Steering Pump (to Bracket) 25 N·m 18 lb ft
Power Steering Pump Bracket (to Block) 50 N·m 37 lb ft
Starter (to Block) 30 N·m 22 lb ft
Starter Motor (Lock Nut) 10 N·m 89 lb in
Thermostat Outlet to Water Pump Cover 10 N·m 89 lb in
Torque Converter to Engine Flywheel Bolt 47 N·m 35 lb ft
Torque Strut Bracket to Cylinder Head 50 N·m 37 lb ft
Torque Strut Bracket to Cylinder Head (Stud) 50 N·m 37 lb ft
Torque Strut Bracket to Water Manifold 25 N·m 18 lb ft
Transaxle Bel Housing to Engine 75 N·m 55 lb ft
Water Crossover (to Block) 25 N·m 18 lb ft
Water Crossover (to Head) 25 N·m 18 lb ft
Water Crossover Plug 25 N·m 18 lb ft
Water Outlet Fitting 50 N·m 37 lb ft
Water Outlet to Cylinder Head 25 N·m 18 lb ft
Water Pump Assembly 100 N·m 74 lb ft
Water Pump Drive Belt Shield Retaining Bolt 10 N·m 89 lb in
Water Pump Drive Belt Shield Retaining Nut 10 N·m 89 lb in
Water Pump Drive Belt Tensioner to Water Crossover (Stud) 10 N·m 89 lb in
Water Pump Cover to Water Pump Housing 10 N·m 89 lb in

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Engine Mechanical Specifications

Application Metric English
General
l Piston Displacement 4.0 Liter 244 cu in
l Compression Ratio 10.3:1
l Compression Pressure at Cranking
965-1172 KPa 140-170 psi
Speed (Throttle Open)
l Power 186.5 kW @ 5600 RPM 250 hp @ 5600 RPM
l Torque 352.5 N·m @ 4000 RPM 260 lb ft @ 4000 RPM
l VIN ID C
l Firing Order 1-2-7-3-4-5-6-8
Cylinder Block
l Material Aluminum with Cast-in Grey Iron sleeves
l Bore 3.424-3.425 in @
86.992-87.008 mm @
1.61 in from deck
41 mm from deck surface
surface
l Stroke 84 mm 3.31 in
l Deck Height 224.55 mm 8.84 in
l Deck Clearance 0.45 mm above deck 0.18 in above deck
surface surface
l Length 528.45 mm 20.81 in
l Piston Clearance @ 41 mm from
0.020-0.051 mm 0.0008-0.002 in
deck face
l Deck Face Flatness --Maximum
0.101 mm 0.004 in
Allowe
l Cylinder Bore Out-of-Round --
0.100 mm 0.004 in
Maximum Allowed
l Cylinder Bore Taper -- Maximum
0.100 mm 0.004 in
Allowed
l Cylinder Bore Out-of-Round
l New 0.010 mm 0.0004 in
l Maximum Allowed 0.100 mm 0.004 in
l Cylinder Bore Taper
l New 0.010 mm 0.0004 in
l Maximum Allowed 0.100 mm 0.004 in
Cylinder Head
l Type DOHC--4 Valves Per Cylinder
l Material Aluminum
l Combustion Chamber Volume 51.8 cc --
l Cylinder Head Flatness Maximum
© 2010 General Motors Corporation. All rights reserved.

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Without Resurfacing 0.05 mm 0.002 in

l Worn Limit 0.20 mm 0.008 in
l Valves
l Clearance Between Stem and
0.028-0.068 mm 0.0011-0.0027 in
Guide, New Limits -- Intake
l Clearance Between Stem and
0.028-0.068 mm 0.0011-0.0027 in
Guide, New Limits -- Exhaust
l Intake Worn Limits (Not Over) 0.11 mm 0.0045 in
l Exhaust Worn Limits (Not Over) 0.12 mm 0.005 in
l Head Diameter, Overall -- Intake 31 mm 1.22 in
l Exhaust 29 mm 1.14 in
l Valve Face Angle 45 degrees
l Valve Seat Angle (In Head) 46 degrees
l Valve Seat Width -- Intake 0.450-0.650 mm 0.017-0.033 in
l Valve Seat Width -- Exhaust 0.700-1.100 mm 0.027-0.043 in
l Seat Eccentricity, Not Over
0.05 mm 0.002 in
(T.I.R.)
l Valve Face Runout 0.05 mm 0.002 in
l Stem Diameter 5.9207-5.9411 mm 0.2331-0.2339 in
l Valve Guide Diameter (in Head) 5.979 mm 0.235 in
l Valve Length -- Intake 105.89 mm 4.169 in
l Valve Length -- Exhaust 90.53 mm 3.564 in
Valve Lifters
l Type Direct Acting, Hydraulic
l Diameter 32.959-32.975 mm 1.297-1.298 in
l Lifter Bore Diameter (In Head) 33 mm 1.299 in
l Clearance 0.025-0.066 mm 0.001-0.003 in
Valve Springs
l Free Length 40.4 mm 1.591 in
l Force required to compress (Valve
205 N @ 30.3 mm 46 lb @ 1.19 in
Closed)
l Force required to compress (Valve
409 N @ 21.7 mm 92 lb @ 0.854 in
Open)
l Installed Height 30.3 mm 1.19 in
Camshaft
l Primary Drive Type Endless Chain
l Adjustment Hydraulic, Automatic
l Pitch 8 mm 0.315 in
l Width Single Row
l Secondary Drive Type Endless Chain
l Adjustment Direct Acting Hydraulic
l Pitch 8 mm 0.315 in

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l Width Single Row

l Camshaft Material Hardened Cast Grey Iron
l Bearing Number 5
l Bearing Number on Left Hand
6
Intake
l Bearing Journal Diameter 26.948-26.972 mm 1.061-1.062 in
l Bearing Bore Diameter (In Head) 27.023 mm 1.064 in
l Bearing Clearance 0.051-0.076 mm 0.002-0.003 in
l New Limits 0.04-0.09 mm 0.002-0.004 in
l Worn Limits (Not Over) 0.152 mm 0.006 in
l Out-of-Round (Not Over) 0.022 mm 0.0009 in
l Valve Timing (With Ramp at
9 degrees BTDC
0.100 mm Lift), Intake Opens
l Intake Closes 55 degrees ABDC
l Exhaust Opens 51 degrees BBDC
l Exhaust Closes 13 degrees ATDC
l Valve Lift, Intake 8.6 mm 0.339 in
l Exhaust 8.6 mm 0.339 in
l Duration (@ 0.100 mm Lift),
244 degrees
Intake
l Exhaust 244 degrees
l Valve Overlap (@ 0.100 mm Lift) 22 degrees
Connecting Rod
l Bearing Material Aluminum
l Clearance Between Bearing and
0.025-0.076 mm 0.001-0.003 in
Crankshaft -- New Limits
l Worn Limits (Not Over) 0.076 mm 0.003 in
l Diameter, Lower End (Without
57.144 mm 2.249 in
Bearing)
l Piston Pin Hole 22.022-22.008 mm 0.8662-0.866 in
l Length, Center to Center 151 mm 5.94 in
l End Play of Rods on Crankpin 0.20-0.50 mm 0.008-0.020 in
Piston Rings
l Side Clearance -- Compression
0.040-0.095 mm 0.0016-0.0037 in
Ring
l Side Clearance -- Oil Rings None--Side Sealing
l Ring End Gap-- Top Compression
0.25-0.40 mm 0.010-0.016 in
Ring
l Ring End Gap-- Second
0.35-0.50 mm 0.014-0.020 in
Compression Ring
l Ring End Gap-- Oil Rings 0.25-0.76 mm 0.010-0.030 in
l Number of Compression Rings 2
l Number of Oil Rings 2 Rails - 1 Expander

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l Width of Compression Ring Groove

1.230-1.255 mm 0.048-0.049 in
-- Top Ring
l Width of Compression Ring Groove
1.530-1.555 mm 0.060-0.061 in
-- Second Ring
l Width of Compression Ring Groove
3.030-3.055 mm 0.119-0.120 in
-- Oil Ring
Pistons
l Piston Material Aluminum
l Piston Diameter @ 46 mm from
86.957-86.972 mm 3.423-3.424 in
Top of Piston
l Piston Taper No Piston Taper Measurement
l Piston Pin Diameter 21.995-22.000 mm 0.865-0.866 in
l Bore Diameter 22.002-22.008 mm 0.8662-0.8665 in
l Pin Retention Snap Rings (2)
Oil System
l Oil Pump Type Gerotor
l Minimum Pressure at Normal
35 kPa 5 psi
Operating Temperature @ Idle
l Minimum Pressure at Normal
Operating Temperature @ 2000 250 kPa 35 psi
RPM
l Oil Pressure Recirculation, Internal
Internal Piston Valve
Relief Valve Assembly
l Oil Filter Type PF 58
l Oil Capacity with Filter -- 7.5 Quarts
l Without Filter -- 7 Quarts
Crankshaft and Main Bearings
l Main Bearing Clearance Limit --
0.015-0.055 mm 0.0006-0.002 in
New Limit
l Main Bearing Clearance Limit --
0.0635 mm 0.0025 in
Worn Limit
l Main Bearing Journal Diameter 64.352-64.346 mm 2.5335-2.5337 in
l Main Bearing Journal Out-of-
0.004 mm 0.00016 in
Round (Not Over)
l Main Bearing Journal Taper 0.004 mm 0.00015 in
l Main Bearing Journal Length --
24.6 mm 0.969 in
No. 1
l Main Bearing Journal Length --
24.6 mm 0.969 in
No. 2
l Main Bearing Journal Length --
25.2 mm 0.992 in
No. 3
l Main Bearing Journal Length --
24.6 mm 0.969 in
No. 4
l Main Bearing Journal Length --
24.6 mm 0.969 in
No. 5

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l Crankpin Journal Diameter 53.948-53.962 mm 2.1239-2.1245 in

l Maximum Crankpin Journal Out-
0.004 mm 0.00016 in
of-Round
l Maximum Crankpin Journal Taper 0.005 mm 0.0002 in
l End Play in Crankshaft -- New
0.05-0.5 mm 0.002-0.019 in
Limits
l End Play in Crankshaft -- Worn
0.5 mm 0.020 in
Limits
l Flywheel Flange Face Runout 0.025 mm 0.001 in
l Rear Main Seal Diameter 95.76-95.98 mm 3.77-3.78 in

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GM SPO Group Numbers

Application GM SPO Group Number
Camshaft Cover 00.386
Camshaft Cover Gasket 00.423
Camshaft Interior Drive Chain 00.724
Camshaft Interior Drive Shaft 00.519
Camshaft Sprocket 00.736
Connecting Rod 00.603
Connecting Rod Bearing Kit 00.616
Coolant Pump 01.069
Coolant Pump Cover 01.073
Coolant Pump Gasket 01.079
Crankshaft 00.646
Crankshaft Balancer 00.659
Crankshaft Bearing Kit 00.096
Crankshaft Sprocket 00.728
Cylinder Head 00.269
Cylinder Head Gasket 00.289
EGR Valve 03.670
EGR Valve Gasket 03.680
4.0L Engine 00.000A
Enigne Coolant Thermostat 01.246
Engine Coolant Thermostat Gasket 01.252
Engine Coolant Thermostat Housing 01.251
Engine Flywheel 00.666
Engine Front Cover 00.206
Engine Front Cover Gasket 00.207
Engine Oil Manifold 01.531
Exhaust Camshaft 00.519
Exhaust Manifold 03.601
Exhaust Manifold Gasket 03.270
Flywheel Housing Cover 00.679
Intake Camshaft 00.519
Intake Manifold 03.265
Intake Manifold Gasket 03.270
Oil Filter 01.836
Oil Filter Gasket 01.840
Oil Level Indicator 01.516
© 2010 General Motors Corporation. All rights reserved.

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Oil Pan 01.426

Oil Pan Gasket 01.429
Oil Pump 01.652
Piston Ring Kit 00.643
Piston with Pin 00.629
Spark Plug 02.270
Spark Plug Wire Kit 02.239
Starter Motor 02.041
Throttle Body 03.336
Throttle Body Gasket 03.335

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Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Type of United
Canada
Application Material States
Camshaft Prelube Lubricant 12345501 992704
Crankshaft Prelube Lubricant 1052367 992869
Fuel Injector Bores Lubricant 12345610 993193
Ignition Coil Spark Plug Boot Lubricant 12345579 1974984
Oxygen Sensor Lubricant 12377953 N/A
Split Lines Between Components for Crankshaft Rear
Sealant 12378521 88901148
Oil Seal and Engine Front Cover Gasket
Sealant -
Upper-to-Lower Crankcase 1052942 10953466
6 ML
Sealant -
Upper-to-Lower Crankcase 1052943 10953491
50 ML
Valve Lifter Lubricant 12345616 993182
Water Pump, Flywheel Bolts Sealant 12346004 10953480

© 2010 General Motors Corporation. All rights reserved.

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Thread Repair Specifications

Table 1: Rear Face of Cylinder Block
Table 2: Left Side of Cylinder Block
Table 3: Front Face of Cylinder Block
Table 4: Right Side of Cylinder Block
Table 5: Cylinder Block Pan Rail
Table 6: Cylinder Block Upper Joint
Table 7: Left Bank Deck Face
Table 8: Right Bank Deck Face
Table 9: Cylinder Head Cam Cover Face
Table 10: Front Face of Cylinder Head
Table 11: Rear Face of Cylinder Head
Table 12: Intake Face of Cylinder Head
Table 13: Exhaust Manifold Face of Cylinder Head

Rear Face of Cylinder Block

© 2010 General Motors Corporation. All rights reserved.

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Rear Face of Cylinder Block

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 12 x 1.75 R1084-12-20 Thru 31/64 3747-12-8
12
2 8 x 1.25 R1084-8-20 24 21/64 2093-8 3747-8
3 8 x 1.25 R1084-8-20 Thru 21/84 2093-8 3747-8

Left Side of Cylinder Block

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Left Side of Cylinder Block

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
1 8 x 1.25 R1084-8 20 21/64 2093-8 3747-8
2093-
2 10 x 1.5 R1084-10-20 24 13/32 3747-10
10
3 10 x 1.5 R1084-8-20 25 27/64 2093-8 3747-8
4 8 x 1.25 R1084-8 16 21/64 2093-8 3747-8
5 6 x 1.0 R1084-6-20 16 1/4 2093-6 3747-6
6 6 x 1.0 R1084-6-20 21 1/4 2093-6 3747-6
7 10 x 1.5 R1084-10-20 24 13/32 2093-6 374-6

Front Face of Cylinder Block

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Front Face of Cylinder Block

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
1 6 x 1.0 R1084-6-20 Thru 1/4 2093-6 3747-6
2 6 x 1.0 R1084-6-20 15-5 1/4 2093-6 3747-6
2093-
3 6 x 1.5 R1084-10-20 Thru 13/32 3747-10
10
2093-
4 10 x 1.5 R1084-10-20 27 13/32 3747-10
10
5 6 x 1.0 R1084-6-20 17 1/4 2093-6 3747-6
6 8 x 1.25 R1084-8-20 Thru 21/64 2093-8 3747-8
7 8 x 1.25 R1084-8-20 22 21/64 2093-8 3747-8

Right Side of Cylinder Block

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Right Side of Cylinder Block

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 10 x 1.5 R1084-10-20 24 13/32 3747-10
10

Cylinder Block Pan Rail

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Cylinder Block Pan Rail

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 6 x 1.0 R1084-6-20 Thru 1/4 3747-6
6
2093-
2 6 x 1.0 R1084-6-20 18 1/4 3747-6
6
2093-
3 6 x 1.0 R1084-6-20 15 1/4 3747-6
6

Cylinder Block Upper Joint

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Cylinder Block Upper Joint

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
J-
J-42385 J-42385 J-42385
42385
1 10 x 1.5 29.5
514 511 513
512
2 8 x 1.25 R1084-8-20 Thru 21/64 2093-8 3747-8
3 8 x 1.25 R1084-8-20 32 21/64 2093-8 3747-8

Left Bank Deck Face

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Left Bank Deck Face

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
J-
J-42385 J-42385 J-42385
42385
1 11 x 1.5 70
507 504 506
505
2 6 x 1.0 R1084-6-20 25 1/4 2093-6 3747-6

Right Bank Deck Face

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Right Bank Deck Face

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
J-
J-42385 J-42385 J-42385
42385
1 11 x 1.5 70
507 504 506
505
2 6 x 1.0 R1084-6-20 25 1/4 2093-6 3747-6

Cylinder Head Cam Cover Face

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Cylinder Head Cam Cover Face

Front Face of Cylinder Head

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Front Face of Cylinder Head

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 10 x 1.5 R1084-10-20 22.5 13/32 3747-10
10
2093-
2 10 x 1.5 R1084-10-20 26 13/32 3747-10
10

Rear Face of Cylinder Head

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Rear Face of Cylinder Head

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 8 x 1.25 R1084-8-20 22 21/64 3747-8
8

Intake Face of Cylinder Head

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Hole Thread Insert Hole Depth Drill Insert

Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 6 x 1.0 R1084-6-20 Thru 1/4 3747-6
6
2093-
2 6 x 1.0 R1084-6-20 21.25 1/4 3747-6
6

Exhaust Manifold Face of Cylinder Head

Hole Thread Insert Hole Depth Drill Insert
Location Size Package (mm) (in) Tap Tool/Driver
2093-
1 10 x 1.5 R1084-10-20 26 13/32 3747-10
10
2 8 x 1.25 R1084-8-20 20 21/64 2093-8 3747-8
3 6 x 1.0 R1084-6-20 18 1/4 2093-6 3747-6

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Upper Engine Components

(1) Intake Manifold Sight Shield

(2) Right Bank Spark Plug Wires
(3) Left Bank Spark Plug Wires
(4) Throttle Body Spacer
(5) Throttle Body Gasket
(6) Throttle Body Assembly
(7) Throttle Cable Bracket
(8) Mass Airflow Sensor
(9) Left Intake Camshaft (Water Pump Drive)
(10) EGR Feed Pipe
(11) Camshaft Bearing Cap Bolt
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(12) Camshaft Bearing Cap

(13) Extra Bearing Cap (Longer Camshaft)
(14) Water Pump Drive Seal
(15) Water Pump Drive Pulley
(16) Water Pump Drive Pulley Bolt
(17) Oil Fill Cap
(18) Left Camshaft Cover
(19) Spark Plug
(20) PCV Feed Tube
(21) Oil Level Indicator
(22) Oil Level Indicator Tube
(23) Oil Gallery Plug
(24) Left Cylinder Head
(25) Left Cylinder Head Gasket
(26) Camshaft Sprocket
(27) Valve Spring
(28) Valve
(29) Intake Manifold
(30) Lift Bracket
(31) Fuel Rail
(32) Fuel Injector Harness
(33) Valve Seats
(34) Right Cylinder Head
(35) Chain Guide Access Plug
(36) Valve Lifter
(37) Valve Seal
(38) Valve Spring Retainer
(39) Valve Locks
(40) Right Exhaust Manifold
(41) Secondary Timing Chain
(42) Camshaft Sprocket
(43) Right Camshaft
(44) Right Camshaft Cover
(45) Ignition Module
(46) PCV Valve
(47) PCV Hose (Partial)
(48) Right Cylinder Head Gasket

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Lower Engine Components

(1) Starter Motor

(2) Cylinder Head Dowel
(3) Piston/Connecting Rod
(4) Cylinder Block
(5) Upper to Lower Crankcase Seal
(6) EGR Valve
(7) EGR Valve Gasket
(8) Engine Mounting Bracket
(9) Throttle Body Coolant Hose Connection
(10) Water Pump Belt Tensioner
(11) Water Pump Belt Bracket
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(12) Water Pump Cover Gasket

(13) Water Pump Cover
(14) Thermostat
(15) Thermostat Housing
(16) Thermostat Housing Gasket
(17) Water Pump
(18) Water Pump Seal
(19) Water Crossover
(20) Flywheel Bolt Washer
(21) Flywheel
(22) Rear Crankshaft Seal
(23) Crankshaft Thrust Bearing
(24) Upper Crankshaft Bearing
(25) Crankshaft
(26) Lower Crankshaft Bearing
(27) Lower Crankcase
(28) Oil Filter Adapter
(29) Oil FIlter Adapter Plug
(30) Crankshaft Oil Scraper
(31) Oil Filter
(32) Oil Pan Gasket
(33) Oil Pump Pick-up Tube
(34) Oil Level Switch
(35) Oil Pan
(36) Main Bearing Stud
(37) Main Bearing Bolt
(38) Oil Manifold Plate
(39) Oil Pump
(40) Crankshaft Sprocket
(41) Intermediate Sprocket Shaft
(42) Cylinder Block Plug
(43) Intermediate Sprocket
(44) Drive Belt Tensioner
(45) Engine Mounting Bracket (N/A Aurora)
(46) Engine Front Cover Gasket
(47) Crankshaft Balancer Bolt
(48) Crankshaft Balancer
(49) Crankshaft Balancer
(50) Intermediate Sprocket Bolt
(51) Primary Timing Chain
(52) Primary Timing Chain Tensioner
(53) Power Steering Pump Pulley
(54) Power Steering Pump
(55) Power Steering Pump Cap
(56) Starter Motor Wire Harness

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Engine Mount Replacement

Removal Procedure

Tools Required

J 28467-A Engine Support Fixture

1. Install the J 28467-A .

2. Install the front core support adapter.
3. Install the engine core support bar.
4. Install the engine support fixture adapter.

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5. Remove the mount to body through bolt.

6. Remove the torque axis mount from the engine mount bracket.
7. Raise the vehicle. Refer to SECTION 0A.
8. Remove the right front wheel/tire assembly.
9. Remove the splash shield from the wheel well.
10. Remove the lower center air deflector.
11. Remove the left transaxle mount to frame through bolt.
12. Remove the lower retaining bolt and nut from the engine mount bracket.
13. Disconnect the power steering line retainer from the bracket.
14. Lower the vehicle.
15. Remove the upper retaining bolt and nut from the engine mount bracket.
16. Release the accessory drive belt tensioner.
17. Remove the belt from the pump.

18. Remove the intake sight shield.

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19. Remove the steering pump. Set the pump aside.

20. Raise the engine at the support fixture.
21. Remove the engine mount bracket from the engine.
22. Remove the torque axis mount from the body.

Installation Procedure

Tools Required

J 28467-A Engine Support Fixture

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1. Install the torque axis mount into the body.

2. Install the engine mount bracket to the engine.
3. Install the engine mount bracket to engine nuts and bolts.

Tighten
• Tighten the mount bracket to engine nuts to 40 N·m (30 lb ft).
• Tighten the mount bracket to engine bolts. to 55 N·m (41 lb ft).

4. Lower the engine at the support fixture.

5. Install the power steering pump.

6. Raise the vehicle.
7. Install the left transaxle mount to frame through bolt.
8. Install the lower center air deflector.
9. Install the splash shield to the wheel well.
10. Install the wheel/tire assembly.
11. Lower the vehicle.
12. Install the torque axis mount to the engine mount bracket.
13. Install the torque axis mount to the engine mount bracket bolt.

Tighten
Tighten the mount to engine bracket bolt to 95 N·m (70 lb ft).

14. Install the mount to body through bolt.

Tighten

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Tighten the mount to body through bolt to 50 N·m (37 lb ft).

15. Remove the J 28467-A .

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Drive Belt Replacement

Removal Procedure

1. Release the belt tensioner (6).

2. Remove the belt from the power steering (1) and generator (2) pulleys.
3. Twist the belt for clearance from the tensioner and the front cover. Also twist the belt in
order to clear the power steering pulley (1) and engine mount bracket.
4. Raise the vehicle. Refer to SECTION 0A.
5. Remove the right side splash shield. Turn the wheel to the extreme right.
6. Remove the belt from the crankshaft (5) and air conditioning compressor (4) pulleys.
7. Twist the belt for clearance between the idler pulley and the engine mount bracket.
8. Remove the belt.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

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1. Place the belt around the power steering pulley (1). Twist the belt in order to clear the front
cover bolts. Let the belt hang from the power steering pulley.
2. Twist the belt in order to clear the tensioner and front cover.
3. Wrap the belt around the generator pulley (2).
4. Remove the belt from the power steering pulley in order to give you slack in the belt.
5. Raise the vehicle.
6. Wrap the belt around the crankshaft (5) and compressor (4) pulleys.
7. Install the right side splash shield.
8. Lower the vehicle.
9. Position the belt around the power steering pulley.
10. Release the tensioner (6).

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Oil Filter Adapter Replacement

Removal Procedure

1. Raise the vehicle.

2. Lower the center air deflector.
3. Disconnect the electrical connector from the oil pressure switch.

4. Remove the oil filter.

5. Disconnect the oil cooler and lines at the adapter.

6. Remove the oil filter adapter retaining bolts.

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7. Remove the oil filter adapter.

8. Remove the oil pressure switch.

Installation Procedure

1. Position the oil filter adapter on the crankcase.

2. Install the oil filter adapter retaining bolts.

Tighten
Tighten the oil filter adapter retaining bolts to 16 N·m (12 lb ft).

3. Install the oil filter pressure sensor.

Tighten
Tighten the oil pressure sensor to 16 N·m (12 lb ft).

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4. Fill the oil filter with oil.

5. Install the oil filter.

Tighten
Tighten the oil filter to 32 N·m (24 lb ft).

6. Install the oil cooler lines using new O-rings.

Tighten
Tighten the oil cooler lines to 18 N·m (12 lb ft).

7. Connect the electrical connector onto the oil pressure switch.

8. Lower the center air deflector.
9. Lower the vehicle.
10. Adjust the oil level to the MAX mark.

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Intake Manifold Replacement

Removal Procedure

Tools Required

J 37088-A Fuel Line Quick Connect Separator Tool Set

1. Disconnect the negative battery cable. Refer to

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or
equipment come in contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle or its components.

in General Information.
2. Remove the four intake manifold sight shield nuts.
3. Remove the intake manifold sight shield.
4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.
5. Remove the air intake duct from the throttle body.
6. Remove the transaxle vent hose and the transaxle shift cable at the bracket.
7. Remove the TP sensor and the IAC valve connectors.
8. Disconnect the accelerator cable and the cruise control cable at the throttle body.
9. Disconnect the front bank spark plug wires and lay aside.

© 2010 General Motors Corporation. All rights reserved.

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10. Disconnect the throttle body coolant hoses at the throttle body and surge tank pipe.

11. Disconnect the EGR pipe and crankcase ventilation pipe at the throttle body spacer.
12. Disconnect the brake booster vacuum hose at the intake manifold vacuum fitting.
13. Disconnect the fuel rail ground wire at the rear cylinder head.
14. Remove the quick-connect fittings at the fuel rail using the following procedure:
14.1. Grasp both sides of the fitting.
14.2. Twist the female connector 1/4 turn in each direction in order to loosen any dirt
within the fitting.

Caution: Wear safety glasses when using compressed air in order to prevent eye
injury.

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14.3. Using compressed air, blow the dirt out of the fitting.
14.4. Choose the correct tool from the J 37088-A for the size of the fitting.
14.5. Insert the tool into the female connector, then push/pull inward to release the locking
tabs.
14.6. Pull the connection apart.
14.7. Using a clean shop towel, wipe off the male pipe end.
14.8. Inspect both ends of the fitting for dirt and burrs.
14.9. Clean or replace the components as required.
15. Disconnect the fuel rail bracket at the EGR valve.
16. Disconnect the PCV hose at the intake manifold.
17. Disconnect the injector harness main connector.

18. Remove the six intake manifold bolts and the four intake manifold studs.
19. Remove the intake manifold.
20. Inspect the intake manifold carrier gaskets. The carrier gaskets are attached to the intake
manifold through a snap-lock feature. When removing the intake manifold, the carrier
gaskets will remain attached to the manifold.

Installation Procedure

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1. Install the intake manifold.

2. Install the six intake manifold bolts.
3. Install the four intake manifold studs.

Important: Only tighten the intake manifold bolts when the engine and manifold are cool.
Do not tighten the intake manifold bolts and studs with the engine at operating temperature.

When tightening the intake manifold bolts and studs, start at the center of the manifold and
work your way outward in a circular pattern.

Tighten
Tighten the bolts and studs to 10 N·m (89 lb in).

4. Install the injector harness main connector.

5. Install the PCV hose at the intake manifold.
6. Connect the fuel rail bracket at the EGR valve.
7. Connect the quick connect fittings to the fuel rail using the following procedure:
7.1. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and
outlet tubes.
7.2. Push both sides of the fitting together in order to cause the retaining tabs to snap into
place.
7.3. Once installed, pull on both sides of the fitting in order to make sure the connection is
secure.
8. Connect the fuel rail ground wire at the rear cylinder head.
9. Connect the brake booster vacuum hose at the intake manifold vacuum fitting.

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10. Install the EGR pipe and crankcase ventilation pipe at the throttle body spacer.

Tighten
Tighten the EGR pipe bolt to 28 N·m (21 lb ft).

11. Connect the throttle body coolant hoses at the throttle body and surge tank pipe.
12. Connect the front bank spark plug wires.
13. Connect the accelerator cable and cruise control cable at the throttle body.
14. Install the TP sensor and the IAC valve connectors.
15. Install the transaxle vent hose and transaxle shift cable at the bracket. Install the air intake
duct.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. Turn the ignition switch to the ON position for two seconds, then turn the OFF position for ten
seconds.
19. Again turn to the ON position. Check for fuel leaks.

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20. Install the intake manifold sight shield.

21. Install the four intake manifold sight shield nuts.

Tighten
Tighten the nuts to 3 N·m (27 lb in).

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Exhaust Manifold Replacement (Left)

Removal Procedure

1. Disconnect the negative battery cable. Refer to

in General Information.

2. Remove the accessory drive belt from the power steering and generator pulleys. Set the belt
aside.
3. Remove the upper retaining bolt from the generator. Refer to Generator Replacement in
Engine Electrical.
4. Raise the vehicle. Refer to SECTION 0A.
5. Remove the splash shield from the right wheel well.
6. Remove the lower center air deflector.
7. Remove the generator rear bracket.
8. Remove the lower retaining bolt from the generator.
9. Set the generator aside.

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10. Remove the left exhaust manifold (5) to exhaust crossover pipe (4) bolts.
11. Remove the electrical connectors at the oxygen sensors.
12. Remove the power steering line retainers.

13. Remove the left exhaust manifold nuts.

14. Remove the left exhaust manifold.
15. Remove the left exhaust manifold gasket. Discard the gasket if damaged.
16. Remove the oxygen sensor from the manifold.

Installation Procedure

1. Coat the threads of the oxygen sensors with high temperature anti-seize, P/N 5613695, or
equivalent.
2. Install the oxygen sensor.

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Tighten
Tighten the oxygen sensors to 40 N·m (30 lb ft).

3. Install the gasket to the manifold. Hold the gasket in position by installing 2 nuts.
4. Install the exhaust manifold by inserting the outlet pipe partially into the exhaust crossover
pipe. Move the exhaust manifold into position.
5. Install the exhaust manifold nuts.

Tighten
Tighten the nuts to 24 N·m (18 lb ft).

6. Install the electrical connector to the oxygen sensors.

7. Install the power steering line retainers.
8. Install the lower retaining bolt to the generator. Refer to Generator Replacement in Engine
Electrical.

Tighten
Tighten the retaining bolt to 50 N·m (37 lb ft).

9. Install the generator rear bracket.

10. Install the generator rear bracket bolt and nut.

Tighten
• Tighten the generator bolt to 47 N·m (35 lb ft).

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• Tighten the generator nut to 38 N·m (28 lb ft).

11. Install the bolts at the manifold outlet flange. New fasteners are recommended for maximum
joint integrity.

Tighten
Tighten the flange bolts to 50 N·m (37 lb ft).

12. Install the lower center air deflector.

13. Install the splash shield to the right wheel well.
14. Lower the vehicle.
15. Install the upper retaining bolt to the generator.

Tighten
Tighten the generator bolt to 50 N·m (37 lb ft).

16. Install the accessory drive belt onto the power steering and generator pulleys.

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Exhaust Manifold Replacement (Right)

Removal Procedure

1. Disconnect the negative battery cable. Refer to

in General Information.
2. Raise the vehicle. Refer to SECTION 0A.
3. Support the catalytic converter.

4. Remove the bolts retaining the exhaust manifold rear pipe (2) to the exhaust manifold (1)
and the crossover exhaust pipe (4).
5. Remove the exhaust manifold rear pipe (2).
6. Remove the exhaust crossover pipe (4).
7. Disconnect the electrical connectors from the oxygen sensors.

© 2010 General Motors Corporation. All rights reserved.

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8. Remove the right exhaust manifold nuts.

9. Remove the right exhaust manifold.
10. Remove the right exhaust manifold gasket. Discard the gasket if damaged.
11. Remove the oxygen sensors.

Installation Procedure

1. Coat the oxygen sensor with high temperature anti-seize, P/N 5613695, or equivalent.
2. Install the oxygen sensor.

Tighten
Tighten the oxygen sensor to 40 N·m (30 lb ft).

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3. Install the right exhaust manifold gasket over the cylinder head studs.
4. Install the right exhaust manifold.
5. Install the right exhaust manifold nuts.

Tighten
Tighten the nuts to 24 N·m (18 lb ft).

6. Connect the electrical connector to the oxygen sensor.

7. Install the exhaust manifold rear pipe (2) to the crossover (4) and exhaust manifold (1).
8. Secure the pipe with two bolts. New bolts are recommended for maximum joint integrity.

Tighten
Tighten the bolts to 40 N·m (30 lb ft).

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9. Connect the exhaust manifold rear pipe (2) to the catalytic converter (3). New bolts and nuts
are recommended for joint integrity.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

10. Remove the support for the catalytic converter.

11. Lower the vehicle.
12. Connect the negative battery cable.

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Camshaft Cover Replacement (Right)

Removal Procedure

1. Disconnect the negative battery cable. Refer to

in General Information.
2. Remove the intake manifold sight shield.
3. Remove the vacuum reservoir.
4. Disconnect the cruise control servo and set aside.
5. Disconnect the ignition system wiring connectors and spark plug wires from the spark plugs.
6. Remove the ignition system retaining bolts.

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7. Remove the ignition system assembly with the spark plug wires attached.
8. Remove the PCV valve.
9. Remove the fuel vapor canister solenoid from the right cover.
10. Raise the vehicle. Refer to SECTION 0A.
11. Remove the electrical connectors from the vehicle speed sensor (VSS).
12. Remove the electrical connectors from the power steering pressure switch (PSP).
13. Lower the vehicle.
14. Remove the wiring harness retainers from the cover.

15. Remove the camshaft cover bolts.

16. Remove the camshaft cover.
17. The camshaft cover seals (perimeter and sparkplug) should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

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Installation Procedure

1. Install new spark plugs if required.

2. Install new camshaft cover seals if required.
3. Place the right camshaft cover in position on the cylinder head by aligning the bolt holes.
4. Install the camshaft cover bolts.

Tighten
Tighten the camshaft cover bolts to 10 N·m (89 lb in).

5. Install the canister purge solenoid.

6. Install the canister purge retaining bolt.

Tighten
Tighten the canister purge retaining bolt to 12 N·m (106 lb in).

7. Install the wiring harness retainers to the camshaft cover.

8. Raise the vehicle. Refer to SECTION 0A.
9. Install the electrical connectors onto the power steering pressure switch (PSP).
10. Install the electrical connectors onto the vehicle speed sensor (VSS).
11. Lower the vehicle.
12. Install the fuel vapor canister solenoid onto the right cam cover.
13. Install the PCV valve.

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14. Install the ignition assembly and spark plug wires onto the right cam cover.

15. Route the spark plug wires exactly as shown. If you do not route the wires as shown, a
misfire or surge condition could occur.
16. Install the ignition system electrical connectors.
17. Install the cruise control servo.
18. Install the vacuum reservoir.

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19. Install the intake manifold sight shield.

20. Connect the negative battery cable.

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Camshaft Cover Replacement (Left)

Removal Procedure

Tools Required

J 38825 Water Pump Drive Pulley Remover

1. Disconnect the negative battery cable. Refer to

in General Information.
2. Remove the intake manifold sight shield.
3. Raise the vehicle.
4. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Engine
Cooling.

© 2010 General Motors Corporation. All rights reserved.

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5. Remove the oil level indicator and tube.

6. Disconnect the upper radiator hose.
7. Disconnect the spark plug wires on the left hand cylinder head.
8. Remove the upper tie-bar assembly.
9. Remove the PCV fresh air tube from the camshaft cover.
10. Remove the air intake hose.

11. Remove the EGR outlet pipe.

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12. Remove the water pump drive belt shield retaining nuts.
13. Remove the water pump drive belt shield.

14. Remove the water pump drive belt by compressing the belt tensioner (1) while sliding the
belt off the drive pulley.

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15. Remove the water pump drive pulley from the intake camshaft. Use the J 38825 .

16. Remove the camshaft seal retaining screws and the seal.

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17. Remove the camshaft cover bolts.

18. Remove the camshaft cover using the following steps:
19. Lift up the front of the cover approximately 10 inches.

20. Lift the rear exhaust edge while holding the front suspended.

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21. Swing the front of the cover over the intake manifold while sliding the entire cover over the
end of the camshaft.
22. The camshaft cover seals (perimeter and sparkplug) should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

Installation Procedure

Tools Required

J 38823 Water Pump Drive Pulley Installer

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1. Install new spark plugs if required.

2. Install a new camshaft cover seal if required.
3. Place the camshaft cover on the cylinder head using the following procedure:
3.1. Insert the intake camshaft end through the hole in the end of the camshaft cover.
3.2. Using your fingers, guide the camshaft cover up over the edge of the cylinder head. Be
careful not to damage the exposed section of the camshaft cover seal on the edge of
the cylinder head.
3.3. Work the camshaft cover into position by pivoting the cover down and to the left
allowing the cover to clear the camshaft drive chain and then aligning the bolt holes.
4. Install the camshaft cover bolts.

Tighten
Tighten the screws to 10 N·m (89 lb in).

5. Lubricate the camshaft seal lips with engine oil.

6. Push the camshaft seal into position around the intake camshaft.

7. Coat the seal retaining screws with sealant, GM P/N 1052080, or equivalent. Install the
screws.

Tighten
Tighten the camshaft cover seal screws to 1.1 N·m (10 lb in).

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8. Install the water pump pulley on the intake camshaft using the J 38823 .

9. Feed the water pump drive belt around the water pump pulley and the water pump drive belt
tensioner.
10. Compress the drive belt tensioner. Feed the drive belt around the camshaft pulley.
11. Check the drive belt for proper seating.

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12. Install the water pump drive belt shield.

13. Install the water pump shield retaining nuts.

Tighten
Tighten the water pump shield retaining nuts to 10 N·m (89 lb in).

14. Install the EGR outlet pipe.

15. Connect the upper radiator hose.
16. Connect the air intake hose.
17. Install the PCV fresh air tube.
18. Connect the spark plug wires.
19. Install the upper tie bar assembly.

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20. Raise the vehicle. Refer to SECTION 0A.

21. Install the oil level tube and indicator.

22. Lower the vehicle.
23. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.

24. Install the intake manifold sight shield.

25. Connect the negative battery cable.

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Oil Level Indicator Tube Replacement

Removal Procedure

1. Raise the vehicle. Refer to SECTION 0A.

2. Lower the center air deflector.

3. Remove the oil level indicator tube retaining bolt.

4. Remove the oil level indicator and tube.

Installation Procedure

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1. Install the oil level tube and indicator.

2. Install the oil level indicator tube retaining bolt.

Tighten
Tighten the oil level indicator tube retaining bolt to 10 N·m (89 lb in).

3. Lower the center air deflector.

4. Lower the vehicle.

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Crankshaft Balancer Replacement

Removal Procedure

Tools Required

• J 28467-A Engine Support Fixture

• J 38416-B Harmonic Balancer Remover
• J 39344 Harmonic Balancer Installer
• J 39411 Flywheel Holder

1. Install the J 28467-A .

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2. Remove the accessory drive belt from the power steering pulley (1).

3. Remove the torque axis engine mount/bracket assembly. Refer to Engine Mount
Replacement .
4. Lower the engine using the support fixture to obtain the clearance for the J 38416-B below
the body rail.
5. Raise and support the vehicle.

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6. Remove the brace between the engine oil pan and transmission case.

7. Secure the flywheel in order to prevent crankshaft rotation. Use the J 39411 .
8. Remove the crankshaft balancer bolt.
9. Place the J 39344 in the end of the crankshaft.

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10. Position the ends of the legs of the J 38416-B onto the backside of the balancer inner hub.
11. Tighten the center screw on the puller until the balancer pulls clear of the crankshaft end.
12. Remove the crankshaft balancer.

Installation Procedure

Tools Required

• J 28467-A Engine Support Fixture

• J 39344 Harmonic Balancer Installer
• J 39411 Flywheel Holder

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1. Position the crankshaft balancer on the nose of the crankshaft.

2. Install the balancer using the J 39344 .
3. Clean the balancer bolt threads.
4. Apply engine oil to the balancer bolt threads.
5. Install the dampener bolt.

Tighten
Tighten the crankshaft balancer bolt to 50 N·m + 120 degrees (37 lb ft + 120 degrees).

6. Use the balancer legs as a reference for the additional 120 degrees of rotation. Make a mark
on the balancer bolt flange in line with the centerline of one balancer spoke. Turn to the next
spoke.
7. Remove the flywheel holder.

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8. Install the oil pan to transaxle brace.

Tighten
Tighten the four oil pan to transaxle brace bolts to 50 N·m (37 lb ft).

9. Install the frame to body bolts.

Tighten
Tighten the frame to body bolts to 192 N·m (142 lb ft).

10. Lower the vehicle.

11. Raise the engine at the J 28467-A .

12. Install the torque axis engine mount/bracket assembly. Refer to Engine Mount Replacement .

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13. Install the accessory drive belt. Refer to Drive Belt Replacement .

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Engine Front Cover Replacement

Removal Procedure

1. Remove the accessory drive belt. Refer to Drive Belt Replacement .

2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

3. Remove the accessory drive belt tensioner (6).

4. Remove the accessory drive belt idler pulley (3).

5. Remove the engine front cover bolts.

6. Remove the engine front cover.
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7. Remove the engine front cover gasket. The gasket is reusable. Do not discard.

Installation Procedure

1. Place a small daub of RTV sealant at the split line of the upper and lower crankcases.
2. Place the front cover gasket over the crankcase dowel pins.
3. Place the front cover in position on the crankcase.
4. Install the front cover retaining bolts.

Tighten
Tighten the front cover retaining bolts to 10 N·m (89 lb in).

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5. Install the accessory drive belt idler pulley.

6. Install the accessory drive belt idler pulley bolt.

Tighten
Tighten the accessory drive belt idler pulley bolt to 50 N·m (37 lb ft).

7. Install the accessory drive belt tensioner.

8. Install the accessory drive belt tensioner bolt.

Tighten
Tighten the accessory drive belt tensioner bolt to 50 N·m (37 lb ft).

9. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

10. Install the accessory drive belt. Refer to Drive Belt Replacement .

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Front Crankshaft Oil Seal Replacement

Removal Procedure

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

2. Using a screw driver or prybar behind the front crankshaft seal, pry out the seal. Use caution
to prevent gouging the front cover bore for seal or crankshaft.

Installation Procedure

Tools Required

• J 38818 Cover Seal Installer

• J 39344 Harmonic Dampener Installer

1. Lubricate the front crankshaft oil seal lips with clean engine oil.
2. Position the seal to the front cover with the garter spring side toward the engine.

© 2010 General Motors Corporation. All rights reserved.

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3. Using the J 38818 and the J 39344 push the seal into the front cover until the tool bottoms
on the cover.
4. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

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Secondary Camshaft Drive Chain Replacement

Removal Procedure

1. Remove the front cover. Refer to Engine Front Cover Replacement .

2. Remove the required camshaft covers. Refer to Camshaft Cover Replacement (Left) and
Camshaft Cover Replacement (Right) .
3. Loosen both of the drive chain tensioner bolts.
4. Remove the tensioner bolts and the tensioner allowing the tensioner to expand as you
remove it.

5. Remove the chain guide access plugs located in the cylinder heads. Note the O-ring seal on
each access plug.
6. Remove the camshaft position sensor.

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7. Remove the secondary chain guide retaining bolts.

8. Remove the secondary chain guides.

9. Remove the camshaft sprocket retaining bolts.

10. Slide the camshaft sprockets off of the camshafts.

11. Remove the camshaft sprockets and the secondary drive chain together. Leave the
intermediate sprocket in place.

Installation Procedure

1. Retime the camshafts. Refer to Setting Camshaft Timing .

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2. Install the engine front cover. Refer to Engine Front Cover Replacement .

3. Install the accessory drive belt idler pulley (3).

4. Install the accessory drive belt idler pulley retainer bolt.

Tighten
Tighten the accessory drive belt idler pulley retainer bolt to 50 N·m (37 lb ft).

5. Install the accessory drive belt tensioner (6).

6. Install the accessory drive belt tensioner bolt.

Tighten
Tighten the accessory drive belt tensioner bolt to 50 N·m (37 lb ft).

7. Install the accessory drive belt. Refer to Drive Belt Replacement .

8. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .

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Oil Pump Replacement

Removal Procedure

1. Remove the engine front cover. Refer to Engine Front Cover Replacement .

2. Remove the oil pump assembly retaining bolts identified by the larger head size.
3. Remove the oil pump assembly with the drive collar in place.
4. Inspect the oil pump. Refer to Oil Pump Inspection .

Installation Procedure

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1. Install the oil pump drive spacer into the oil pump so that the drive flat engages the pump
rotor.
2. Position the oil pump on the crankshaft.
3. Install the retaining bolts.
4. Apply upward pressure on the pump while tightening the three retaining bolts. Tighten the
bolts in a counter clockwise pattern starting with the lower left bolt when facing the pump.

Tighten
1. Tighten the oil pump mounting bolts in sequence to 10 N·m (89 lb in).
2. Tighten the oil pump mounting bolts in sequence to 26 N·m (19 lb ft).

5. Install the engine front cover. Refer to Engine Front Cover Replacement .

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Oil Pump Pick-Up Replacement

Removal Procedure

1. Remove the transmission assembly. Refer to Transmission Replacement in Automatic

Transmission.

2. Remove the exhaust crossover pipe retaining bolts from the left exhaust manifold (5) flange
and the exhaust manifold rear pipe (2).
3. Remove the exhaust cross over pipe (4).
4. Remove the engine oil pan. Refer to Oil Pan Replacement .

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5. Remove the support nut and mounting bolt.

6. Remove the oil pump pickup pipe.

Installation Procedure

1. Lubricate the pickup seal, located in the oil manifold, with engine oil.
2. Position the oil pump pickup pipe to the lower crankcase.
3. Install the mounting bolt and support nut.

Tighten
• Tighten the mounting bolt to 10 N·m (89 lb in).
• Tighten the support nut to 25 N·m (18 lb ft).

4. Install the oil pan. Refer to Oil Pan Replacement .

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5. Install the exhaust crossover pipe (4).

6. Install the exhaust crossover retaining bolts into the left exhaust manifold (5) flange and the
exhaust manifold rear pipe (2).

Tighten
Tighten the exhaust crossover retaining bolts to 30 N·m (22 lb ft).

7. Install the transmission assembly. Refer to Transmission Replacement in Automatic

Transmission.

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Camshaft Drive Chain Tensioner Replacement

Removal Procedure

Tools Required

• J 39411 Flywheel Holder

• J 39946 Crankshaft Rotation Socket

1. Remove the engine front cover. Refer to Engine Front Cover Replacement .

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2. Remove the transmission-to-oil pan brace.

3. Install the J 39411 in order to lock the flywheel.

4. Remove the two tensioner mounting bolts.

5. Remove the primary drive chain tensioner.

Installation Procedure

Tools Required

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• J 39411 Flywheel Holder

• J 39946 Crankshaft Rotation Socket

1. Collapse the tensioner using the following procedure:

1.1. Rotate the ratchet release lever counterclockwise and hold.
1.2. Collapse the tensioner shoe and hold.
1.3. Release the ratchet lever.
1.4. Slowly release pressure on the shoe.

2. As the ratchet lever moves to the first click, hold the tensioner shoe inward. Insert a pin

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through the hole in the release lever.

3. The locked ratchet mechanism should hold the shoe in a collapsed position.

Important: Be sure the tensioner release lever is facing toward you when the tensioner is
installed.

4. Install the tensioner.

5. Install the tensioner bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

6. Remove the retaining pin. Allow the tensioner shoe to extend.

7. Remove the J 39411 .

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8. Install the transmission-to-oil pan brace.

9. Install the transmission-to-oil pan brace bolts.

Tighten
Tighten the transmission-to-oil pan brace bolts to 50 N·m (37 lb ft).

10. Install the front cover. Refer to Engine Front Cover Replacement .

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Primary Camshaft Drive Chain Replacement

Removal Procedure

1. Remove the engine front cover. Refer to Engine Front Cover Replacement .
2. Remove the oil pump. Refer to Oil Pump Replacement .
3. Remove the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .

4. Remove the three timing chain tensioners.

5. Remove the camshaft sprocket bolts from all four camshafts.

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6. Remove the camshaft sprockets.

7. Remove the secondary drive chains from around the intermediate shaft sprocket.
8. Remove the one bolt from the intermediate shaft sprocket.

9. Slide the gears and primary drive chain off the crankshaft and intermediate shaft.
10. Do not remove the intermediate shaft unless wear is evident.

Installation Procedure

1. Retime the camshafts. Refer to Setting Camshaft Timing .

2. Install the oil pump. Refer to Oil Pump Replacement .
3. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .
4. Install the engine front cover. Refer to Engine Front Cover Replacement .

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5. Install the idler puller and the belt tensioner.

6. Install the accessory drive belt. Refer to Drive Belt Replacement .

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Setting Camshaft Timing

Tools Required

• J 39946 Crankshaft Rotation Socket

• J 39411 Flywheel Holder

Setting the camshaft timing is necessary whenever the camshaft drive system has been disturbed
such that the relationship between any chain and sprocket has been lost. Even when only one
sprocket is involved the following procedure should be observed since one crankshaft rotation will
not provide conditions where correct timing can be confirmed.

The camshafts and crankshaft events are correctly timed when the relationships shown exist. The
following procedure explains how to establish this condition. Correct timing exists when the crank
sprocket and the intermediate shaft sprocket have their timing marks aligned and all four camshaft
drive pins are perpendicular (90 degrees) to the cylinder head surface.

1. Remove the following components for access:

• The left camshaft cover. Refer toCamshaft Cover Replacement (Left) .
• The right camshaft cover. Refer toCamshaft Cover Replacement (Right) .
• The front cover. Refer toEngine Front Cover Replacement .
• The three chain tensioners (the tensioners may be in their installed positions but must be
fully retracted).
• The oil pump. Refer toOil Pump Replacement .

2. The primary and secondary chain guides should be reinstalled if previously removed.
3. Rotate the crankshaft until the sprocket drive key is at approximately the 1 o'clock position.
UseJ 39946 to rotate the crankshaft.
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4. Install the crankshaft and the intermediate shaft sprockets to the primary drive chain with
their timing marks adjacent to each other.
5. Install the crank and intermediate sprockets over their respective shafts.
6. Rotate the crankshaft as necessary to engage the crankshaft key in the sprocket without
changing the relationship of the timing marks to each other. UseJ 39946 to rotate the
crankshaft.

7. Install the intermediate sprocket retainer bolt.

Tighten
Tighten the bolt to 60 N·m (44 lb ft).

8. Install the primary chain tensioner or release the tensioner shoe.

Tighten
Tighten the tensioner mounting bolts to 25 N·m (18 lb ft).

9. Install flywheel holderJ 39411 to lock crankshaft in this position. If the engine is on a stand,
an alternate method should be devised.
10. Route the secondary drive chain for the LH cylinder head over the inner row of intermediate
shaft teeth.

Important: The RE camshaft sprocket must contain the camshaft position sensor pick-up.

11. Route the secondary drive chain over the chain guide and install the exhaust camshaft
sprocket to the chain such that the camshaft drive pin engages the sprocket notch marked LE
(left head exhaust). There should be no slack in the lower section of the chain and the
camshaft drive pin must be perpendicular to the cylinder head face.

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12. Install the intake camshaft sprocket into the chain so that the sprocket notch marked LI (left
head intake) engages the camshaft drive pin while the pin remains perpendicular to the
cylinder head face. A hex is cast into the camshafts behind the lobes for cylinder -1 (or -2,
LH) so that an open end wrench may be used to provide minor repositioning of the
camshafts.
13. Loosely install the exhaust camshaft sprocket retainer bolt.
14. Loosely install the intake camshaft sprocket retainer bolt.
15. Install the chain tensioner or release the tension on the shoe.

Tighten
• Tighten the tensioner mounting bolts to 25 N·m (18 lb ft).
• Tighten the camshaft sprocket bolts to 120 N·m (90 lb ft).

Important: The RE camshaft sprocket must contain the camshaft position sensor pick-up.

16. Route the secondary drive chain for right side cylinder head over outer row of intermediate
shaft teeth and repeat steps 11 through 15 for right side camshafts. Right side camshaft
sprockets are identified as RI (right intake) and RE (right exhaust). In addition the RE
sprocket must contain the camshaft position sensor pickup.

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Camshaft Replacement
Removal Procedure

Tools Required

J 38822 Cam Chain Tension Holder

Important: Do not mix the camshaft bearing caps between positions or between heads.
Each cap must be reassembled in the position from which it was removed and in the original
orientation (arrow pointing toward the front of the engine).

1. Remove the camshaft cover. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .

2. Set the engine at base timing (top dead center number one piston).
3. Align the timing marks to the correct position. Refer to Setting Camshaft Timing for the
correct timing mark alignment.

Important: The sprocket-to-chain relationship must be maintained throughout this

procedure or the camshaft timing will be lost and require further engine disassembly for
retiming.

4. Secure the camshaft sprocket to the secondary timing chain using tie-straps through the
camshaft sprocket holes. Use two tie-straps per sprocket.

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5. Working behind the sprockets, install the J 38822 between the chain tensioner and the chain
guide. Apply tension by tightening the tool adjusting screw.

Important: When using J 38822 on the right hand cylinder bank, remove the wiper motor in
order to gain access for the tool usage.

6. Remove the camshaft sprocket bolts. Note the relative location of the camshaft drive pins in
the ends of the camshafts.
7. Work the sprockets off of the camshafts using the play in the chain.
8. Alternately loosen the camshaft bearing cap screws a few turns at a time until all valve spring
pressure has been released.
9. Remove the camshaft bearing cap bolts and caps.

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10. Remove the camshaft.

11. Inspect and measure the camshaft lobes and valve lifters. Measurement can be performed
with the camshaft still in the engine. Refer to Camshaft Inspection and Measurement .
12. Replace the camshaft if any of the following conditions exist:
• Excessive lifter wear
• Excessive scoring on the lifters and/or camshaft
• Excessive flaking on the lifters and/or camshaft
• Scored or burned bearing journals

Installation Procedure

Tools Required

J 38822 Camshaft Chain Tension Holder

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1. Apply GM approved camshaft prelube, P/N 1052365, to the face of each camshaft lobe and
journal.
2. Install the camshaft.

3. Position the camshaft bearing caps to the cylinder head.

• Each cap is identified for position and direction.
• The arrow should point toward the front of the engine.
• These caps are stamped for identification. The E indicates a cap for the exhaust camshaft.
The I indicates a cap for the intake camshaft. The E1 or I1 is the first cap at the front of
the engine.
4. Loosely install the camshaft bearing cap bolts.
5. Alternately tighten each bearing cap bolt a few turns at a time against the valve spring
pressure until all bolts are snug.

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Tighten
Tighten the bolts to 12 N·m (106 lb in).

6. Slide the camshaft sprockets onto the camshafts. Using the hex cast into the camshaft,
rotate the camshafts until the drive pins are in the correct position to engage the camshaft
sprockets over the camshafts.

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7. Install the camshaft sprocket retaining bolts.

Tighten
Tighten the sprocket bolts to 120 N·m (89 lb ft).

8. Remove the J 38822 .

9. Remove the tie-straps from the camshaft sprockets.
10. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .

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Valve Stem Oil Seal and Valve Spring Replacement

Removal Procedure

Tools Required

• J 38824 Valve Spring Compressor

• J 38821 Valve Spring Compressor Adapter
• J 39313 Spark Plug Port Adapter
• J 38819 Valve Keeper Installer
• J 38820 Valve Stem Seal Remover and Installer
• J 39411 Flywheel Holder

1. Install the J 39411 .

2. Remove the camshaft cover. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .
3. Remove the camshaft. Refer to Camshaft Replacement .
4. Store the valve lifters on their camshaft face so that the residual oil is retained in the lifter.

© 2010 General Motors Corporation. All rights reserved.

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Important: If more than one lifter is removed, retain the valve lifters in order so that they
may be reinstalled in the same bore from which they were removed.

5. Fasten the J 38824 and J 38821 to the cylinder head over the cylinder being worked on.

6. Remove the spark plug from the cylinder being worked on. Install the J 39313 .
7. Attach shop air to the J 39313 .
8. Compress the valve spring.

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9. Remove the valve keepers. Use the magnetic end of the J 38819 .
10. Remove the J 38821 from the J 38824 .
11. Remove the valve spring and retainer.

Important: Do not remove the valve stem seal unless replacement is required.

12. In order to remove the valve stem seal, install the J 38820-2.
13. Use the J 38820 in order to grip the seal/seat assembly. Remove the seal by exerting a
twisting, pulling motion.
14. Discard the seal. Do not reuse the valve stem seal/seat assembly as the sealing lip will be
damaged by the sharp edge of the lock groove in the valve stem during removal.

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Installation Procedure

Tools Required

• J 38824 Valve Spring Compressor

• J 38821 Valve Spring Compressor Adapter
• J 39313 Spark Plug Port Adapter
• J 38819 Valve Keeper Installer
• J 38820 Valve Stem Seal Remover and Installer
• J 39411 Flywheel Holder

1. Lubricate the valve stem and the inner diameter of the new seal/seat assembly.
2. Install the J 38820-2.
3. Using a twisting, pushing motion, install the seal/seat. Use the J 38820 .
4. Position the spring retainer to the valve spring.
5. Install the valve spring and retainer.

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6. Compress the spring using the J 38824 and J 38821 .

7. Position the valve keepers under the fingers of the J 38819 . Place the pilot end of the J
38819 over the valve stem.
8. Compress the tool until the keepers fall off the tool and drop into the retainer groove.

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9. Release the valve spring tension from the J 38824 .

10. Remove the J 38824 , J 38821 , and J 38820-2.

11. Remove the J 39313 .

12. Install the valve lifters into the same bore from which they were removed.
13. Install the camshafts. Refer to Camshaft Replacement .
14. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .
15. Install the spark plug.
16. Remove the J 39411 .

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Cylinder Head Replacement

Removal Procedure

Tools Required

• J 28410 Gasket Remover

• J 45059 Angle Meter

1. Remove the powertrain assembly. Refer to Engine Replacement .

Notice: Align all timing marks before removing the timing chains, especially if you are
removing only one head.

2. Remove the intake manifold. Refer to Intake Manifold Replacement .

3. Remove the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
5. Remove the engine front cover. Refer to Engine Front Cover Replacement .
6. Remove the oil pump. Refer to Oil Pump Replacement .

7. Remove the chain tensioner from the secondary drive chain for the cylinder head being
removed.
8. Remove the camshaft sprockets from the head being removed. The secondary drive chain
should remain in the crankcase.

© 2010 General Motors Corporation. All rights reserved.

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9. Remove the timing chain guides. Access to the retaining screws is through the plugs at the
front of the cylinder head.
10. Remove the water crossover. Refer to Water Crossover Removal .

11. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (Left) and Exhaust
Manifold Replacement (Right) .
12. Remove the cylinder head bolts.

Notice: With the camshafts remaining in the cylinder head, some valves will be open,
therefore, do not place the cylinder head on a flat surface with the valves face down. Valve
damage may occur.

13. Remove the cylinder head.

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Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

Notice: Exercise caution when cleaning aluminum gasket surfaces in order to prevent
damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers such as J
28410. You can also use chemical agents to dissolve gasket materials. Follow the
manufacturer's recommendations.

14. Remove the cylinder head gasket.

15. Clean the gasket surfaces.
16. Clean the combustion chambers.
17. Clean the head bolt holes in the crankcase with compressed air.
18. Clean the head bolt bosses in the cylinder head.

Installation Procedure

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1. Ensure all the cylinder head locating pins are securely mounted in the cylinder block deck
face.
2. Make sure any old thread sealant material is removed from the cylinder head bolts holes in
the cylinder block.

Important: Failure to remove all the old thread sealant material from the cylinder block
could cause false torque readings.

3. Install a new right cylinder head gasket using the deck face locating pins for retention.

4. Install a new left cylinder head gasket using the deck face locating pins for retention.

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5. Align the cylinder head with the deck face locating pins.
6. Place the cylinder head in position on the deck face.

Important: DO NOT reuse the old M11 cylinder head bolts.

7. Install new M11 cylinder head bolts (1) in the cylinder head.
8. Install the M6 cylinder head bolts (2) at the front of the cylinder head.
9. Repeat these procedures for the remaining cylinder head.

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10. Tighten the left cylinder head bolts in the sequence shown.
10.1. First Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts to 30 N·m (22 lb ft ) in the sequence
shown.

10.2. Second Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts an additional 60 degrees in the
sequence shown using the J 45059 .

10.3. Third Pass

Tighten
Repeat the sequence turning each bolt another 60 degrees.

10.4. Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 180 degrees).

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11. Tighten the M6 bolts at the front of the cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).

12. Tighten the right cylinder head bolts in the sequence shown.
12.1. First Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts to 30 N·m (22 lb ft) in the sequence
shown.

12.2. Second Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts an additional 60 degrees in the
sequence shown using the J 45059 .

12.3. Third Pass

Tighten
Repeat the sequence turning each bolt an another 60 degrees.

12.4. Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 180 degrees).

13. Tighten the M6 bolts at the front of the right cylinder head.

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Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).

14. Set the camshaft timing. Refer to Setting Camshaft Timing.

15. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft
Cover Replacement (Right) .
16. Install the oil pump. Refer to Oil Pump Replacement .
17. Install the engine front cover. Refer to Engine Front Cover Replacement .
18. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
19. Install the intake manifold. Refer to Intake Manifold Replacement .
20. Install the water crossover. Refer to Water Crossover Installation .
21. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (Left) and Exhaust
Manifold Replacement (Right) .
22. Install the powertrain assembly. Refer to Engine Replacement .

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Engine Flywheel Replacement

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement in Automatic Transmission.

2. Remove the flywheel bolts.

3. Remove the flywheel.

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

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1. Apply sealant, GM P/N 12346004 or equivalent, to flywheel retaining bolts.

2. Place the flywheel in position on the crankshaft.
3. Slip one bolt into the flywheel washer.
4. Install the washer and bolt in a location at the top of its rotation allowing the flywheel to
hang in position.
5. Install the remaining flywheel bolts.

Tighten
Tighten the flywheel retaining bolts to 15 N·m + 50 degrees (11 lb ft + 50 degrees).

6. Install the transmission. Refer to Transmission Replacement in Automatic Transmission.

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Oil Pan Replacement

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement in Automatic Transmission.

2. Drain the engine oil.

3. Remove the exhaust crossover pipe (4) retaining bolts from the left exhaust manifold (5)
flange and the exhaust manifold rear pipe (2).
4. Remove the exhaust crossover pipe (4).

5. Remove the oil pan bolts.

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6. Remove the oil pan.

7. Remove and discard the gasket from the oil pan groove, if present.

Installation Procedure

1. Reseal the oil pan. Refer to Oil Pan Installation.

2. Install the exhaust crossover pipe (4).

3. Install the exhaust crossover retaining bolts into the left exhaust manifold (5) flange and the
exhaust manifold rear pipe (5).

Tighten
Tighten the exhaust crossover retaining bolts to 30 N·m (22 lb ft).

4. Install the transmission assembly. Refer to Transmission Replacement in Automatic

Transmission.
5. Refill the engine oil. Oil capacity is 6.65 liters (7 quarts) without a filter change and 7.1 liters
(7.5 quarts) with an oil filter change.

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Crankshaft Rear Oil Seal Replacement

Removal Procedure

1. Remove the transmission. Refer to Transmission Replacement in Automatic Transmission.

2. Remove the flywheel. Refer to Engine Flywheel Replacement .

3. Remove the rear crankshaft oil seal using the following procedure:
3.1. Drill a 1/8 inch hole in the metal body of the seal.
3.2. Use a slide hammer to remove the seal.
4. Seal removal with a flat blade screwdriver between the seal lip and the crankshaft is also
possible but extreme care is required in order to avoid damage to the crankshaft sealing
surface.

Installation Procedure

Tools Required

J 38817-A Rear Main Seal Installer

© 2010 General Motors Corporation. All rights reserved.

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1. Place a small amount of GM Gasket Maker, GM P/N 1052942 or equivalent, at the crankcase
split line across the end of the upper/lower crankcase seal.
2. Lubricate the rear main seal sealing lips with clean engine oil.

3. Slide the seal over the arbor of the J 38817-A . The garter spring should face the engine.
4. Thread the J 38817-A into the crankshaft flange.
5. Install the seal by turning the handle until the tool bottoms against the crankcase.
6. When properly installed, the outer surface of the seal should be 0.5 mm below the surface of
the engine block.
7. Install the flywheel. Refer to Engine Flywheel Replacement .
8. Install the transmission. Refer to Transmission Replacement in Automatic Transmission.

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Engine Replacement
Removal Procedure

Tools Required

• J 37088-A Fuel Line Quick Connect Separator

• J 28467-A Engine Support Fixture
• J 39580 Engine Support Table

1. Disconnect the negative battery cable. Refer to

in General Information.

2. Remove the air cleaner intake duct.

3. Drain the cooling system. Refer to Engine Coolant Replacement in Engine Cooling.
4. Drain the oil from the crankcase.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.
6. Recover the air conditioning system. Refer to SECTION 1B.

© 2010 General Motors Corporation. All rights reserved.

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7. Disconnect the fuel feed (1) and return lines (2) using the J 37088-A .
8. Disconnect the vacuum harness at the rear of intake.

9. Disconnect the throttle (1) and cruise control (2) cables at the throttle body.
10. Disconnect the wire harness at the bulk head.
11. Disconnect the coolant hoses from the surge tank.

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12. Disconnect the upper radiator hose from the coolant crossover.

13. Disconnect the lower radiator hose at the thermostat housing.

14. Disconnect the upper transmission cooler hose at the radiator.
15. Disconnect the lower transmission cooler hose at the transmission.

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16. Disconnect the heater hoses from the coolant pipes at the rear of the engine.
17. Disconnect the vacuum hose from the brake booster.
18. Remove the shift control cable retaining bracket from the transmission.
19. Disconnect the shift control cable from the lever on the transmission.
20. Remove the vacuum reservoir.
21. Disconnect the vacuum and electrical connectors at the cruise servo.
22. Install the J 28467-A .
23. Disconnect the positive battery cable at the junction block.

24. Remove the through bolt from the torque axis mount.
25. Remove the front engine mount bolts from the torque axis mount bracket. Set the mount
aside.
26. Disconnect the negative battery cable from the engine block.
27. Raise the vehicle.
28. Remove both front wheels.

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29. Remove the right and left side splash shields.

30. Disconnect the electrical connector from the steering gear.
31. Remove the cotter pin and nut from the right ball joint. Disconnect the ball joint from the
steering knuckle.
32. Disconnect the right hand tie-rod from the knuckle.
33. Remove the right axle shaft from the hub assembly.
34. Remove the pinch bolt from the steering gear intermediate shaft.
35. Remove the cotter pin and nut from the left ball joint. Disconnect the ball joint from the
steering knuckle.
36. Disconnect the left hand tie-rod from the knuckle.
37. Remove the left axle shaft from the hub assembly.
38. Remove the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
39. Disconnect the engine oil cooler hoses at the adapter.

40. Remove the engine to transmission braces at the oil pan.

41. Remove the engine to transmission braces at the right bank toward the front of the engine.
42. Remove the engine to transmission braces at the left bank at both the front and the rear of
the engine.

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43. Remove the flywheel cover.

44. Remove the flywheel to converter bolts

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45. Remove the transmission to engine bolts.

46. Remove the oil filter adapter from the engine block.
47. Remove the air conditioning hose and muffler from the rear of the air conditioning
compressor.
48. Position the J 39580 under the engine.
49. Lower the vehicle.

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50. Remove the left transmission mount.

51. Release the engine support.
52. Remove the bolts from the frame.
53. Raise the vehicle.
54. Remove the engine/transmission/frame assembly from under the vehicle.

Installation Procedure

Tools Required

• J 37088-A Fuel Line Quick Connect Separator

• J 28467-A Engine Support Fixture
• J 39580 Engine Support Table

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1. Install the engine to transmission bolts.

Tighten
Tighten the engine to transmission bolts to 75 N·m (55 lb ft).

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2. Install the flywheel to converter bolts.

Tighten
Tighten the flywheel to converter bolts to 47 N·m (35 lb ft).

3. Install the flywheel cover.

4. Install the engine to transmission brace at the oil pan.

Tighten

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Tighten the bolt to 50 N·m (37 lb ft).

5. Install the engine to transmission brace at the right bank, toward the rear of the engine.

Tighten
Tighten the bolt to 60 N·m (44 lb ft).

6. Install the engine to transmission brace at the left bank, front and rear of the engine.

Tighten
Tighten the bolt to 60 N·m (44 lb ft).

7. Raise the vehicle on a hoist.

8. With the powertrain on a dolly, move the powertrain into the approximate position under the
vehicle.
9. Lower the vehicle onto the powertrain.
10. Align the powertrain frame to the body.
11. Install the mounting bolt.

Tighten
Tighten the bolts to 192 N·m (142 lb ft).

12. Raise the vehicle.

13. Remove the dolly.
14. Install the J 28467-A .

15. Install the left transmission mount.

16. Install the air conditioning and muffler to the rear of the air conditioning compressor.

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17. Install the oil filter adapter to the engine block.

18. Install the oil filter adapter bolts.

Tighten
Tighten the oil filter adapter bolts to 16 N·m (12 lb ft).

19. Connect the engine oil cooler hoses to the adapter.

Tighten
Tighten the oil cooler fittings to 18 N·m (12 lb ft).

20. Install the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
21. Install the left axle shaft to the hub assembly.
22. Install the left tie-rod to the steering knuckle.
23. Install the left ball joint to the steering knuckle.
24. Install the pinch bolt to the steering gear intermediate shaft.
25. Install the right axle shaft to the hub assembly.
26. Install the right tie-rod to the steering knuckle.
27. Install the right ball joint to the steering knuckle.
28. Connect the electrical connector to the steering gear.
29. Install the right and left side splash shields.
30. Install both front wheels.
31. Lower the vehicle.
32. Connect the negative battery cable to the engine block.

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33. Install the front engine mount bolts to the torque axis bracket.
34. Install the through bolt to engine torque axis mount.
35. Connect the positive battery cable to the junction block.
36. Remove the J 28467-A .
37. Connect the vacuum and electrical connectors at the cruise servo.
38. Install the vacuum reservoir.
39. Connect the shift control cable to the transmission shift lever.
40. Install the shift control cable retaining bracket.
41. Connect the vacuum hose to the brake booster.

42. Connect the heater hoses to the coolant pipes at the rear of the engine.
43. Connect the lower transmission cooler hose to the transmission.
44. Connect the upper transmission cooler hose to the radiator.

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45. Connect the lower radiator hose to the thermostat housing.

46. Connect the upper radiator hose to the coolant crossover.

47. Connect the coolant hoses to the surge tank.
48. Connect the engine wire harness to the bulk head.

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49. Connect the throttle (1) and cruise control (2) cables to the throttle body.
50. Connect the vacuum hose to the rear of the intake.

51. Connect the fuel feed (1) and return (2) lines.
52. Refill the oil level.
53. Refill the coolant level. Refer to Engine Coolant Replacement in Engine Cooling.

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54. Install the air cleaner intake duct.

55. Connect the negative battery cable.
56. Recharge the air conditioning. Refer to SECTION 1C.

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Intake Manifold Removal

1. Remove the intake manifold sight shield.

2. Disconnect the PCV valve and both feed tubes from the camshaft covers.

3. Disconnect the EGR and crankcase ventilation pipe at the throttle body spacer.
4. Disconnect the fuel rail ground wire at the rear cylinder head.
5. Disconnect the fuel rail bracket at the EGR valve.

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6. Loosen and remove the intake manifold bolts.

7. Remove the intake manifold assembly.

Important: The intake manifold carrier gaskets are attached to the intake manifold through
a snap-lock feature. When you remove the intake manifold, the carrier gaskets will remain
attached to the manifold. It is not necessary to replace the gaskets unless there is damage to
the seals.

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Drive Belt Removal

1. Insert a 1/2-inch drive ratchet in the drive belt tensioner (6).

2. Rotate the drive belt tensioner clockwise in order to release the belt tension.
3. Remove the drive belt from the power steering pulley (1).
4. Slowly return the drive belt tensioner to its original position.
5. Remove the drive belt from the remaining pulleys (2-5).

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Accessory Removal
Power Steering Pump

1. Remove the power steering pump retaining bolt. The bolt is located perpendicular to the
crankshaft centerline and behind the power steering pulley.
2. Remove the power steering pump.

Generator

1. Remove the generator retaining bolts located at the front and rear of the generator.
2. Remove the generator.

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3. Remove the rear generator mounting bracket retaining bolts.

4. Remove the rear generator mounting bracket.

Air Conditioning Compressor

1. Remove the five air conditioning compressor mounting bolts. Three bolts are located at the
front of the compressor. Two bolts are located at the rear of the compressor.
2. Remove the air conditioning compressor.

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3. Remove the air conditioning compressor mounting bracket bolt.

4. Remove the air conditioning compressor mounting bracket.

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Oil Filter Adapter Removal

1. Remove the generator/air conditioning compressor mounting bracket bolts.

2. Remove the generator/air conditioning compressor mounting bracket.

3. Remove the oil filter.

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4. Remove the oil filter adapter mounting bolts.

5. Remove the oil filter adapter and discard the O-ring seals.
6. Remove the oil pressure switch (if necessary).

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Exhaust Manifold Removal (Left)

1. Remove the oil level indicator.

2. Remove the oil level indicator tube retaining bolt.
3. Remove the oil level indicator tube.

4. Disconnect the left exhaust manifold (3) from the crossover pipe (1).

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5. Remove the exhaust manifold bolts.

6. Remove the exhaust manifold and the gasket. Do not reuse the gasket.
7. Remove the oxygen sensor and inspect the sensor for excessive deposits or damage. Replace
the oxygen sensor if necessary.

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Exhaust Manifold Removal (Right)

1. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage.
Replace the oxygen sensor if necessary.

Important: In some cases, the stud will remain attached to the nut during removal. If this
happens, you must install the nut/stud combination in its ORIGINAL location or an exhaust
leak could occur.

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2. Remove the right exhaust manifold retaining nuts (3).

Important: DO NOT reuse the exhaust manifold gasket.

3. Remove the exhaust manifold and the gasket (1).

4. If equipped, remove the right coolant heater (1) as follows:

4.1. Remove the coolant heater retaining bolt.
4.2. Remove coolant heater from the cylinder block.

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Camshaft Cover Removal (Left)

Tools Required

J 38825 Water Pump Drive Pulley Remover

1. Remove the water pump drive belt shield retaining bolt (2) and nuts (3).
2. Remove the water pump drive belt shield (1).

3. Remove the water pump drive belt (4) by compressing the belt tensioner (3) while sliding the
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belt off the drive pulley (1) and the water pump pulley (2).

4. Remove the water pump drive belt tensioner retaining bolts (2) from the tensioner.
5. Remove the water pump drive belt tensioner (1) from the water crossover.

6. Remove the end cap (3) from the intake camshaft (1).

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7. Remove the water pump drive pulley from the intake camshaft using theJ 38825 .

8. Remove the camshaft seal retaining screws.

9. Slide the seal off the end of the camshaft.

Important: DO NOT reuse the camshaft seal.

10. Loosen the camshaft cover bolts.

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11. Lift up the front of the cover approximately 10 inches.

12. Lift the rear exhaust edge up against the oil level indicator tube while holding the front
suspended.

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13. Swing the front of the cover over the intake manifold while sliding the entire cover over the
end of the camshaft.
14. The camshaft cover seals (perimeter and sparkplug) should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

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Camshaft Cover Removal (Right)

1. Remove the camshaft cover bolts.

2. Lift the camshaft cover from the cylinder head.
3. The camshaft cover seals (perimeter and sparkplug) should be reused unless they are
damaged or if the perimeter seal is pulled from its groove during removal.

© 2010 General Motors Corporation. All rights reserved.

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Crankshaft Balancer Removal

Tools Required

• J 38416-2 Crankshaft Button

• J 41816 Crankshaft Balancer Remover
• J 44214 Flywheel Holder

1. Install the J 44214 to the engine block.

2. Secure the flywheel in order to prevent crankshaft rotation.

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3. Remove the crankshaft balancer bolt.

4. Place the J 38416-2 in the end of the crankshaft.

5. Position the legs of the J 41816 onto the backside of the balancer inner hub.
6. Tighten the center screw on the puller until the balancer pulls clear of the crankshaft end.

7. Remove the crankshaft balancer.

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Ignition Coil Module Removal

1. Disconnect the spark plug wires from the spark plugs.

2. Remove the ignition system module retaining bolts from the right (rear) camshaft cover.
3. Remove the ignition system module from the camshaft cover with the spark plug wires
attached.

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Engine Front Cover Removal

1. Remove the front cover perimeter bolts.

2. Remove the front cover and the gasket. Ensure that you do not damage the sealing surface.

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Crankshaft Front Oil Seal Removal

1. Insert a screwdriver between the engine front cover (1) and the front crankshaft oil seal (2).

Important: Be careful not to gouge the front cover when prying out the seal.

2. Pry out the seal. The seal should remove easily.

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Secondary Camshaft Drive Chain Removal

1. Remove the right secondary drive chain tensioner retaining bolts.

2. Remove the right secondary drive tensioner allowing it to expand as you remove it.

3. Remove the left secondary drive chain tensioner retaining bolts.

4. Remove the left secondary drive tensioner allowing it to expand as you remove it.

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5. Remove the chain guide access plugs (1) located in the cylinder heads. Note the O-ring seal
on each access plug.

6. Remove the camshaft position sensor retaining bolt and sensor (1).

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7. Remove the camshaft sprocket retaining bolts from all four camshafts. Use an open wrench
on the hex cast near the front of each camshaft to prevent engine rotation when loosening
the camshaft sprocket bolts.
8. Lift the secondary chain from the sprocket teeth and slide the camshaft sprockets off of the
camshafts.

9. Remove the upper bolt from the upper secondary chain guide for the right cylinder head.

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10. Remove the upper bolt from the lower secondary chain guide for the left cylinder head.
11. Allow the chain to fall into the front cover area.
12. Remove the secondary drive chain from the cylinder block and store in a clean location.

13. Remove the right secondary chain guide retaining bolts and guide.

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14. Remove the right secondary chain tensioner shoe retaining bolt and shoe.

15. Remove the left secondary chain guide retaining bolts and guide (1).

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16. Remove the left secondary tensioner shoe retaining bolt and shoe (1).

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Oil Pump Removal

1. Remove the oil pump assembly retaining bolts (1, 2, 3) identified by the larger head size.
2. Slide the oil pump assembly off the nose of the crankshaft with the drive collar in place.
3. Wrap the oil pump in a towel for safe, clean storage until inspection or assembly is
necessary.

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Primary Camshaft Intermediate Drive Chain Removal

1. Remove the intermediate sprocket retaining bolt.

2. Remove the primary drive chain tensioner.

3. Remove the primary chain drive sprocket, the primary chain and the intermediate sprocket
as an assembly.

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4. Remove the intermediate sprocket shaft retaining bolts.

5. Remove the intermediate sprocket shaft.
6. Remove the crankshaft drive key. Do not damage the crankshaft.

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Camshaft Removal
1. Remove the camshaft bearing cap bolts.
2. Observe the markings on the bearing caps. Each bearing cap is marked in order to identify its
location. The markings have the following meanings:
• The arrow points toward the front of the engine.
• The I indicates the intake camshaft.
• The E indicates the exhaust camshaft.
• The number indicates the journal position from the front of the engine.
3. Remove the camshaft bearing caps. Store the bearing caps in a clean shop towel.

4. Remove the camshaft. Place the camshaft in a secure location.

5. Cover the camshaft with an oil soaked towel in order to prevent corrosion.
6. Repeat the procedure for each camshaft.

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Valve Lifter Removal

1. Inspect the face of the lifter for excessive wear (1). The lifter face should be highly polished
with no visible grooves.
• A large circular pattern with deep grooves starting at the center and moving outward (1)
indicates the lifter is not wearing correctly. This pattern most likely is caused by
improperly machined or worn camshaft lobes.
• The lifter must be replaced if wear is evident.
2. Using a marker, mark the location of each valve lifter. Use the following coding for marking
the valve lifters:
• Cylinder number
• Follow the cylinder number with I for intake or E for exhaust
• Valve number, 1 or 2, from the front of the engine
• For example, 3E1 would be defined as number three cylinder, first exhaust valve from the
front of the engine.
3. Prepare a clean piece of cardboard to place the lifters on.
4. Remove the lifters and place them on the cardboard.
5. Secure the cardboard and the followers in order to prevent damage or contamination.

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Engine Coolant Thermostat Removal

1. Remove the thermostat housing retaining bolts.

2. Remove the thermostat housing and the thermostat.

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Water Pump Removal

Tools Required

J 38816-1A Water Pump Remover/Installer

1. Remove the water pump housing bolts.

2. Remove the water pump housing and the gasket.
3. Remove the water pump from the water crossover. Use the J 38816-1A . Index the J 38816-
1A into the water pump locking ears and twist in order to unlock the pump from the housing.

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Water Crossover Removal

1. Remove the lift bracket retaining studs (2).

2. Remove the lift bracket (1) from the cylinder head.

3. Remove the coolant temperature sensor from the cylinder head.

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4. Remove the EGR valve bolts.

5. Remove the EGR valve and the gasket.

6. Loosen the water crossover mounting bolts (1-5).

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7. Remove the water crossover and all mounting bolts (1-3).

8. Remove the upper (1) and lower (2) water crossover gaskets. Do not damage the water
crossover gaskets. These gaskets are reusable.

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Valve Removal
Tools Required

• J 8062 Valve Spring Compressor

• J 38821 Valve Spring Compressor Adapter
• J 38819 Valve Keeper Installer
• J 38820 Valve Stem Seal Installer

1. Using an appropriately sized deep socket and a plastic hammer, lightly tap on the valve
spring retainer in order to loosen the valve keepers.

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2. Compress the valve spring with the J 8062 and the J 38821 .

3. Use the magnetic end of the J 38819 in order to remove the valve keepers.

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4. Remove the valve spring compressor and the pilot.

5. Remove the valve spring.

6. Remove the valve seal. Use the J 38820 .

7. Remove the valve.
8. Repeat the procedure for the remaining valves.

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Starter Removal

1. Disconnect the knock sensor wire lead.

2. Remove the knock sensor (1).

3. Remove the two starter motor retaining bolts.

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4. Using two hands, remove the starter motor and the wiring harness by sliding the motor
toward the front of the engine. Leave the wiring harness attached unless replacing the
starter.

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Cylinder Head Removal

1. Remove the coolant temperature sensor. Refer to Engine Coolant Temperature (ECT) Sensor
Replacement in Engine Controls.
2. Remove the three M6 external drive bolts from the front portion of the cylinder head.
3. Remove the ten M11 internal drive cylinder head bolts.

4. Remove the cylinder head. Make sure that no dowel guide pins are stuck in the cylinder
head.

5. Remove the cylinder head gasket. Make sure all of the gasket material is removed.
6. Place the cylinder head on a flat, clean surface with the combustion chambers face-up in
order to prevent damage to General
© 2010 the deck face.
Motors Corporation. All rights reserved.

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7. Remove the oil gallery plugs at the rear of the cylinder head.

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Engine Flywheel Removal

Tools Required

J 44214 Flywheel Holder

1. Rotate the engine so that the main bearing bolts are facing up.
2. Hold the flywheel in order to prevent rotation.
3. Loosen the 8 flywheel mounting bolts.
4. Remove 7 of the eight flywheel mounting bolts leaving one bolt at the top of the crankshaft
rotation.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing
the final bolt.

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6. Remove the J 44214 from the engine block.

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Piston, Piston Pin, and Connecting Rod Disassemble

1. Using a small screwdriver, pry out the piston pin retainers by using the removal access notch
in the side of the piston.

Important: Be careful not to nick or gouge the piston or the retaining ring groove with the
screwdriver if you plan to reuse the piston.

2. Slide the piston pin out of the piston. The piston will disconnect from the connecting rod.

Notice: You must use a piston ring expander to remove and install the piston rings. Only
expand the rings far enough to fit over the piston lands. If the rings are overexpanded, the
top ring will shatter and the others will distort.

3. Remove the piston rings using a piston ring expander. Place each ring in a clean shop towel
for storage.

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Oil Pan Removal

1. Rotate the engine so that the oil pan is facing up.

2. Remove the oil pan bolts.

3. Remove the oil pan from the lower crankcase oil distribution manifold plate.

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4. Remove the oil pump pickup tube retaining nut (2) from the main bearing stud.
5. Remove the retaining bolt (4) from the oil manifold plate.
6. Remove the oil pump pickup tube (1).
7. Remove the oil pump tube O-ring (3).

8. Remove and discard the oil pan gasket.

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9. Remove the oil level sensor (1).

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Lower Crankcase Removal

1. Remove the transaxle brace bolts.

2. Remove the transaxle brace (1).

3. Remove the 2 crankshaft position sensors (1, 2).

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4. Remove the 4 lower crankcase perimeter retaining bolts along the right side of the engine.

5. Remove the 4 lower crankcase perimeter retaining bolts along the left side of the engine.

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6. Remove the main bearing bolts. Note the location of the single stud-end bolt (1) used to
attach the oil pump pickup tube.
7. Remove the oil scraper plate.

8. Remove the oil manifold plate bolts.

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9. Remove the oil manifold plate.

Notice: Use a plastic pry tool when prying case halves apart to prevent damage to the Upper

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and Lower Crankcase surface. Do not continue to push the pry tool in the crankcase as the
Upper and Lower Crankcase halves separate. This may damage the sealing surface.

10. Working on either side of the lower crankcase, separate the crankcase halves by alternately
prying in the grooves provided until the lower crankcase is free of the dowel pins.

11. Remove the lower crankcase.

12. Remove and discard the upper-to-lower crankcase seals.

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Connecting Rod Bearing Removal

1. Prepare a piece of cardboard with marking to identify the upper and lower connecting rod
bearings and their respective cylinders.
2. Remove the connecting rod bearing halves from the connecting rod and the connecting rod
cap.
3. Wipe any excess oil from the bearings.
4. Place the bearings on the prepared piece of cardboard.
5. Loosely reattach each connecting rod cap to the original connecting rod for protection of the
mating surface.

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Connecting Rod, Bearing, and Piston Removal

1. Before removing the connecting rods, check the connecting rod end play using the following
procedure:
1.1. Tap the connecting rod to one end of the crankshaft journal.
1.2. Using feeler gages, measure the clearance between the crankshaft counterweight and
the connecting rod.
1.3. The connecting rod end play should not exceed 0.050 mm (0.020 in).
1.4. If the end play exceeds the specified limits, measure the width of the crankpin end of
the connecting rod.
1.5. The width of the crankpin end of the connecting rod should be 21.745 - 21.805 mm
(0.856 - 0.858 in).
1.6. If the connecting rod width is significantly smaller than specified and severe wear is
present on the side of the connecting rod, replace the connecting rod.
1.7. If the connecting rod width is within specification and excessive scoring is present on
the crankshaft journals, replace the crankshaft.
2. Using a marker, number each piston face. Draw an arrow along the centerline of the piston
pin pointing toward the front of the engine.
3. Mark the cylinder number on the connecting rod and the connecting rod cap with scribe or
marker. The connecting rod caps must remain with the original connecting rod.

Notice: Powdered metal connecting rods have rod bolts which yield when torqued. If the rod
bolts are loosened or removed the rod bolts must be replaced. Rod bolts that are not
replaced will not torque to the correct clamp load and can lead to serious engine damage.

4. Remove the connecting rod bolts. Discard the bolts.

5. Remove the connecting rod cap.
6. Push the connecting rod and the piston assembly down through the top of the cylinder. Do
not scratch the crankshaft
© 2010journal
General or cylinder wall
the Corporation.
Motors whenreserved.
All rights removing the connecting rod and

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the piston assembly.

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Crankshaft Removal

1. Before removing the crankshaft, measure the crankshaft end play. Use the following
procedure:
1.1. Reinstall the lower crankcase.
1.2. Place a dial indicator at the crankshaft nose.
1.3. Gently force the crankshaft to the extreme front and rear positions with a pry tool
while monitoring the movement of the dial indicator.
1.4. The crankshaft end play should not exceed 0.05-0.5 mm (0.002-0.020 in).
1.5. If the specifications are exceeded, replace the thrust bearing.
1.6. If a new thrust bearing does not bring the tolerances within specification, replace the
crankshaft.
1.7. Remove the lower crankcase.
2. Locate or fabricate two v-blocks to support the crankshaft.
3. Using two hands, lift the crankshaft straight up from the engine block.
4. Place the crankshaft on the v-blocks in a secure place.

© 2010 General Motors Corporation. All rights reserved.

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Crankshaft Bearing Removal

1. Prepare a piece of cardboard, or equivalent, numbered one to five for bearing identification.
Main bearing journals are numbered from the front of the engine.
2. Remove the upper main bearing halves from the upper crankcase.
3. Place the upper main bearing halves on the cardboard in the correct positions. Note that the
number three bearing is the thrust bearing.

4. Remove the lower main bearing halves from the lower crankcase.
5. Place the lower main bearing halves in the correct positions on the cardboard.
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Cylinder Bore Inspection, Cylinder Boring, and Honing

1. Clean all gasket surfaces, the oil passages, the coolant passages and the engine block with
solvent.
2. Inspect the cylinder block for cracks in the cylinder walls, the coolant jackets and the
crankshaft bearing webs.
3. If cracks are found, the cylinder block must be replaced.

4. Measure the cylinder bore diameter for wear at 20 mm (0.7874 in), 50 mm (1.9685 in), and
60 mm (2.3622 in) below the deck face.
5. Measure the cylinder bores for out-of-round.
6. Measure the cylinder bores for taper.
7. Compare the results with the engine mechanical specifications. Refer to Engine Mechanical
Specifications .
8. If the cylinders exceed these specifications, replace the cylinder block. There are no
oversized pistons and rings available for service.

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Connecting Rod Inspection and Measurement

1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rods for the following:
• Signs of being twisted, bent, nicked, or cracked
• Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular
direction with a light emery paper. DO NOT scrape the rod or rod cap.
4. Measure the piston pin to connecting rod bore using the following procedure:
4.1. Using an outside micrometer, take two measurements of the piston pin in the area of
the connecting rod contact.
4.2. Using an inside micrometer, measure the connecting rod piston pin bore.
4.3. Subtract the piston pin diameter from the piston pin bore.
4.4. The clearance should not exceed 0.016 mm (0.0006 in).
5. If the clearance is excessive, replace the piston pin.

© 2010 General Motors Corporation. All rights reserved.

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Crankshaft Inspection and Measurement

1. Clean the crankshaft bearings and the crankshaft journals with solvent and compressed air.
2. Inspect each bearing journal and bearing for damage.
3. Inspect the reluctor ring for any damage to the sensor ring teeth.
4. Support the crankshaft on wooden v-blocks at the front (1) and rear (5) journals.

5. Check the crankpins for undersize using an outside micrometer.

6. Check crankshaft journals for out-of-round and taper using the following procedure:
6.1. Using an outside micrometer, measure the journal at the extreme front and rear
locations on the journal. Call these points A and B.
© 2010 General Motors Corporation. All rights reserved.

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6.2. Measure the journal in two new locations exactly 90 degrees from the first points. Call
these points C and D.
6.3. Subtract A from C and B from D. The differences will indicate journal out-of-round.
6.4. The out-of-round should not exceed 0.006 mm (0.0002 in.) maximum.
6.5. If the specifications are exceeded, replace the crankshaft.
7. Measure the crankshaft bearing journals for taper using the following procedure:
7.1. Using an outside micrometer, measure the journal at the extreme front and rear of the
journal parallel to the crankshaft centerline.
7.2. Subtract the smallest from the largest measurement. The result will be the journal
taper.
7.3. If the crankshaft bearing journal taper exceeds 0.004 mm (0.00015 in), replace the
crankshaft.
7.4. If the connecting bearing journal taper exceeds 0.007 mm (0.0003 in), replace the
crankshaft.
8. If the crankshaft journals are damaged or worn beyond dimensions, replace the crankshaft.
No machining of the crankshaft journals is allowed.

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Crankshaft Bearing Inspection and Measurement

1. Inspect the main bearings for fatigue indicated by craters or pockets. Flattened sections on
the bearing halves also indicate fatigue.

2. Inspect the main bearings for excessive scoring or discoloration on both front and back of the
bearing halves.
3. Inspect the main bearings for dirt imbedded into the bedding material.

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4. Inspect the main bearings for improper seating indicated by bright, polished sections.

5. Inspect the main bearings for a lack of oil or improper clearance indicated by the overlay
being wiped out.
6. If any of the above conditions exist, replace the crankshaft bearings.
7. Wipe any oil from the crankshaft journals and the bearing inserts.

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8. Place a length of fresh, room temperature plastic gaging material all the way across all the
main bearing journals.
9. Reinstall the lower crankcase and the oil scraper.
10. After reaching final torque, allow the assembly to sit for two minutes.
11. Remove the main bearing bolts.
12. Remove the lower crankcase.
13. Determine the main bearing clearance by comparing the width of the flattened plastic gaging
material at its widest point with the graduation on the gaging material container.
14. If the bearing clearance is greater than 0.0635 mm (0.0025 in), replace the main bearings.
15. If the new bearings do not reduce the clearance to 0.015-0.055 mm (0.0006-0.002 in) a new
crankshaft will be required. Undersized bearings are not available and no crankshaft grinding
is allowed.
16. If reusing the crankshaft, clean the plastic gaging material from the bearing journals.

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Cylinder Head Inspection and Measurement

1. Inspect the camshaft bearings and the journals for evidence of scoring.
2. If the camshaft bearing journals appear to be scored or damaged, you must replace the
cylinder head. DO NOT machine the camshaft bearing journals.
3. Inspect the valve seats for cracking or pitting.

4. Inspect the cylinder head gasket for signs of coolant leakage.

5. Measure the cylinder head flatness using the following procedure:

5.1. Clean any remaining head gasket material from the cylinder head face.
5.2. Place a straight-edge diagonally across the cylinder head face surface.
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5.3. Measure the clearance between the straight-edge and the cylinder head using a feeler
gage at four points along the straight-edge.
5.4. If warpage is less than 0.05 mm (0.002 in), the cylinder head surface does not require
resurfacing.
5.5. If the warpage is between 0.05 mm and 0.2 mm (0.002 in and 0.008 in), you must
resurface the head. When resurfaced, the dimension between combustion chamber
gauge pad and deck surface must be at least 10.5 mm.

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Connecting Rod Bearing Inspection and Measurement

1. Inspect the connecting rod bearings for excessive wear or damage and discard. Connecting
rod bearings with run time should never be reused.
2. Install new connecting rod bearings. Position the tangs on the bearings in the notches in the
rod and cap or both could be damaged.

3. Measure the bearing clearances using the following procedures:

3.1. With the crankshaft still on the v-blocks, rotate the crankshaft until the bearing journal
to be measured is most accessible.
3.2. Wipe any oil from the crankshaft journal and the bearing insert.
3.3. Place a piece of fresh, room temperature plastic gaging material in the center of the
connecting rod bearing.
3.4. Install the connecting rod on the crankshaft

Tighten
Tighten the connecting rod cap bolts to 25 N·m+ 110° (18 lb ft + 110°).

3.5. Remove the bearing cap and determine the clearance by comparing the width of
gaging material, at its widest point, with the graduations on the plastic gaging material
container. The number within the matching graduation on the envelope indicates the
clearance.
© 2010 General Motors Corporation. All rights reserved.

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4. If the new connecting rod bearings do not reduce clearance to less than 0.076 mm
(0.003 in), replace the crankshaft.
5. If both new bearings and a new crankshaft are installed, the connecting rod bearing
clearance should be from 0.025 mm-0.076 mm (0.001-0.003 in).
6. Repeat the procedure for the remaining connecting rod bearings.

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Piston Inspection and Measurement

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of
the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure oil ring holes and slots are
clean.
3. Inspect the pistons for the following conditions:
• Cracked ring lands, skirts, or pin bosses
• Ring grooves for nicks, burrs that may cause binding
• Warped or worn ring lands
• Piston pin retainer grooves for burrs
• Scuffed or damaged skirts
• Eroded areas at the top of the piston
• Worn piston pin bores or worn piston pins
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure:
5.1. Piston pin bores and pins must be free of varnish or scuffing.
5.2. Use an outside micrometer to measure the piston pin in the piston contact areas.
5.3. Using an inside micrometer, measure the piston pin bore.
5.4. Subtract the measurement of the piston pin bore from the piston pin. The clearance
should not exceed 0.002-0.013 mm (0.0001-0.0005 in).
5.5. If the clearance is excessive, determine which piece is out of specification.

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6. Measure the piston ring end gap using the following procedure:
6.1. Place the piston ring in the area of the bore where the piston ring will travel
(approximately 25 mm or 1 inch down from the deck surface). Be sure the ring is
square with the cylinder bore by positioning the ring with the piston head.
6.2. Measure the end gap of the piston ring with feeler gages. Compare the measurements
with those provided below:
• The top compression ring end gap should be 0.25-0.40 mm (0.010-0.016 in).
• The second compression ring end gap should be 0.35-0.50 mm (0.014-0.020 in).
• The oil ring end gap should be 0.25-0.76 mm (0.010-0.030 in).
6.3. If the clearance exceeds the provided specifications, the piston rings must be replaced.
6.4. Repeat the procedure for all the piston rings.

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7. Measure the piston ring side clearance using the following procedure:
7.1. Roll the piston ring entirely around the piston ring groove. If any binding is caused by
the ring groove, dress the groove with a fine file. If any binding is caused by a
distorted piston ring, replace the ring.
7.2. With the piston ring on the piston, use feeler gages to check clearance at multiple
locations.
7.3. The clearance between the surface of the piston ring and the ring land should be no
greater than 0.095 mm (0.004 in).
7.4. If the clearance is greater than specifications, replace the piston rings.
8. When replacing the piston rings, only install re-ring sets that have a 1.2 mm thick nitrided
steel upper compression ring and multi-piece oil rings. The top compression ring may be
installed with either side up. There is a locating dimple on the 2nd compression ring near the
end for identification of the top side. Install the 2nd compression ring with the dimple facing
up.
9. If the new ring does not reduce the clearance to 0.04 mm (0.002 in.) or less, install a new
piston.

10. Measure piston width using the following procedure:

10.1. Using an outside micrometer, measure the width of the piston 50 mm below the
crown (top) of the piston at the thrust surface which is perpendicular to the centerline
of the piston pin.
10.2. Compare the measurement of the piston to its original cylinder by subtracting the
piston width from the cylinder diameter.
10.3. The proper clearance specification for the piston is 0.020-0.051 mm (0.0007-
0.0020 in).
11. If the clearance obtained through measurement is greater than these specifications and the
cylinder bores are within specification, replace the piston.

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Camshaft Intermediate Drive Shaft Cleaning and

Inspection
Cleaning Procedure

1. Clean the camshaft intermediate drive shaft in solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the camshaft intermediate drive shaft with compressed air.

Inspection Procedure

1. Inspect the camshaft intermediate drive shaft for the following:

• Worn or damaged hub-to-camshaft intermediate drive shaft sprocket bearing surface (1)
• Cracks or damage to the camshaft intermediate drive shaft fastener holes (2)
• Restrictions to the oil passage (3)
• Damaged or stripped thread (4)
2. Repair or replace the camshaft intermediate drive shaft as necessary.

© 2010 General Motors Corporation. All rights reserved.

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Valve Spring Inspection and Measurement

Valve Guide Clearance

1. Check the valve stem to guide clearance using a hole gage and an outside micrometer.
2. Measure the valve guide inside diameter with a hole gage, crossways to the engine, at both
the top and 10 mm (0.39 in) up from the bottom of the guide, measuring gage each time
with micrometer. A standard size valve guide is 5.979 mm (0.235 in).
3. Measure the valve stem diameter with the micrometer and subtract from the greater of two
guide measurements to obtain the maximum clearance.
4. If the clearance is greater than 0.12 mm (0.0005 in) and a new standard diameter valve
stem will not bring the clearance within specifications, the cylinder head must be replaced.
5. Valve guide wear at the bottom 10 mm (0.39 in) of the valve guide is not significant to
normal operation.

Valve and Seat Grinding

1. In order to determine valve stem height, measure the distance from the valve spring seat to
the tip of the valve. The specifications for the valve stem height are as follows:
• Intake valve: 35.30-36.92 mm nominal, 37.17 mm maximum
• Exhaust valve: 33.85-35.38 mm nominal, 35.63 mm maximum
2. If the maximum length specification is exceeded, the valve or the cylinder head must be
replaced.
3. Measure the valve seat width. The specifications for seat width are as follows:
• Intake valve seat width: 0.450-0.850 mm (0.017-0.033 in)
• Exhaust valve seat width: 0.700-1.100 mm (0.027-0.043

4. If the valve seat width is beyond these specifications, you must grind the seats in order to
ensure proper heat dissipation and in order to prevent the build up of carbon on the seats.
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Use the following procedure:

4.1. Grind the valve seats with a 46° grinding stone. Use 20° and 65° grinding stones in
order to narrow the seat.
4.2. Narrow the valve seat width to 0.065 mm (0.025 in) for the intake valve seat and
0.900 mm (0.035 in) for the exhaust valve seat.
4.3. When grinding the valves and seats, grind off as little material as possible.
5. If the valve seat widths are acceptable, check the valve seat roundness.
6. The roundness should be within 0.10 mm (0.004 in) total, as measured with a dial indicator
and a solid, slightly tapered pilot which has a slight bind in the valve guide when installed.
7. If the valve seats exceed the roundness specification, grind the valve seats to within
0.05 mm (0.002 in) indicator reading when new valves are being installed, or if the
roundness, seat width, or full contact of the valves is within specification.
8. Grind the valves at a 45° angle.
9. Install the refaced valve in the cylinder head.

10. Measure the valve margin. The specifications for minimum valve margin are as follows:
• Intake valve margin: 0.127 mm (0.005 in)
• Exhaust valve margin: 0.762 mm (0.030 in)
11. If the valves are below this specification, replace the valves.
12. If you are using refaced valves, lap the valves into the seats with a fine grinding compound.
The refacing and reseating operations should leave the refinished surfaces smooth and true
so that minimal lapping is required. Excessive lapping will groove the valve face and prevent
a good seat when hot.
13. If you are using new valves, do not lap the valves under any condition.

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14. Test the valves for seat concentricity and tight seating using the following procedure:
14.1. Coat the valve face(3) lightly with Prussian blue, or equivalent.
14.2. Turn the valve against the seat(2).
14.3. If the valve face is concentric with the valve stem, a mark will be made all around the
face(3). If the face is not concentric with the stem, a mark will be made on only one
side of the face.
14.4. Coat the valve seat lightly with Prussian blue, or equivalent.
14.5. Rotate the valve against the seat to determine if the valve seat is concentric with the
valve guide and if the valve is seating all the way around.
14.6. Both of these tests are necessary in order to prove that a proper seat is obtained.

Valve Spring Load Measurement

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1. Measure the valve spring tension. Specifications for the valve spring tension are as follows:
• Valve Closed: 205 N (46 lb) @ 30.3 mm (1.19 in)
• Valve Open: 409 N (91 lbs) @ 21.7 mm (0.854 in)
2. If low valve spring load is found, replace the valve springs. DO NOT use shims to increase
spring load. The use of shims will cause the valve spring to bottom out before the camshaft
lobe is at peak lift.

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Oil Pump Inspection

1. Disassemble the oil pump using the following procedure:

1.1. Remove the drive spacer from the oil pump housing.
1.2. Remove the two screws holding the pump housing halves together.
1.3. Remove the inner (drive) and the outer (driven) rotors from the housing. Mark the
mating surfaces. The inner rotor will have a dimple while the outer rotor has a
chamfered edge.
1.4. Remove the oil pressure relief valve and the spring.
1.5. Clean the oil pump components in solvent.
2. Inspect the oil pump components for the following conditions:

Important: The internal parts of the oil pump are not serviced separately. If wear or
damage is noted, replace the entire pump assembly.

• The housing and the cover for cracks, scoring, casting imperfections, and damaged
threads
• The rotor gears for chipping, galling or wear
• Pressure relief valve for embedded particles and/or damage
3. Assemble the oil pump using the following procedure:
3.1. Install the inner and the outer rotors in the pump cover in the same orientation as
removed.
3.2. Install the pressure relief valve seat, spring and pilot in the pump housing.
3.3. Pack the pump housing with white petroleum jelly to ensure pump priming.
3.4. Assemble the housing and cover over the locating dowel.
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3.5. Insert a 3/8 in. (9.5 mm) drill in the pump mounting hole on the opposite side in order
to aid in the alignment of the housing and cover.
3.6. Install the two retaining screws.

Tighten
Tighten the screws to 10 N·m + 35 degrees (89 lb in + 35 degrees).

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Camshaft Inspection and Measurement

Tools Required

J 7872 Magnetic Base Dial Indicator Set

1. Inspect the camshaft journals, lobes and bearings for the following conditions:
• Excessive scoring or pitting
• Discoloration from overheating
• Deformation from excessive wear, especially the camshaft lobes
2. If any of the above conditions exist on the camshaft, replace the camshaft.
3. If any of the above conditions exist on the camshaft bearings, replace the cylinder head.

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4. Measure the camshaft journals for diameter and out-of-round using an outside micrometer.
• If the diameter is smaller than 26.948 mm (1.061 in), replace the camshaft.
• If the out-of-round exceeds 0.022 mm (0.0009 in), replace the camshaft.
5. Install the camshaft bearing cap in the cylinder head without the camshaft.
6. Measure the camshaft bearings using an inside micrometer.
7. Subtract the camshaft journal diameter from the bearing diameter. This will provide the
running clearance.

If the running clearance exceeds 0.041-0.085 mm (0.0016-0.0033 in) and the camshaft
journals are within specification, replace the cylinder head.

8. Measure the camshaft lobes for wear using the following procedure:

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8.1. With the camshaft supported in v-blocks, set up the J 7872 with the indicator tip on the
base circle of the camshaft lobe.
8.2. Rotate the camshaft until the indicator tip is at the highest point on the lobe. This
reading is the lift(1) of the camshaft lobe.
• The specified lift for the intake camshaft is 8.6 mm (0.339 in).
• The specified lift for the exhaust camshaft is 8.6 mm (0.339 in).
9. If the indicated measurement is significantly lower than these specifications, replace the
camshaft or engine performance will be reduced.

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Water Pump Cleaning and Inspection

Notice: Do not immerse the water pump in solvent. The solvent may enter the water pump's
permanently lubricated bearings and cause premature bearing failure.

1. Rotate the water pump shaft. The shaft and the fan hub should turn straight and smoothly. If
the hub wobbles or the shaft is noisy or feels "lumpy" when turned, replace the water pump.
2. Inspect the water crossover for signs of leakage. If coolant leakage is evident, inspect and
replace the O-ring seal in the crossover housing.
3. Examine the water pump shaft on the pulley side of the pump. If coolant leakage is evident,
replace the water pump.

© 2010 General Motors Corporation. All rights reserved.

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Crankshaft Bearing Installation

1. Clean the upper and lower crankcase crank bore with a lint-free cloth.

2. Clean all the oil from the backside of new bearing halves.
3. Install new upper crankshaft bearings into position. The thrust bearing belongs in the number
three journal. Be sure the upper bearing insert contains the oil transfer hole and groove. Roll
the bearing into position so that the lock tang engages the crank slot. The bearing must fit
flush with the upper crankcase.

4. Install new lower crankcase crankshaft bearings into position in the lower crankcase. The
lower crankcase crankshaft bearings are identified by NO grooves or holes. The bearings
must fit flush with the©lower crankcase.
2010 General Motors Corporation. All rights reserved.

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5. Apply a liberal amount of GM crankshaft prelube, GM P/N 1052367, or engine oil, to the
upper and lower bearing surfaces.

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Crankshaft Installation

1. Carefully lower the crankshaft into the upper crankcase.

2. Lubricate the bearing surfaces with GM crankshaft prelube, GM P/N 1052367.
3. Rotate the crankshaft to ensure smooth rotation before piston and connecting rod
installation.

© 2010 General Motors Corporation. All rights reserved.

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Piston and Connecting Rod Installation

Tools Required

• J 29789 Piston Ring Compressor

• J 39946 Crankshaft Rotation Socket

1. Liberally lubricate the cylinder walls, piston rings and piston skirts with engine oil.

2. Select the correctly numbered piston/connecting rod assembly for the cylinder.
3. Coat the crankshaft bearing journal and installed connecting rod bearings with GM crankshaft
prelube, GM P/N 1052367.
4. Compress the piston rings using the J 29789 or equivalent.

Important: Extreme care must be exercised when installing the piston and connecting rod in
order to be sure the rod does not scrape or nick the cylinder bore or the crankshaft surfaces.

© 2010 General Motors Corporation. All rights reserved.

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5. Using both hands, slowly guide the piston and connecting rod assembly into the cylinder from
the top and bottom of the cylinder. DO NOT allow the connecting rod to contact the cylinder
wall.
6. When the piston ring compressor contacts the deck surface, gently tap the piston into the
cylinder using the handle end of a dead-blow hammer. Guide the connecting rod onto the
crankshaft bearing journal while tapping the piston into the cylinder.

7. Install the connecting rod end cap making sure the bearing lock tangs are aligned on the
same side of the rod. When porperly installed, the connecting rod bearing cap notches(2)
should point towards each other.
8. Lubricate the connecting rod cap bolts with engine oil and install in the connecting rod.

Tighten
Tighten the connecting rod bolts to 25 N·m + 110 degrees (18 lb ft + 110 degrees).

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9. Repeat these procedures for the remaining piston/connecting rod assemblies using the J
39946 in order to rotate the crankshaft.

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Connecting Rod Bearing Installation

1. Clean the connecting rod and the connecting rod cap bearing bore with a lint-free cloth.

2. Clean all the oil from behind the connecting rod bearing halves.
3. Install new upper connecting rod bearings into position. Roll the bearing into position so that
the lock tang engages the alignment slot. The bearing must fit flush in the connecting rod.
4. Install new lower connecting rod bearings into position in the connecting rod cap. Roll the
bearing into position so that the lock tang engages the alignment slot. The bearings must fit
flush with the connecting rod cap.

© 2010 General Motors Corporation. All rights reserved.

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Piston, Piston Pin, and Connecting Rod Assemble

Tools Required

J 38637 Piston Pin Retaining Ring Installer

Piston Rings

1. Using a piston ring expander, install the oil control ring assembly using the following
procedure:
1.1. Install the expander ring (1).
1.2. Install the two oil scraper rings (2). Expand the rings only enough to clear the piston
diameter. Overexpanding the piston rings will distort or crack the rings.
2. Install the second (3) and top piston (4) rings using the piston ring expander. Make sure you
do not overexpand the rings.
3. Once the rings are installed, set the ring gaps at least 30 degrees apart from each other.

Piston Installation

© 2010 General Motors Corporation. All rights reserved.

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1. Properly orient the piston on the connecting rod as follows:

• The locating mark (4) cast into the underside of the piston should point towards the front
of the engine.
• The locating notch (3) on the connecting rod cap should be pointing towards the rear of
the engine on odd-numbered cylinders and towards the front of the engine on even-
numbered cylinders.
2. Align the piston pin bore with the connecting rod pin bore.
3. Slide the piston pin into the piston and the connecting rod.
4. Install the piston pin retainers using the J 38637 .
5. Repeat these procedures for the remaining pistons.

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Lower Crankcase Installation

Tools Required

• EN 46109 Guide Pins

• J 39946 Crankshaft Socket - 4.0L and 4.6L
• J 45059 Angle Meter

Important: Ensure components being sealed with RTV are assembled within 20 minutes.
Components assembled after the RTV has skinned-over, approximately 20 minutes, will not
seal properly.

1. Completely fill and slightly overfill the engine block seal groove with a continuous bead of
RTV sealant GM P/N 12378521 or equivalent.
2. Ensure the RTV sealant GM P/N 12378521 or equivalent bead is higher then the rail
surface (1) by 3 mm (0.118 in).

© 2010 General Motors Corporation. All rights reserved.

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3. Using a suitable tool spread the sealant in the area near the oil drain back passages (1) away
from the oil drain back passages toward the outboard edge of the rail surface.

4. To prevent shifting of the lower crankcase install one of the EN 46109 into a bolt hole in each
rail.

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5. Install the cleaned lower crankcase onto the engine.

6. Using a rubber mallet gently tap the lower crankcase into position.
7. Remove both of the EN 46109 .

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8. Loosely install the crankcase perimeter bolts on the right side.

9. Loosely install the crankcase perimeter bolts on the left side.

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10. Using a small long blade screwdriver clean out any sealant in the oil drain back passages (1).

Important: Ensure components being sealed with RTV are assembled within 20 minutes.
Components assembled after the RTV has skinned-over, approximately 20 minutes, will not
seal properly.

11. Using a NEW oil distribution plate place a continuous 3 mm (0.118 in) wide bead of RTV
sealant GM P/N 12378521 or equivalent on top of the outer seal (1) of the oil distribution
plate place.

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12. To prevent shifting of the oil distribution plate install one of the EN 46109 into a bolt hole in
each side of the lower crankcase.

13. Install the NEW oil distribution plate.

14. Remove both of the EN 46109 .

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15. Install the oil distribution plate bolts.

Tighten
Tighten the oil distribution plate bolts to 10 N·m (89 lb in).

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16. Using a small long blade screwdriver clean out any sealant in the oil drain back passages.

17. Install the crankshaft oil scraper plate.

18. Install the main bearing bolts. Ensure the stud-head bolt (1) used for the oil suction tube
support bracket is placed in the proper position.

19. Tighten the main bearing bolts in the proper sequence.

19.1. First Pass

Tighten
Tighten the main bearing bolts (1-20) to 20 N·m (15 lb ft ) in the proper sequence.

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19.2. Final Pass

Tighten
Tighten the main bearing bolts (1-20) an additional 65 degrees in the proper sequence using
the J 45059 .

20. Tighten the crankcase perimeter bolts in sequence shown.

Tighten
Tighten the crankcase perimeter bolts to 30 N·m (22 lb ft).

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21. Using a small long blade screwdriver verify that the threaded holes for the oil pan bolts and
the oil drain back passages are clear of sealant.

22. Lubricate the silicone seal (3) in the oil manifold plate. With a twisting motion, install the end
of the oil pump pick-up tube (1).
23. Install the oil pump pick-up bolt (4) and nut (2).

Tighten
• Tighten the oil pump pick-up tube nut to 24 N·m (18 lb ft).
• Tighten the oil pump pick-up tube bolt to 10 N·m (89 lb in).

24. Install the crankshaft position (CKP) sensors. Ensure the CKP sensor with the darker colored
connector end (1) is installed in the lower crankcase and CKP sensor with the lighter colored
connector end (2) is installed in the block.

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25. Install the CKP sensor bolts.

Tighten
Tighten the CKP sensor bolts to 10 N·m (89 lb in).

26. Using the J 39946 rotate the crankshaft until the number one piston is at top dead center
(TDC) and the crankshaft key way is approximately at the 7 o'clock position.

27. Place the transaxle brace (1) in position on the cylinder block.
28. Install the transaxle brace bolts.

Tighten
Tighten the transaxle brace bolts to 50 N·m (37 lb ft).

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Rear Crankshaft Oil Seal Installation

Tools Required

J 38817-A Rear Main Seal Installer

© 2010 General Motors Corporation. All rights reserved.

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Oil Pan Installation

Tools Required

EN 46109 Guide Pins

1. Install the oil level switch (1).

Tighten
Tighten the oil level switch to 20 N·m (15 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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Important: Ensure components being sealed with room temperature vulcanizing (RTV)
sealant are assembled within 20 minutes. Components assembled after the RTV sealant has
skinned-over, approximately 20 minutes, will not seal properly.

2. Completely fill and slightly overfill the oil pan seal groove with a continuous bead of RTV
sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent.
3. Ensure the RTV sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent bead is
higher than the oil pan sealing surface (1) by 3 mm (0.118 in).

4. To prevent shifting of the oil pan, install one EN 46109 into a bolt hole in each side of the
lower crankcase.

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5. Position the oil pan onto the lower crankcase.

6. Loosely install several of the oil pan bolts.

7. Remove the EN 46109 .
8. Finish loosely installing the remaining oil pan bolts.

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9. Tighten the oil pan bolts in the sequence shown.

Tighten
1. Tighten the oil pan bolts a first pass to 8 N·m (71 lb in) in the sequence shown.
2. Tighten the oil pan bolts a final pass to 12 N·m (106 lb in) in the sequence shown.
10. Clean off any sealant that has protruded to the exterior of the engine.

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Engine Flywheel Installation

Tools Required

• J 36660-A Torque Angle Meter

• J 44214 Flywheel Holder

1. Apply sealant, GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the engine
flywheel retaining bolts.

2. Place the engine flywheel in position on the crankshaft.

3. Slip one bolt into the engine flywheel washer.
4. Install the washer and bolt in a location at the top of its rotation allowing the engine flywheel
to hang in position.

© 2010 General Motors Corporation. All rights reserved.

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5. Install the remaining engine flywheel bolts.

5.1. Install the J 44214 to the engine block.
5.2. First Pass

Tighten
Tighten the engine flywheel retaining bolts to 15 N·m (11 lb ft).

5.3. Final Pass

Tighten
Tighten the engine flywheel retaining bolts an additional 50 degrees using the J 36660-A .

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Valve Installation
Tools Required

• J 38820 Valve Stem Seal Installer

• J 8062 Valve Spring Compressor
• J 38821 Valve Spring Compressor Adapter
• J 38819 Valve Keeper Installer

1. Lubricate the valve stem with clean engine oil.

2. Insert the valve into the valve guide until it bottoms on the valve seat.
3. Lubricate the valve seal with engine oil.
4. Using the J 38820 , install the valve seal using the following procedure:
4.1. Place the valve lifter bore protector into the lifter bore.
4.2. Mount the valve seal in the J 38820 .
4.3. Push and twist the valve seal into position on the valve guide until the seal positively
locks on the guide.
5. Position the valve spring on the spring seat.

© 2010 General Motors Corporation. All rights reserved.

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6. Compress the valve spring using the J 8062 and the J 38821 .

7. With the spring compressed, install the valve keepers into the J 38819 .
8. Place the keepers into position by pushing the tool downward.
9. Release the tension on the spring compressor and remove the J 38821 .
10. Verify that the valve keepers are installed by placing a rag over the valve tip and tapping
with a dead-blow hammer. The valve keepers and the spring should remain in place.
11. Repeat this procedure for the remaining valves.

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Cylinder Head Installation

Tools Required

J 45059 Angle Meter

Important: Failure to remove all the old thread sealant material from the cylinder block
could cause false torque readings.

3. Install a new right cylinder head gasket using the deck face locating pins for retention.

© 2010 General Motors Corporation. All rights reserved.

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4. Install a new left cylinder head gasket using the deck face locating pins for retention.

5. Align the cylinder head with the deck face locating pins.
6. Place the cylinder head in position on the deck face.

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Important: DO NOT reuse the old M11 cylinder head bolts.

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installing fasteners in order to avoid damage to parts and systems.

10. Tighten the left cylinder head bolts in the sequence shown.
10.1. First Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts to 40 N·m (30 lb ft ) in the sequence
shown.

10.2. Second Pass

Tighten
Tighten the left cylinder head M11 cylinder head bolts an additional 70 degrees in the
sequence shown using the J 45059 .

10.3. Third Pass

Tighten
Repeat the sequence turning each bolt another 60 degrees.

10.4. Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).

11. Tighten the M6 bolts at the front of the cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).

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12. Tighten the right cylinder head bolts in the sequence shown.
12.1. First Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts to 40 N·m (30 lb ft) in the sequence
shown.

12.2. Second Pass

Tighten
Tighten the right cylinder head M11 cylinder head bolts an additional 70 degrees in the
sequence shown using the J 45059 .

12.3. Third Pass

Tighten
Repeat the sequence turning each bolt an another 60 degrees.

12.4. Final Pass

Tighten
Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees).

13. Tighten the M6 bolts at the front of the right cylinder head.

Tighten
Tighten the M6 cylinder head bolts to 12 N·m (106 lb in).

14. Install the oil gallery plugs at the front and rear of the cylinder head.

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Tighten
Tighten the oil gallery plugs to 12 N·m (106 lb in).

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Water Crossover Installation

1. With the water crossover on the bench, install all eight crossover retaining bolts.
1.1. The longest bolts belong in the positions (1) and (4).
1.2. The medium length bolts belong in positions (2) and (3).
1.3. The single short bolt belongs in position (5).

2. Slide the upper (1) and lower (2) water crossover gaskets onto the bolts with the crossover
still on the bench. © 2010 General Motors Corporation. All rights reserved.

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3. Place the water crossover in position and hand start the bolts identified (1-3) to hold the
crossover in place.

4. Hand start the remaining bolts.

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Tighten
Tighten all water crossover bolts (1-5) to 25 N·m (18 lb ft).

5. Install a new EGR valve gasket on the EGR valve.

6. Install the EGR valve and the retaining bolts.

Tighten
Tighten the EGR valve bolts to 24 N·m (18 lb ft).

7. Install the coolant temperature sensor in the cylinder head.

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Tighten
Tighten the coolant temperature sensor to 20 N·m (15 lb ft).

8. Place the rear lift bracket (1) in position at the rear of the cylinder head.
9. Install the lift bracket retaining studs (2).

Tighten
Tighten the lift bracket retaining studs to 50 N·m 37 lb ft).

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Water Pump Installation

Tools Required

J 38816-1A Water Pump Remover/Installer

1. Check water pump seal (2) in the water crossover (1) for tears or cuts. Replace the seal if
necessary.
2. Place the water pump (3) in the J 38816-1A by indexing the tool into the water pump locking
ears (4).
3. Install the water pump (3) into the water crossover (1) using the following procedure:
3.1. Index the pump locking ears with the tangs in the water crossover.
3.2. With the locking ears indexed, twist to lock the pump in place. Remove the tool.

© 2010 General Motors Corporation. All rights reserved.

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4. Install the water pump cover and gasket.

5. Install the water pump cover bolts.

Tighten
Tighten the water pump cover bolts to 10 N·m (89 lb in).

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Engine Coolant Thermostat Installation

1. Place the thermostat in the thermostat housing with the spring facing the engine.
2. Place the thermostat housing, gasket and thermostat in position on the water pump cover.
3. Install the thermostat housing bolts.

Tighten
Tighten thermostat housing bolts to 10 N·m (89 lb in).

© 2010 General Motors Corporation. All rights reserved.

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Camshaft Installation
1. Install the valve lifters with the flat surface facing up.

2. Clean the camshaft carriers with a clean, lint-free cloth.

3. Apply a liberal amount of clean engine oil to the carriers.
4. Place the camshaft in the camshaft carriers with the camshaft sprocket drive pins at the top
of their rotation. The camshafts can be identified by a stamping near the rear journal. For
example: L-EXH is defined as Left Bank Exhaust.

5. Install the camshaft bearing caps according to the identification marks. The arrow should
point toward the front of the engine. The number indicates the position from the front of the
engine and the I or E ©indicates intake
2010 General or Corporation.
Motors exhaust camshaft.
All rights reserved.

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6. Hand start all the camshaft bearing cap bolts.

7. Tighten the left cylinder head camshaft bearing caps.

Tighten
Tighten the camshaft bearing cap bolts in sequence shown to 5 N·m + 30 degrees (44 lb in +
30 degrees).

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8. Tighten the right cylinder head camshaft bearing caps.

Tighten
Tighten the camshaft bearing cap bolts in sequence shown to 5 N·m + 30 degrees (44 lb in +
30 degrees).

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Primary Camshaft Intermediate Drive Chain

Installation
Tools Required

J 39946 Crankshaft Rotation Socket

1. Install the intermediate sprocket shaft and the retaining bolts.

Tighten
Tighten the intermediate shaft sprockets bolts to 10 N·m (89 lb in).

2. Install the crankshaft sprocket drive key. If necessary, tap the key in place with a small
hammer until it bottoms on the crankshaft.

© 2010 General Motors Corporation. All rights reserved.

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3. Align the timing marks of the intermediate and crankshaft sprockets. The marks should be
aligned vertically in the installed position.
4. Install the primary timing chain on the drive sprockets.
5. Make sure that piston number one is at top dead center (TDC) and the crankshaft keyway is
approximately at the one o'clock position.
6. Install the primary timing chain, intermediate, sprocket and crankshaft sprocket as an
assembly onto their respective shafts. Use the J 39946 in order to align the crankshaft key
with the drive sprocket.

7. Install the intermediate sprocket retaining bolt.

Tighten
Tighten the intermediate sprocket shaft bolt to 60 N·m (44 lb ft).

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8. Collapse the primary drive chain tensioner using the following procedure:
8.1. Rotate the ratchet release lever counterclockwise and hold.
8.2. Collapse the tensioner shoe and hold.
8.3. Release the ratchet lever and slowly release the pressure on the shoe.

9. As the ratchet lever moves to its first click, hold the tensioner shoe inward. Insert a pin
through the hole in the release lever.
10. The locked ratchet mechanism should hold the shoe in a collapsed position.

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Important: Make sure the tensioner release lever faces toward you before tightening.

11. Install the primary drive chain tensioner and retaining bolts.

Tighten
Tighten the primary drive chain tensioner bolts to 25 N·m (18 lb ft).

12. Remove the retaining pin allowing the tensioner shoe to extend.
13. Check the timing marks to make sure they are aligned vertically.

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Oil Pump Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the oil pump drive spacer into the oil pump so that the drive flat engages the pump
rotor.
2. Position the oil pump on the crankshaft.
3. Install the retaining bolts.

4. Apply upward pressure on the pump while tightening the three retaining bolts. Tighten the
bolts in the sequence (1, 2, 3) shown.
4.1. First Pass

Tighten
Tighten the oil pump mounting bolts in sequence to 10 N·m (89 lb in).

4.2. Final Pass

Tighten © 2010 General Motors Corporation. All rights reserved.

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Tighten the oil pump mounting bolts in sequence an additional 35 degrees using the J 36660-
A.

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Secondary Camshaft Drive Chain Installation

1. Install all eight spark plugs.
2. Lock the flywheel to prevent crankshaft rotation.

3. Install the left timing chain tensioner shoe (1) and retaining bolt.

Tighten
Tighten the left timing chain tensioner shoe bolt to 25 N·m (18 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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4. Install the left timing chain guide (1) and lower retaining bolt.

5. Install the left timing chain by feeding the chain down through the cylinder head and hanging
the chain on the camshafts.
6. Route the left timing chain over the inner row of the intermediate sprocket teeth.
7. Install the left guide upper retaining bolt through the cylinder head access hole.

Tighten
Tighten the left timing chain guide bolts to 25 N·m (18 lb ft).

8. Install the intake and exhaust camshaft sprockets into the chain and onto the camshafts so
that the sprocket notch marked LI (left head intake) engages the intake cam drive pin and
the sprocket notch marked LE (left head exhaust) engages the exhaust cam drive pin.
9. Loosely install the intake and exhaust camshaft sprocket retaining bolts.

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10. Check the sprocket drive pin, it must be perpendicular to the head face.

11. Use the hex cast into the camshafts in front of the first set of lobes to reposition the
camshafts if necessary.

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12. Install the right timing chain guide and lower retaining bolt.

13. Install the right timing chain by feeding the chain down through the cylinder head and
hanging the chain on the camshafts.
14. Route the right timing chain over the outer row of intermediate sprocket teeth.
15. Install the right chain guide upper retaining bolt through the cylinder head access hole.

Tighten
Tighten the right timing chain guide bolts to 25 N·m (18 lb ft).

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16. Install the intake and exhaust camshaft sprockets into the chain and onto the camshafts so
that the sprocket notch marked RI (right head intake) engages the intake cam drive pin and
the sprocket notch marked RE (right head exhaust) engages the exhaust cam drive pin. The
cam drive pin must be perpendicular to the head face. A hex is cast into the camshafts in
front of the lobes for cylinder 1 so that an open end wrench may be used in order to provide
minor repositioning of the cams.
17. Loosely install the intake and exhaust camshaft sprocket retaining bolts.

18. Install the timing chain guide access plugs (1) in the front of the cylinder heads.

Tighten
Tighten the chain guide access plugs to 4.5 N·m (39 lb in).

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19. Collapse the secondary drive chain tensioners using the following procedure:
19.1. Rotate the ratchet release lever counterclockwise and hold.
19.2. Collapse the tensioner shoe and hold.
19.3. Release the ratchet lever. Slowly release the pressure on the shoe.
20. As the ratchet lever moves to its first click, hold the tensioner shoe inward and insert a pin
through the hole in the release lever. The locked ratchet mechanism should hold the shoe in
a collapsed position.

Important: Make sure the tensioner release lever faces toward you before tightening.

21. Install the left timing chain tensioner and retaining bolts.

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Tighten
Tighten the secondary drive chain tensioner bolts to 25 N·m (18 lb ft).

Important: Make sure the tensioner release lever faces toward you before tightening.

22. Install the right timing chain tensioner and retaining bolts.

Tighten
Tighten the secondary drive chain tensioner bolts to 25 N·m (18 lb ft).

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23. Tighten the camshaft sprocket bolts. Use the hex cast into each camshaft to prevent engine
rotation and provide leverage.

Tighten
Tighten the camshaft sprocket bolts to 120 N·m (90 lb ft).

24. Install the camshaft position sensor (1) and retaining bolt.

Tighten
Tighten the camshaft position sensor retaining bolt to 10 N·m (89 lb in).

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25. Check all timing marks to make sure they are in proper position for base engine timing.
26. When proper timing is assured, remove all pins from the timing chain tensioner release
levers allowing the tensioner to expand and remove any slack in the timing chains.
27. Check for proper base engine timing.

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Front Crankshaft Oil Seal Installation

Tools Required

J 38818 Front Cover Seal Installer

1. Support the backside of the front cover around the seal opening with two blocks of wood.
2. Lubricate the seal lips with clean engine oil.
3. Install the new seal using a hammer and the J 38818 . Make sure the tool bottoms on the
cover in order to properly position the seal.

© 2010 General Motors Corporation. All rights reserved.

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4. Check the installed depth (1) of the seal. The inner edge of the seal must be 7.5 mm
(0.30 in.) below the rear face of the front cover around the entire seal.

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Engine Front Cover Installation

Tools Required

J 28410 Gasket Remover (Aluminum Components)

1. Using the J 28410 remove any cured excess RTV sealant at the split line of the upper and
lower crankcase (1).
2. Place a small amount of fresh RTV sealant GM P/N 12378521, (Canadian P/N 88901148), or
equivalent at the split line of the upper and lower crankcases (1).

© 2010 General Motors Corporation. All rights reserved.

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3. Place the engine front cover gasket over the crankcase dowel pins.
4. Place the engine front cover in position on the crankcase.
5. Apply the thread locking compound GM P/N 12345382 (Canadian P/N 10953489) or
equivalent to the threads of the engine front cover bolts.
6. Install the engine front cover bolts.

7. Tighten the engine front cover bolts in the sequence shown.

Tighten
Tighten the engine front cover bolts in the proper sequence to 10 N·m (89 lb in).

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Crankshaft Balancer Installation

Tools Required

• J 41998-B Crankshaft Balancer Installer

• J 36660-A Torque Angle Meter
• J 44214 Flywheel Holder

1. Position the crankshaft balancer on the nose of the crankshaft.

© 2010 General Motors Corporation. All rights reserved.

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2. Press the crankshaft balancer in place using the J 41998-B .

3. Clean the crankshaft balancer bolt threads.

4. Apply engine oil to the crankshaft balancer bolt threads.

5. Install the crankshaft balancer bolt.

5.1. First Pass

Tighten
Tighten the crankshaft balancer bolt to 50 N·m (37 lb ft).

5.2. Final Pass

Tighten
Tighten the crankshaft balancer bolt an additional 120 degrees using the J 36660-A .

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6. Remove the J 44214 from the engine block.

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Camshaft Cover Installation (Left)

Tools Required

J 38823 Water Pump Drive Pulley Installer

1. Place the camshaft cover in position on the cylinder head.

2. Insert the intake camshaft end through the hole in the end of the camshaft cover.
© 2010 General Motors Corporation. All rights reserved.

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3. Using your fingers, guide the camshaft cover up over the edge of the cylinder head. Be
careful not to damage the exposed section of the camshaft cover seal on the edge of the
cylinder head.

4. Work the camshaft cover into position by pivoting the cover down and to the left allowing the
cover to clear the camshaft drive chain and then aligning the bolt holes.

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5. Tighten the camshaft cover bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

6. Install a new camshaft seal as follows:

6.1. Lubricate the lips of the camshaft seal with engine oil.
6.2. Push the camshaft seal into position around the intake camshaft using the protective
sleeve supplied with the seal.
6.3. Coat the seal retaining screws with sealant, GM P/N 1052080 or equivalent. Install the
screws.

Tighten
Tighten the camshaft cover seal screws to 3 N·m (27 lb in).

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7. Place the water pump drive pulley (2) in position on the intake camshaft (1).

8. Install the water pump pulley on the intake camshaft using the J 38823 . During installation,
the tool will bottom out on the camshaft at the proper depth.

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9. Install the camshaft end cap (3) in the camshaft (1).

10. Place the water pump drive belt tensioner (1) in position on the water pump housing.
11. Install the water pump drive belt tensioner bolts.

Tighten
Tighten the drive belt tensioner retaining bolts to 10 N·m (89 lb in).

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12. Feed the water pump drive belt (4) around the water pump pulley (2) and the water pump
drive belt tensioner (3).
13. Compress the drive belt tensioner (3). Feed the drive belt around the drive pulley (1).
14. Check the drive belt (4) for proper seating in all the pulley grooves.

15. Place the water pump drive belt shield (1) in position.
16. Hand start the water pump drive belt shield retaining nuts (3) on the studs (4).

Tighten
Tighten the water pump shield retaining nuts to 10 N·m (89 lb in).

17. Hand start the water pump drive belt shield retaining bolt (2).

Tighten

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Tighten the water pump shield retaining bolt to 10 N·m (89 lb in).

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Camshaft Cover Installation (Right)

1. Install new camshaft cover seals if required.

2. Place the right camshaft cover in position on the cylinder head by aligning the bolt holes.

3. Tighten the camshaft cover bolts.

Tighten
Tighten the camshaft cover bolts to 10 N·m (89 lb in).

© 2010 General Motors Corporation. All rights reserved.

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Starter Installation

1. Place the starter motor in position in the engine valley.

2. Install the two starter motor retaining bolts.

Tighten
Tighten the starter motor retaining bolts to 30 N·m (22 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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3. Install the knock sensor (1).

Tighten
Tighten the knock sensor (1) to 20 N·m (15 lb ft).

4. Connect the knock sensor wire lead.

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Exhaust Manifold Installation (Left)

1. With the manifold still on the bench, position a new manifold gasket in place on the manifold
sealing surface.
2. Install two outer manifold bolts in the manifold to retain the gasket.
3. Using two hands, position the manifold and gasket onto the cylinder head.
4. Hand tighten the two outer manifold bolts.
5. Install the remaining manifold retaining bolts.

Tighten
Tighten the exhaust manifold retaining bolts to 24 N·m (18 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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6. Insert the end of the oil level indicator tube in the cylinder block. Align the mounting tab with
the mounting bolt hole.
7. Install the oil level tube retaining bolt.

Tighten
Tighten the oil level tube retaining bolt to 10 N·m (89 lb ft).

8. Install the oil level indicator.

9. Position the exhaust crossover pipe (1) in the left exhaust manifold (3) flange.
10. Install new manifold flange bolts for maximum joint integrity. Hand tighten. Do not torque
the flange bolts to specification until the engine is mounted in the vehicle.
11. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695, or
equivalent.

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12. Install the oxygen sensor.

Tighten
Tighten the oxygen sensor to 40 N·m (30 lb ft).

13. Install the crossover retaining bolts at the cylinder head and lower crankcase.

Tighten
Tighten the crossover-to-cylinder head retaining bolt to 25 N·m (18 lb ft).

Tighten
Tighten the crossover-to-lower crankcase retaining bolt to 30 N·m (22 lb ft).

14. Install the EGR feed tube to the crossover pipe.

Tighten
Tighten the EGR feed tube-to-crossover pipe nut to 60 N·m (44 lb ft).

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Exhaust Manifold Installation (Right)

1. If the engine is equipped with coolant heaters, install the right side (1) heater as follows:
1.1. Place the coolant heater (1) in position on the cylinder block.
1.2. Install the coolant heater bolt.

Tighten
Tighten the coolant heater bolt to 10 N·m (89 lb in).

© 2010 General Motors Corporation. All rights reserved.

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2. Position a new manifold gasket (1) in place on the cylinder head studs.
3. Using two hands, position the manifold (2) onto the cylinder head.
4. Install two outer manifold nuts (3) to hold the manifold in place.
5. Install the remaining manifold nuts.

Tighten
Tighten the exhaust manifold nuts (3) to 25 N·m (18 lb ft).

6. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695 or
equivalent.
7. Install the oxygen sensor (1).

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Tighten
Tighten the oxygen sensor to 40 N·m (30 lb ft).

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Intake Manifold Installation

1. Place the intake manifold in position on the cylinder heads.

2. Install the six bolts and four studs.

Tighten
Tighten the intake manifold bolts and studs starting from the center and working outward in
a circular pattern to 10 N·m (89 lb in).

3. Install the fuel injector harness main connector.

4. Install the PCV valve and feed tubes into the camshaft covers.

© 2010 General Motors Corporation. All rights reserved.

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5. Connect the EGR pipe to the water crossover and throttle body spacer.

Tighten
Tighten the EGR pipe to 28 N·m (21 lb in).

6. Connect the crankcase ventilation pipe to the throttle body spacer.

7. Connect the fuel rail bracket at the EGR valve.
8. Connect the fuel rail ground wire at the rear cylinder head.

9. Install the intake manifold sight shield with four nuts.

Tighten
Tighten the intake manifold sight shield nuts to 3 N·m (27 lb in).

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Ignition Coil Module Installation

1. Position the ignition module on the right camshaft cover.

2. Install the ignition module retaining bolts.

Tighten
Tighten the ignition module retaining bolts to 12 N·m (106 lb in).

3. Connect all the spark plug wires to the spark plugs.

4. Secure the left bank wires in the retaining features formed into the intake manifold.

© 2010 General Motors Corporation. All rights reserved.

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5. The right bank wires must be routed as shown to prevent possible misfires.

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Oil Filter Adapter Installation

1. Position the oil filter adapter on the crankcase.

2. Install the oil filter adapter retaining bolts.

Tighten
Tighten the oil filter adapter retaining bolts to 16 N·m (12 lb ft).

3. Install the oil filter pressure sensor.

Tighten
Tighten the oil pressure sensor to 16 N·m (12 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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4. Fill the oil filter with oil.

5. Install the oil filter.

Tighten
Tighten the oil filter to 32 N·m (24 lb ft).

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Accessory Installation
Air Conditioning Compressor

1. Install the air conditioning compressor bracket.

2. Install the air conditioning compressor bracket retaining nut.

Tighten
Tighten the air conditioning compressor bracket nut to 30 N·m (22 lb ft).

© 2010 General Motors Corporation. All rights reserved.

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3. Position the air conditioning compressor on the cylinder block.

4. Install the front and rear retaining bolts.

Tighten
Tighten the air conditioning compressor retaining bolts to 50 N·m (37 lb ft).

Generator

1. Install the rear generator mounting bracket.

2. Install the rear generator mounting bracket bolt and nut.

Tighten

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• Tighten the rear generator mounting bracket bolt to 47 N·m (35 lb ft).
• Tighten the rear generator mounting bracket nut to 38 N·m (28 lb ft).

3. Install the generator.

4. Install the generator retaining bolts.

Tighten
Tighten the generator retaining bolts to 50 N·m (37 lb ft).

Power Steering Pump

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1. Place the power steering pump in position in the engine valley. Slide the molded wedge into
the retaining feature cast into the cylinder block.
2. Install the power steering pump retaining bolt.

Tighten
Tighten the power steering pump retaining bolt to 50 N·m (37 lb ft).

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Drive Belt Installation

1. Route the accessory drive belt around the crankshaft (5), the air conditioning
compressor (4), the idler (3), the generator (2), and the drive belt tensioner (6) pulleys.
2. Insert a 1/2 inch drive ratchet into the drive belt tensioner (6).
3. Rotate the tensioner clockwise.
4. Route the remainder of the belt around the power steering pulley (1).
5. Slowly rotate the drive belt tensioner counter clockwise until the drive belt is tight.
6. Remove the 1/2 inch drive ratchet.
7. Check the drive belt for proper seating in all pulleys.

© 2010 General Motors Corporation. All rights reserved.

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Lubrication System Priming

Engine Priming Procedure

After completing service to an Aurora engine requiring engine oil pump removal, you must perform
the following procedures to prime the lubrication system before start up.

1. Verify that the engine oil is at the proper level. System capacity is 7 quarts with the oil filter
full.
2. Fill the oil system to the proper level if necessary.

3. Disconnect the right front connector (Power Lead) from the ignition module.
4. Crank the engine for 30 seconds.
5. Reconnect the power lead to the ignition module.
6. Start the engine.
7. Check the DIC for a Low Oil Pressure message.
8. Listen for any audible engine noise such as lifters ticking.
9. If engine noises persist, stop the engine and remove the oil pressure sensor from the oil filter
adapter.
10. Install an oil pressure gauge. Do not damage the threads in the adapter.
11. If the oil pressure is indicated on the gauge and no unusual sounds are heard, oil pressure is
present and both the oil pump and the engine lubrication system are primed.
12. If no oil pressure is recorded, repeat from step 3 then proceed to step 13.
13. If no oil pressure is recorded after repeating the process, remove the oil filter adapter and
force engine oil under pressure (using shop air) in the engine block outlet port (the port
closest to the front of the engine).
14. Reinstall the oil filter adapter.
15. Restart the engine.
16. If oil pressure is obtained, stop the engine.
17. Reinstall the oil pressure sensor in the oil filter adapter.
18. Once the oil pressure sensor is connected, check the instrument display for a no oil pressure
or low oil pressure message.
© 2010 General Motors Corporation. All rights reserved.

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19. If a no oil pressure or low oil pressure message is present, check the switch connection.
Repair the switch connection as necessary.

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Thread Repair (Except Cylinder Head/Main Cap Bolts)

Tools Required

J 39345 Thread Repair Kit

The following procedure is used to accomplish proper and durable thread repairs except for thread
repairs in the cylinder head and the cylinder block. Only holes specified in this procedure are
serviceable.

Important: Take appropriate precautions to assure that machining chips will not remain
inside the engine. For example, block all intake passages, oil drainback holes and exhaust
passages with a towel or tape before performing thread repairs.

1. Select the proper size drill as indicated in the schematic charts found in the Thread Repair
Specifications for the hole being repaired.
2. Drill out the damaged threads to the original depth or completely through for through holes.

Caution: Wear safety glasses in order to avoid eye damage.

3. Clean out the hole using compressed air with a shop rag wrapped around the air spout to
prevent aluminum chips from leaving the hole.

4. Select the correct size tap, using the appropriate chart for the hole being repaired.
5. Coat the tap and the hole with spray machining oil.
6. Tap the hole to the original depth. In order to clean the threads, reverse the rotation of the
tap periodically.
7. Use aluminum safe solvent to clean out all of the aluminum chips.
8. Apply compressed air with a shop towel wrapped around the air spout, in order to retain the
chips forced out of the hole.
9. Tap the hole again to clean the threads. The tap should thread in with little resistance.
© 2010 General Motors Corporation. All rights reserved.

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Important: Make sure all of the aluminum chips are cleared from the hole.

10. Use aluminum safe solvent to clean out all of the aluminum chips.
11. Apply compressed air with a shop towel wrapped around the air spout, in order to retain the
chips forced out of the hole.
12. Use a flashlight to confirm that all of the chips are removed from the hole.
13. Continue to clean the hole until all of the aluminum chips are cleared.
14. Install the heli-coil insert as follows:
14.1. In order to determine the correct size installation tool and length insert, refer to the
appropriate picture and chart.
14.2. Screw the insert on the mandrel of the installation tool until the driving tang is fully
engaged in the driving contour.
14.3. Coat the insert with spray machining oil.
14.4. Install the insert as follows:
14.4.1. Slide the prewinder over the mandrel and insert.
14.4.2. Rotate the mandrel clockwise until 1 or 2 threads of the insert are threaded
into the prewinder.
14.4.3. Place the insert in position on the threaded hole being repaired.
14.4.4. Rotate the mandrel clockwise until the insert is flush with the top surface of
the threaded hole.
14.4.5. Remove the prewinder except when repairing cylinder head bolts.
14.4.6. Continue to install the insert until reaching the original thread depth.
14.4.7. Remove the mandrel.
14.5. Remove the driving tang from the thread insert as follows. The tang must be removed
in order to allow passage of the fastener through the insert.
14.5.1. Place the square end of the punch, no chamfer, on the tang after installation.
14.5.2. Strike the punch sharply with the hammer. The tang will break off at the
notch.
15. Clean the hole using compressed air. Take appropriate steps to assure that chips are not
blown into the engine.

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Thread Repair (Cylinder Head/Main Cap Bolts)

Tools Required

• J-42385-500 Thread Repair Kit

• J 43965 Thread Repair Extension Kit

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type
insert. During the insert installation process, the installation driver tool cold-rolls the bottom
internal threads and expands the bottom external threads of the insert into the base material. This
action mechanically locks the insert into place.

The drill bit and counter bore tool from the tool kit J-42385-500 is designed for use with either a
suitable tap wrench or drill motor. Limited access and larger hole repair may process better using a
tap wrench. An extension from kit J 43965 may also be necessary to drive the thread repair tooling
dependent on access to the hole being repaired. Use only a tap wrench when tapping the hole and
during installation of the insert.

© 2010 General Motors Corporation. All rights reserved.

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It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same
centerline as the original hole.

During the drilling and tapping of the hole being repaired ensure the tooling is consistently
machining perpendicular to the surface of the base material.

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If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping
guides are available to aid in tapping the hole.

Tap Size Tap Guide Tape Size Tape Guide Tap Size Tape Guide
-- J 42385- -- J 42385- -- J 42385-
6 x 1.0 729 10 x 1.5 731 14 x 1.5 736
8 x 1.25 730 12 x 1.5 732 20 x 1.5 737

Standard Thread Repair - Flush Hole

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Caution: Wear safety glasses in order to avoid eye damage.

Important: The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or
equivalent is recommended when performing the drilling, counterboring and tapping procedures.

When installed to the proper depth, the flange (1) of the insert will be seated against the
counterbore of the drilled/tapped hole and just below the surface (2) of the base material.

Important:
• During the drilling process, it is necessary to repeatedly remove the drill and clean chips
from the hole and the flutes of the drill.
• DO NOT drill any further than the original hole depth.

1. Drill out the threads of the damaged hole.

• M6 inserts require a minimum drill depth of 15 mm (0.59 in).
• M8 inserts require a minimum drill depth of 20 mm (0.79 in).
• M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).

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Important: All chips must be removed from the drilled hole prior to tapping.

2. Using compressed air, clean out any chips.

Important: A properly counterbored hole will show a slight burnishing on the surface of the
base material for 360 degrees around the drilled hole.

3. Counterbore the drilled hole to the full depth permitted by the tool (1).

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Important: All chips must be removed from the drilled hole prior to tapping.

4. Using compressed air, clean out any chips.

Important:
• During the tapping process, it is necessary to repeatedly remove the tap and clean
chips from the hole and the flutes of the tap.
• Ensure the tap has created full threads at least to the depth equal to the insert length.

5. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.
• M6 inserts require a minimum tap depth of 15 mm (0.59 in).

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• 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).

Important: All chips must be removed from the tapped hole prior to insert installation.

6. Using compressed air, clean out any chips.

7. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

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Important: All chips must be removed from the tapped hole prior to insert installation.

8. Using compressed air, clean out any chips.

Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of
the insert.

9. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

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10. Install the insert (2) onto the driver installation tool (1).

11. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277® or equivalent (1) to the insert OD threads (2).

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12. Install the insert (2) into the tapped hole by hand only.

Important: If the insert will not thread down until the flange contacts the counterbored
surface, remove the insert immediately with a screw extracting tool and inspect the tapped
hole for any remaining chips and/or improper tapping.

13. Install the insert until the flange (2) of the insert contacts the counterbored surface.

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Important: The driver installation tool will tighten up before screwing completely through
the insert. This is acceptable. The threads at the bottom of the insert are being formed and
the insert is mechanically locking the insert into the base material threads.

14. Continue to rotate the driver installation tool (1) through the insert (2).

15. Inspect the insert for proper installation into the tapped hole. A properly installed insert (1)
will be either flush or slightly below flush with the surface of the base material (2).

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16. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to
have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine
coolant passage. After drilling the restriction or blockage, clean out any chips and thread the
installation driver tool through the insert again to remove any burrs caused by the drilling of
the oil or engine coolant passage.

Recessed Thread Repair

Caution: Wear safety glasses in order to avoid eye damage.

Important:

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• The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or
equivalent is recommended when performing the drilling, counterboring and tapping
procedures.
• Do NOT remove the original stop collar from a counterbore drill.

When installed to the proper depth, the flange of the insert (1) will be seated against the
counterbore (2) of the drilled/tapped hole.

1. Install a stop collar (2) on the counterbore drill (1), if required.

Important:

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• During the drilling process, it is necessary to repeatedly remove the drill and clean chips
from the hole and the flutes of the drill.
• Drill the hole until the stop collar contacts the surface of the base material.

2. Drill out the threads of the damaged hole.

Important: All chips must be removed from the drilled hole prior to tapping.

3. Using compressed air, clean out any chips.

Important:
• During the tapping process, it is necessary to repeatedly remove the tap and clean

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chips from the hole and the flutes of the tap.

• Ensure the tap has created full threads at least to the depth equal to the insert length.

4. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

Important: All chips must be removed from the tapped hole prior to insert installation.

5. Using compressed air, clean out any chips.

6. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

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Important: All chips must be removed from the tapped hole prior to insert installation.

7. Using compressed air, clean out any chips.

Important: Do not allow oil or other foreign material to contact the OD of the insert.

8. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

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9. Install the insert (2) onto the driver installation tool (1).

10. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277® or equivalent (1) to the insert OD threads (2).

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11. Install the insert (2) into the tapped hole by hand only.

Important: If the insert will not thread down until the flange contacts the counterbored
surface remove the insert immediately with a screw extracting tool and inspect the tapped
hole for any remaining chips and/or improper tapping.

12. Install the insert until the flange (2) of the insert contacts the counterbored surface.

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13. Continue to rotate the driver installation tool (1) through the insert (2).

14. Inspect the insert (1) for proper installation (2) into the tapped hole.

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15. Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to
have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine
coolant passage. After drilling the restriction or blockage, clean out any chips and thread the
installation driver tool through the insert again to remove any burrs caused by the drilling of
the oil or engine coolant passage.

Tapered Pipe Thread Repair

The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

Caution: Wear safety glasses in order to avoid eye damage.

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Important: The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or
equivalent is recommended when performing the drilling, counterboring and tapping procedures.

When installed to the proper depth, the flange (1) of the insert will be seated against surface (2) of
the base material of the drilled/tapped hole.

Important:
• During the drilling process, it is necessary to repeatedly remove the drill and clean chips
from the hole and the flutes of the drill.
• Drill the hole until the stop collar contacts the surface of the base material.

1. Drill out the threads of the damaged hole.

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Important: All chips must be removed from the drilled hole prior to tapping.

2. Using compressed air, clean out any chips.

3. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

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4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the
base material.

Important: All chips must be removed from the tapped hole prior to insert installation.

5. Using compressed air, clean out any chips.

6. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

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Important: All chips must be removed from the tapped hole prior to insert installation.

7. Using compressed air, clean out any chips.

Important: Do not allow oil or other foreign material to contact the OD of the insert.

8. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

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9. Install the insert (2) onto the driver installation tool (1).

10. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277® or equivalent (1) to the insert OD threads (2).

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11. Install the insert (2) into the tapped hole by hand only.

Important: If the insert will not thread down until the flange contacts the surface of the
base material remove the insert immediately with a screw extracting tool and inspect the
tapped hole for any remaining chips and/or improper tapping.

12. Install the insert until the flange (2) of the insert contacts the surface of the base material.

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13. Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is
level with the top of the insert (3).

14. Inspect the insert (1) for proper installation (2) into the tapped hole.

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Cylinder Head Bolt Hole Thread Repair

Important: Verify the depth of the cylinder head bolt hole and the pitch of the cylinder head bolt
threads. Measure the depth from the deck surface of the block to the bottom of the cylinder head
hole. All cylinder head holes should use only one of the bushings. Never use both bushings to
repair a block.

With M11 bolts with a 1.5 mm pitch:

• Use the bushing J 42385-2022 for inboard holes that measure 73 mm (2.874 in) deep and
outboard holes that measure 89.5 mm (3.524 in) deep.
• Use the bushing J 42385-302 for inboard holes that measure 80 mm (3.150 in) deep and
outboard holes that measure 96.5 mm (3.799 in) deep.

Inboard Bolt Holes

Caution: Wear safety glasses in order to avoid eye damage.

Important:
• Remove the fixture plate prior to installing the insert with the installer tool.
• The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or
equivalent is recommended when performing the drilling, counterboring and tapping
procedures.

When installed to the proper depth, the flange of the insert will be seated against the counterbore

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of the drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to
be repaired (4).
2. Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.

3. Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
4. With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining
bolts (2).
5. Remove the alignment pin (1) from the cylinder head bolt hole.

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6. Install the stop collar (2) onto the drill (1).

7. Drill out the threads of the damaged hole.

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Important: All chips must be removed from the drilled hole prior to tapping.

8. Using compressed air, clean out any chips.

9. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

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10. In order to tap the new threads for the insert to the proper depth, rotate the tap into the
cylinder head bolt hole until the first mark (1) on the tap aligns with the top of the drill
bushing (3).

Important: Remove the fixture plate prior to installing the insert with the installer tool.

11. Remove the fixture plate bolts (2).

12. Remove the fixture plate (3) and bushing (1).

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Important: All chips must be removed from the tapped hole prior to insert installation.

13. Using compressed air, clean out any chips.

14. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

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Important: All chips must be removed from the tapped hole prior to insert installation.

15. Using compressed air, clean out any chips.

Important: Do not allow oil or other foreign material to contact the OD of the insert.

16. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

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17. Install the insert (2) onto the driver installation tool (1).

18. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277®, or equivalent (1) to the insert OD threads (2).

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19. Install the insert and installation driver (1) into the tapped hole by hand only.
20. Start the insert into the threaded hole.

21. Install the insert until the flange of the insert contacts the counterbored surface.

22. Continue to rotate the driver installation tool through the insert.
23. Inspect the insert for proper installation into the tapped hole.

Outboard Bolt Holes

Caution: Wear safety glasses in order to avoid eye damage.

When installed to the proper depth, the flange of the insert will be seated against the counterbore
of the drilled/tapped hole.

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1. Position the fixture plate (3) with the bushing (2) installed over the cylinder head bolt hole to
be repaired (4).
2. Loosely install the fixture plate bolts (1) into the remaining cylinder head bolt holes.

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6. Drill out the threads of the damaged hole.

Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.

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8. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the
cylinder head bolt hole until the second mark (1) on the tap aligns with the top of the drill
bushing (3).

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Important: Remove the fixture plate prior to installing the insert with the installer tool.

10. Remove the fixture plate bolts (1).

11. Remove the fixture plate (3) and bushing.

Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.

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13. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

Important: All chips must be removed from the tapped hole prior to insert installation.

14. Using compressed air, clean out any chips.

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Important: Do not allow oil or other foreign material to contact the OD of the insert.

15. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

16. Install the insert (2) onto the driver installation tool (1).

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17. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277® or equivalent (1) to the insert OD threads (2).

18. Install the insert and installation driver (1) into the tapped hole by hand only.
19. Start the insert into the threaded hole.

20. Install the insert until the flange of the insert contacts the counterbored surface.

Important: The driver installation tool will tighten up before screwing completely through
the insert. This is acceptable. The threads at the bottom of the insert are being formed and

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the insert is mechanically locking the insert into the base material threads.

21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the tapped hole.

Crankshaft Main Bolt Hole Thread Repair

Tools Required

J-42385-500 Thread Repair Kit

Important:
• In order to repair some crankshaft main bolt holes it will be necessary to mount the fixture
plate upside down.
• Do NOT remove the fixture plate prior to installing the insert with the installation driver. The
fixture plate remains in position throughout the thread repair process.

The crankshaft main bearing bolt hole thread repair kit J-42385-500 components consist of the
following:

• Drill (1) J 42385-511

• Tap (2) J 42385-512
• Installation driver (3) J 42385-513
• Fixture plate (4) J 42385-306
• Bushing (5) J 42385-307
• Alignment pin (6) J 42385-308
• Bolts (7) J 42385-510

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Caution: Wear safety glasses in order to avoid eye damage.

Important:
• Ensure the fixture plate is installed during the machining and installation processes of the
insert.
• The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or
equivalent is recommended when performing the drilling, counterboring and tapping
procedures.

When installed to the proper depth, the flange of the insert will be seated against the counterbore
of the drilled/tapped hole.

1. Position the fixture plate (3) with the bushing (2), installed over the crankshaft main cap bolt
hole to be repaired.
2. Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.

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3. Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt
hole.
4. With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture
retaining bolts (2).
5. Remove the alignment pin (1) from the crankshaft main cap bolt hole.

Important:
• During the drilling process, it is necessary to repeatedly remove the drill and clean chips
from the hole and the flutes of the drill.
• Drill the crankshaft main bolt hole until the mark (1) on the drill aligns with the top of
the drill bushing (2).

6. Drill out the threads of the damaged hole.

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Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.

Important:
• Do not remove the fixture plate, ensure the fixture plate is installed during the
machining and installation processes of the insert.
• During the tapping process, it is necessary to repeatedly remove the tap and clean
chips from the hole and the flutes of the tap.
• Ensure the tap has created full threads at least to the depth equal to the insert length.

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8. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

9. In order to tap the new threads for the insert to the proper depth, rotate the tap into the
crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill
bushing (2).

Important: All chips must be removed from the tapped hole prior to insert installation.

10. Using compressed air, clean out any chips.

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11. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent
into the tapped hole.

Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.

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Important:
• Do not remove the fixture plate, ensure the fixture plate is installed during the
installation process of the insert.
• Do not allow oil or other foreign material to contact the OD of the insert.

13. Lubricate the threads of the driver installation tool (2) with the driver oil J 42385-110 (1).

14. Install the insert (2) onto the driver installation tool (1).

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15. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109,
LOCTITE 277® or equivalent (1) to the insert OD threads (2).

16. Install the insert and installation driver into the tapped hole by hand only.
17. Start the insert into the threaded hole.

18. Install the insert until the flange of the insert contacts the counterbored surface.

Important: The driver installation tool will tighten up before screwing completely through
the insert. This is acceptable. The threads at the bottom of the insert are being formed and

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the insert is mechanically locking the insert into the base material threads.

19. Continue to rotate the driver installation tool through the insert.

20. Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with
the top of the drill bushing (2).
21. Inspect the insert for proper installation into the tapped hole.

22. Remove the fixture plate bolts (1).

23. Remove the fixture plate (3) and bushing (2).

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Fastener Tightening Specifications

Specification
Application Metric English
AIR Cross Over Pipe Bolt 9 N·m 80 lb in
AIR Cross Over Pipe Nut 9 N·m 80 lb in
AIR Manifold Bolt 10 N·m 89 lb in
AIR Pump to Bracket Nut 9 N·m 80 lb in
AIR Shut-off Valve Bracket Bolt 25 N·m 18 lb ft
AIR Shut-off Valve Outlet Pipe Bolt 9 N·m 80 lb in
AIR Shut-off Valve Outlet Pipe Nut 9 N·m 80 lb in
AIR Vacuum Control Solenoid Valve Bracket Bolt 10 N·m 89 lb in
AIR Vacuum Control Solenoid Valve to Bracket Screw 10 N·m 89 lb in
A/C Refrigerant Pressure Sensor 5 N·m 44 lb in
Accelerator Bracket Bolt 13 N·m 115 lb in
Accelerator Bracket Nut 10 N·m 88 lb in
Accelerator Pedal Bolt 3 N·m 27 lb in
Air Cleaner Housing Attaching Screw 3 N·m 27 lb in
Air Cleaner Intake Duct Clamp 2 N·m 18 lb in
Brake Master Cylinder 23 N·m 17 lb ft
Camshaft Position (CMP) Sensor Bolt 6-12 N·m 53-106 lb in
Coolant Recovery Tank Mounting Nuts 1 N·m 9 lb in
50 N·m 37 lb ft
Crankshaft Balancer Bolt
+120 degrees +120 degrees
Crankshaft Position (CKP) Sensor MountingBolt 9 N·m 80 lb in
EGR Inlet Pipe to Exhaust Manifold Nut 60 N·m 44 lb ft
EGR Inlet Pipe to Intake Manifold Bolt 24 N·m 18 lb ft
EGR Outlet Pipe to Intake Manifold Bolt 10 N·m 89 lb ft
EGR Outlet Pipe to Water Pump Crossover Bolt 24 N·m 18 lb ft
EGR Valve Mounting Nut 19 N·m 14 lb ft
EGR Valve Mounting Stud 24 N·m 18 lb ft
EGR Valve to Water Pump Crossover Bolts 4-14 N·m 35-124 lb in
EVAP Canister Purge Vent Solenoid Valve Retaining Bolt 10 N·m 89 lb in
EVAP Canister Retaining Nut 6 N·m 53 lb in
EVAP Pipe Clip Screw 5.8 N·m 51 lb in
EVAP Vent Valve Bracket Attaching Screw 6 N·m 53 lb in
Engine Coolant Temperature (ECT) Sensor 20 N·m 15 lb ft
Engine Fuel Pipe Retaining Clip 7.5 N·m 67 lb in
© 2014 General Motors Corporation. All rights reserved.

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Engine Oil Level Sensor Bolt 6-12 N·m 53-106 lb in

Fuel Filler Pipe Attaching Screws 10 N·m 89 lb in
Fuel Filler Pipe Ground Wire Attaching Bolt 9 N·m 80 lb in
Fuel Injector Harness Bolts 9 N·m 80 lb in
Fuel Sender Access Panel Attaching Bolts 2 N·m 18 lb in
Fuel Tank Filler Pipe Hose Clamp 2.5 N·m 22 lb in
Fuel Tank Retaining Strap Bolts 47 N·m 35 lb ft
Heated Oxygen Sensors 41 N·m 30 lb ft
IAC Valve Attaching Screws 3 N·m 27 lb in
Ignition Coil Cassette to Cam Cover Bolts 9.5 N·m 84 lb in
Ignition Control Module to Ignition Coil Assembly Screws 1.1 N·m 10 lb in
In-Pipe Fuel Filter Bracket Attaching Screw 10 N·m 89 lb in
In-Line Fuel Filter Mounting Bracket Bolts 20 N·m 15 lb ft
In-Pipe Fuel Filter Fitting 30 N·m 22 lb ft
Injector Sight Shield Stud Nut 3 N·m 27 lb in
Knock Sensor 15 N·m 11 lb ft
MAF Sensor Band Clamps 3.5 N·m 31 lb in
Oil Lever Indicator Tube Retaining Bolt 9 N·m 80 lb in
PCM Connector 8 N·m 71 lb in
Power Steering Hose Retainer Bolt 9 N·m 80 lb in
Spark Plugs 20 N·m 15 lb ft
Throttle Body to Intake Manifold Nuts 10 N·m 89 lb in
Throttle Position Sensor Attaching Screw 2.3 N·m 20 lb in
Transaxle Range Switch Bolts 28 N·m 21 lb ft

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Fuel System Specifications

Fuel (Premium Required)
The following information appears in the General Motors Owner's Manual for this vehicle.

Use premium unleaded gasoline rated at 91 octane or higher. At a minimum, it should meet
specifications ASTM D4814 in the United States and CGSB 3.5-M93 in Canada. Improved gasoline
specifications have been developed by the American Automobile Manufacturers Association (AAMA)
for better vehicle performance and engine protection. Gasoline meeting the AAMA specification
could provide improved driveability and emission control system protection compared to other
gasoline.

Be sure the posted octane for premium is at least 91. If the octane is less than 91, you may get a
heavy knocking noise when you drive. In an emergency, you may be able to use a lower octane, as
low as 87, if heavy knocking does not occur. If you are using 91 or higher octane unleaded
gasoline and you still hear heavy knocking, your engine needs service.

If your vehicle is certified to meet California Emission Standards, indicated on the underhood tune-
up label, it is designed to operate on fuels that meet California specifications. If such fuels are not
available in states adopting California emissions standards, your vehicle will operate satisfactorily
on fuels meeting federal specifications, but emission control system performance may be affected.
The malfunction indicator lamp (MIL) on your instrument panel may turn ON and/or your vehicle
may fail a smog-check test. If this occurs, return to a qualified service outlet for diagnosis to
determine the cause of failure. In the event it is determined that the cause of the condition is the
type of fuels used, repairs may not be covered by your warranty.

Some gasolines that are not reformulated for low emissions contain an octane-enhancing additive
called methylcyclopentadlenyl manganese tricarbonyl (MMT); ask your service station operator
whether or not this fuel contains MMT. General Motors does not recommend the use of such
gasolines. If fuels containing MMT are used, spark plug life may be reduced and your emission
control system performance may be affected. The MIL on your instrument panel may turn ON. If
this occurs, return to a qualified service outlet for service.

Notice: Your vehicle was not designed for fuel that contains methanol. Do not use methanol fuel
which can corrode metal parts in your fuel system and also damage plastic and rubber parts. This
kind of damage would not be covered under your warranty.

To provide cleaner air, all gasolines in the United States are now required to contain additives that
will help prevent deposits from forming in your engine and fuel system, allowing your emission
control system to function properly. Therefore, you should not have to add anything to the fuel. In
addition, gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines
may be available in your area to help clean the air. General Motors recommends that you use these
gasolines if they comply with the specifications described earlier.

© 2014 General Motors Corporation. All rights reserved.

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Ignition System Specifications

Specification
Application Metric English
Firing Order 1-2-3-4-5-6
Spark Plug Torque 20 N·m 15 lb ft
Spark Plug Gap 1.27 mm 0.050 in
Spark Plug Type 41-950 [AC plug type]

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Temperature Versus Resistance

°C °F OHMS
Temperature vs Resistance Values (Approximate)
150 302 47
140 284 60
130 266 77
120 248 100
110 230 132
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700

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EVAP System Overview

(1) EVAP Canister Purge Solenoid

(2) EVAP Canister
(3) Fuel Fill Neck/Fill Cap
(4) Rollover Valve/Fuel Tank Pressure (FTP) Sensor
(5) Fuel Tank
(6) EVAP Canister Vent Solenoid
(7) Vent Hose/Pipe
(8) EVAP Vapor Pipe
(9) EVAP Purge Pipe
(10) EVAP Service Port

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Evaporative Emissions Hose Routing Diagram

EVAP System Overview

(1) EVAP Canister Purge Solenoid

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Vacuum Hose Routing

(1) Air Control Valve

(2) AIR Vacuum Solenoid Valve
(3) Intake Manifold
(4) Fuel Pressure Regulator
(5) EVAP Purge Pipe to EVAP Canister
(6) EVAP Canister Purge Valve
(7) Throttle Body
(8) AIR Control Valve
(9) PCV Valve

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AIR Pump and Controls

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Camshaft and Crankshaft Position Sensors, TCC/Cruise

Release Switch

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EVAP Canister Purge Valve, IAC, and MAF

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Fuel Injectors

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Fuel Pressure Sensor and EVAP Canister Purge Vent

Valve

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Fuel Tank and Sender Assembly and Controls

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Heated Oxygen Sensors

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Igntion Control Modules

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Ignition Switch and Controls

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PCM Controls (1 of 2)

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PCM Controls (2 of 2)

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Sensors

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Accelerator Control Cable Bracket Replacement

Removal Procedure

1. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
2. Remove the cruise control cable (1) from the bracket (3). Refer to Cruise Control Cable
Replacement in Cruise Control.
3. Remove the accelerator controls cable (2) from the bracket (3).

4. Remove the nuts and©bolt

2014from theMotors
General accelerator controls
Corporation. cable
All rights bracket (2).
reserved.

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Installation Procedure

1. Install the accelerator controls cable bracket (2).

Tighten
• Tighten the bolts to 13 N·m (115 lb in).
• Tighten the nuts to 10 N·m (88 lb in).

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2. Install the accelerator controls cable (2) to the bracket (3).

3. Install the cruise control cable (1) to the bracket (3). Refer to Cruise Control Cable
Replacement in Cruise Control.
4. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .

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Accelerator Control Cable Replacement

Removal Procedure

1. Remove the left instrument panel insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console.
2. Remove the accelerator controls cable from the accelerator controls pedal.

3. Squeeze the cover tangs on the accelerator controls cable .

4. Push the accelerator controls cableMotors
© 2014 General through the bulkhead.
Corporation. All rights reserved.

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5. Remove the accelerator controls cable from the retaining clips.

6. Remove the accelerator controls cable from the throttle body lever and bracket.

Installation Procedure
Notice: Do not route flexible components (hoses, wires, conduits, etc.) within 50 mm (2 in) of
moving parts unless flexible components can be securely fastened. This is necessary in order to
prevent possible interference and damage to the component.

Important: The throttle should operate freely and without binding between full closed and wide
open throttle.

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1. Install the accelerator controls cable through the bulkhead, the cable will snap in place.

2. place the accelerator controls cable through the slot in the accelerator controls pedal lever.
3. Seat the snap retainer in the accelerator controls pedal lever.

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4. Connect the accelerator controls cable to the throttle body lever and bracket.

5. Snap the accelerator controls cable into the retaining clips.

6. Check for the correct throttle opening and closing positions by operating the accelerator
controls pedal. Also check for correct carpet fit under the accelerator controls pedal.
7. Install the left instrument panel insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console.

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Accelerator Pedal Replacement

Removal Procedure

1. Remove the left instrument panel insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console.
2. Disconnect the accelerator controls cable from the accelerator controls pedal.
3. Remove the clip retaining the accelerator controls pedal.
4. Remove the accelerator controls pedal.

Installation Procedure
Important: The throttle should operate freely and without binding between full closed and wide
open throttle.

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1. Install the accelerator controls pedal to the pivot shaft.

2. Install the accelerator controls pedal retaining clip.

Tighten
Tighten the pedal bolts and studs to 3.0 N·m (27 lb in).

3. Connect the accelerator controls cable to the accelerator controls pedal .

4. Check for complete throttle opening and closing positions by operating the accelerator pedal.
Also check for a correct carpet fit under the accelerator controls pedal.
5. Install the left instrument panel insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console.

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Air Cleaner Assembly Replacement

Removal Procedure
1. Remove the air cleaner element and cover. Refer to Air Cleaner Element Replacement .

2. Remove the screws from the upper air cleaner housing (4) and remove it from the vehicle.

Important: The PCM wiring harness does not need to be disconnected..

3. Remove the powertrain control module (PCM) from the lower air cleaner housing.
4. Pull the lower air cleaner housing from the rubber insulators.
5. Remove any loose debris found laying in the base of the air cleaner.
6. Inspect the air cleaner and replace if necessary.

Installation Procedure

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1. Press the lower air cleaner housing into the rubber insulators.
2. Install the powertrain control module (PCM) in the lower air cleaner housing.
3. Align the upper air cleaner housing by inserting the tabs into the air cleaner lower housing.

4. Install the screws through the upper housing into the lower air cleaner housing.

Tighten
Tighten the air cleaner housing screws to 3 N·m (27 lb in).

5. Install the air cleaner element and cover. Refer to Air Cleaner Element Replacement .

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Air Cleaner Element Replacement

Removal Procedure

1. Disconnect the IAT sensor electrical connector (2).

2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .

3. Loosen the retaining screws on the air cleaner cover.

4. Remove the housing cover and remove the air cleaner element.
5. Inspect the housing cover,
© 2014the sealMotors
General assembly, and the
Corporation. air cleaner
All rights reserved.duct for damage. If a

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problem is found, replace as necessary.

Installation Procedure

1. Carefully install the air cleaner element into the air cleaner assembly.
2. Install the air cleaner housing cover and tighten the retaining screws.
3. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .

4. Connect the IAT sensor electrical connector (2).

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Air Cleaner Inlet Duct Replacement

Removal Procedure

1. Disconnect the mass air flow (MAF) sensor electrical connector (3).

2. Loosen the air cleaner intake/MAF assembly clamps from the throttle body side (2) and air
cleaner cover side (4).
3. Remove the air cleaner intake/MAF assembly from the vehicle.
4. Separate the air cleaner intake
© 2014 duct
General fromCorporation.
Motors the mass Allairrights
flow reserved.
(MAF) sensor.

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Installation Procedure
1. Combine the air cleaner intake duct and mass air flow (MAF) sensor.

2. Install the air cleaner intake/MAF assembly on the throttle body (1) and air cleaner cover.

3. Inspect for proper alignment of the air cleaner intake/MAF assembly and tighten the hose
clamps.

Tighten
Tighten the air cleaner intake/MAF sensor band clamps to 3.5 N·m (31 lb in).

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4. Connect the mass air flow (MAF) sensor electrical connector (3).

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Camshaft Position Sensor Replacement

Removal Procedure
1. Remove the mounting nuts retaining the coolant recovery tank .
2. Lift the coolant recovery tank to gain access to the camshaft position (CMP) sensor.

3. Disconnect the electrical connector from the CMP sensor.

4. Remove the CMP sensor mounting bolt (2).
5. Remove the CMP sensor (1) from the cylinder head.
• Remove the sensor by pulling on the sensor connector. Do not pry on the bracket.
• Do not rotate or twist the sensor or damage the mounting bracket if the sensor is being
reused.

Installation Procedure
Important: When replacing the CMP sensor with a new sensor or reinstalling the original sensor,
use the following recommended procedures:
• Ensure that the CMP sensor bore is completely free of any foreign material, such as old O-
ring, dirt, burrs, etc.
• Ensure that the flange on the CMP sensor bore is not damaged.
• Clean all of the mounting surfaces before re-installing any components.
• Inspect the CMP sensor and replace the sensor if any of the following conditions are present:
- The bracket is damaged.
- The bottom of brass housing exhibits any damage.
- Never install a sensor that has been dropped.
• Lubricate the O-ring on the sensor with Amojell or clean engine oil prior to installing the
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sensor.
• Check all of the connectors for any damaged terminals.

1. Install and fully seat the CMP sensor (1) into the cylinder head.

2. Install the CMP sensor mounting bolt (2).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

3. Connect the electrical connector to the CMP sensor.

4. Lower the coolant recovery tank onto the mounting studs.
5. Install the 2 mounting nuts to retain the coolant recovery tank .

Tighten
Tighten the nuts to 1 N·m (9 lb in).

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Crankshaft Position Sensor Replacement

Removal Procedure

1. Disconnect the negative battery cable.

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 and strap the vehicle to the hoist.

2. Raise the vehicle.

3. Loosen or remove the starter motor (1) as necessary. Refer to Starter Motor Replacement in
Engine Electrical.
4. Disconnect the electrical connector from the crankshaft position (CKP) sensor (2).

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5. Remove the CKP sensor mounting bolt (1).

6. Remove the CKP sensor (2) from the engine block:
• Remove the sensor by pulling on the sensor connector. Do not pry on the bracket.
• Do not rotate or twist the sensor or damage the mounting bracket if the sensor is being
reused.

Installation Procedure
Important: When replacing the CKP sensor with a new sensor or reinstalling the original sensor,
use the following recommended procedures:
• Make sure that the CKP sensor bore is completely free of any foreign material, such as old O-
ring, dirt, burrs, etc.
• Make sure that the flange on the CKP sensor bore is not damaged.
• Clean all the mounting surfaces before re-installing any components.
• Inspect the CKP sensor and replace the sensor if any of the following conditions are present:
- The bracket is damaged.
- The bottom of the brass housing exhibits any damage.
- Never install a sensor that has been dropped.
• Lubricate the O-ring on the sensor with Amojell or clean engine oil prior to installing the
sensor .
• Check all the connectors for any damaged terminals.

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1. Lubricate the CKP sensor O-rings.

2. Install and fully seat the CKP sensor (2) into the engine block.

3. Install the CKP sensor mounting bolt (1).

Tighten
Tighten the mounting bolt to 9 N·m (80 lb in).

4. Ensure that the CKP sensor mounting flange is contacting the engine block.

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5. Connect the electrical connector to the CKP sensor (2).

6. Re-install or tighten the starter motor (1) as necessary. Refer to Starter Motor Replacement
in Engine Electrical.
7. Reconnect the negative battery cable.
8. Lower the vehicle.
9. The Crankshaft Position System Variation Learn must be performed after replacing the CKP
sensor. Even if the original sensor is reinstalled, the Learn Procedure must be performed.

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Crankshaft Position System Variation Learn

The crankshaft position system variation compensating values are stored in the PCM non-volatile
memory after a learn procedure has been performed. If the actual crankshaft position system
variation is not within the crankshaft position system variation compensating values stored in the
powertrain control module (PCM), DTC P0300 may set. Refer to Diagnostic Aids in DTC P0300 .

The crankshaft position system variation learn procedure should be performed if any of the
following conditions are true:

• DTC P1336 is not set.

• The PCM has been replaced.
• The PCM has been reprogrammed.
• The engine has been replaced.
• The crankshaft has been replaced.
• The crankshaft position (CKP) sensor has been replaced.

Caution: Before performing the Crankshaft Position System Variation Learning Procedure always
set the vehicle parking brake and block the drive wheels in order to prevent personal injury.
Release the throttle immediately when the engine starts to decelerate in order to eliminate over
revving the engine. Once the learn procedure is completed, the control module will return engine
control to the operator and the engine will respond to the throttle position.

Important: The scan tool crankshaft position system variation learn function will be inhibited if the
engine coolant temperature is less than 70°C (158°F). Allow the engine to warm to at least 70°C
(158F) before attempting the Crankshaft Position System Variation Learn procedure.

The crankshaft position system variation learn function will be inhibited if any powertrain DTCs
other than DTC P1336 are set before or during the crankshaft position system variation learn
procedure. Diagnose and repair any DTCs, if set.

1. Set the parking brake.

2. Block the drive wheels.
3. Close the hood.
4. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F).
5. Turn OFF the engine, then turn the key to ON.
6. Select and enable the crankshaft position variation learn procedure with the scan tool.
7. Start the engine.
8. Wait until instructed by the scan tool, then apply the brake pedal firmly.
9. Ensure that the transaxle is in Park.
10. Increase accelerator pedal position until the CKP system variation learn fuel cut-off is
reached at 4050 RPM. Release the accelerator pedal after the second fuel cut-off is reached.
11. The crankshaft position system variation compensating values are learned when the RPM
decreases back to idle. If the procedure terminates, refer to the Important above for
instructions.
12. Observe the DTC status for DTC P1336.
13. If the scan tool indicates that DTC P1336 ran and passed, the crankshaft position system
variation learn procedure is complete.
14. Use the scan tool to clear any DTCs. DTC P1336 will not automatically clear after a successful
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learn procedure. DTC P1336 will not clear from memory if the learn procedure was
unsucessful.

If the scan tool indicates that DTC P1336 failed or did not run, recheck for other DTCs that may
have set during the procedure. If no DTCs other than P1336 are set, repeat the crankshaft position
system variation learn procedure. If the learn procedure will not pass, a mechanical engine
problem may exist.

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Engine Coolant Temperature Sensor Replacement

Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.

1. Turn OFF the ignition.

2. Drain the coolant to below the level of the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling in Engine Cooling.

3. Disconnect the ECT sensor (1) .

4. Remove the ECT sensor.

Installation Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.

Notice: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or
sealants are identified in the service procedure. Some replacement components may come with
these coatings already applied. Do not use these coatings on components unless specified. These
coatings can affect the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid damage.

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1. Coat the sensor threads with sealer GM P/N 1050805, or equivalent.

2. Install the ECT sensor (1)

Tighten
Tighten the sensor to 20 N·m (15 lb ft).

3. Connect the connector to the ECT sensor .

4. Refill the coolant system. Refer to Cooling System Draining and Filling in Engine Cooling.

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Evaporative Emission Canister Purge Solenoid Valve

Replacement
Removal Procedure
1. Remove the engine sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

2. Disconnect the evaporative emission EVAP canister purge solenoid electrical connector (5).
3. Disconnect the EVAP purge pipe (4) from the EVAP canister purge solenoid.
4. Partially open the throttle.

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5. Remove the EVAP canister purge solenoid retaining bolt (2).

6. Remove the EVAP canister purge solenoid (3) from the intake manifold (1).

Installation Procedure
Important: Be sure to install the new O-ring on the EVAP purge solenoid.

1. Partially open the throttle.

2. Position the EVAP canister purge solenoid (3) on the intake manifold (1).

3. Install the EVAP canister purge solenoid valve retaining bolt (2).

Tighten
Tighten the bolt to 10 N·m (89 lb in).

4. Allow the throttle to close.

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5. Reconnect the EVAP purge pipe (4) to the EVAP canister purge solenoid.
6. Reconnect the EVAP canister purge solenoid electrical connector (5).
7. Install the engine sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Evaporative Emission Canister Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect EVAP purge pipe (3), vapor pipe (2) and vent hose/pipe (1) from the EVAP
canister.

3. Remove the three EVAP canister bracket retaining nuts (2).

4. Remove the canister ©
(1)2014
from the EVAP
General Motorscanister bracket
Corporation. (3).
All rights reserved.

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Installation Procedure

1. Install the EVAP canister (1) to the EVAP canister bracket (3) and position on the underbody.

2. Install the three EVAP canister bracket retaining nuts (2).

Tighten
Tighten the nuts to 6 N·m (53 lb in).

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3. Connect the EVAP purge pipe (3), vapor pipe (2) and vent hose/pipe (1) to the EVAP
canister.
4. Lower the vehicle.

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Evaporative Emission Canister Vent Solenoid Valve

Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the EVAP canister vent solenoid harness connector.

3. Disconnect the hose from the EVAP canister vent solenoid.
4. Remove the EVAP canister vent solenoid bolt.
5. Remove the EVAP canister vent solenoid from the vehicle.

Installation Procedure

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1. Position the EVAP canister vent solenoid on the vehicle.

2. Install the EVAP canister purge vent solenoid valve retaining bolt.

Tighten
Tighten the bolt to 6 N·m (53 lb in).

3. Connect the hose to the EVAP canister vent solenoid.

4. Connect the EVAP vent valve harness connector.
5. Lower the vehicle.

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Evaporative Emission Hoses/Pipes Replacement -

Canister/Fuel Tank
Removal Procedure

1. Remove the fuel tank (5). Refer to Fuel Tank Replacement .

2. Disconnect the EVAP vapor hose/pipe (1) from the fill limiter vent valve.
3. Remove the EVAP vapor hose/pipe from the fuel tank (5).

Installation Procedure

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1. Position the EVAP vapor hose/pipe (1) on the fuel tank (5).
2. Connect the EVAP vapor hose/pipe (1) to the fuel limiter vent valve.
3. Install the fuel tank. Refer to Fuel Tank Replacement .
4. Lower the vehicle.

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Evaporative Emission Hoses/Pipes Replacement -

Engine/Chassis
Removal Procedure
1. Remove the chassis fuel pipe bundle. Refer to Fuel Hose/Pipes Replacement - Filter to
Engine .

2. Separate the purge pipe from the fuel pipe bundle.

Installation Procedure

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1. Install the EVAP purge pipe in the fuel pipe bundle.

2. Install the fuel pipe bundle. Refer to Fuel Hose/Pipes Replacement - Filter to Engine .

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Evaporative Emission System Cleaning

Tools Required
J 41413 EVAP Pressure/Purge Diagnostic Station

Inspection Procedure
Notice: Use the EVAP Pressure/Purge Diagnostic Station J 41413 in order to provide a clean, dry,
low pressure gas source. Do not substitute any other pressurized gas source. Damage may result
to the EVAP system.

Important: Proceed with the following procedure only if referenced by a EVAP diagnostic or
repair procedure.

1. Turn OFF the ignition.

2. Remove the EVAP canister purge valve. Refer to Evaporative Emission Canister Purge
Solenoid Valve Replacement .
3. Lightly tap the EVAP canister purge valve on a hard surface.
4. Inspect for carbon particles exiting either of the vacuum ports.
• If no carbon particles were detected, but a blockage was detected during a diagnostic
procedure. Install the original EVAP canister purge valve and continue with the cleaning
procedure.
• If carbon particles are found during the inspection procedure. Replace the EVAP canister
purge valve and continue with the cleaning procedure.
• If a diagnostic procedure directed you to replace the EVAP canister purge valve and no
carbon particles were detected. Replace the EVAP canister purge valve and return to the
published service procedure.

Cleaning Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
3. Turn OFF the main valve on the J 41413 .
4. Disconnect the hose from the diagnostic station pressure regulator.
5. Using a section of vacuum hose, connect one end onto the diagnostic station pressure
regulator.
6. Connect the other end of the vacuum hose to the canister side of the purge pipe.
7. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
8. If the nitrogen does not dislodge the carbon particles, replace the purge pipe. Refer to
Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis .
9. Return the J 41413 to original condition.
10. Install a new EVAP canister. Refer to Evaporative Emission Canister Replacement .
11. Lower the vehicle.
12. Install a new EVAP canister purge valve. Refer to Evaporative Emission Canister Purge
Solenoid Valve Replacement .
13. Return to the published service procedure.

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Exhaust Gas Recirculation (EGR) System Cleaning

Caution: Avoid breathing fumes and swallowing EGR exhaust deposits when removing components
for cleaning as bodily injury may result.

Whenever the EGR valve is removed the EGR system should be inspected and cleaned if necessary.
This will ensure that the EGR system will function properly under all operating conditions. Proper
EGR system service consists of the following 5 steps:

1. EGR system diagnosis. Diagnosis of the EGR system should be performed if PCM DTCs are
set .
2. EGR valve pipe cleaning and checking for leaks. Clean and check the EGR pipe from the
exhaust manifold to the EGR valve and the EGR pipe from the water pump crossover to the
throttle body spacer. Refer to Exhaust Gas Recirculation Pipe Replacement .
3. EGR valve cleaning. If the EGR system is operating correctly, the EGR valve can be removed,
checked for deposits, cleaned, and re-installed. Use the procedure below for this operation.
3.1. Remove the EGR valve from the engine. Refer to Exhaust Gas Recirculation Valve
Replacement .
3.2. While holding the EGR valve in your hand, use a pencil eraser or other suitable soft
instrument to depress the pintle several times. The pintle should move in and out
smoothly. Replace any valve that exhibits tendencies to stick.
3.3. While holding the EGR valve base in your hand, try to rotate the connector housing.
Repeat for the coil housing. Replace any valve that exhibits looseness.
3.4. Inspect the EGR valve pintle and seat for deposits. Use a cloth or other suitable soft
device to remove deposits. Remove all loose particles. If the deposits are such that
pintle/base interface cannot be cleaned adequately to allow the pintle to seal against
the seat, replace the valve. Damage to the powdered metal EGR valve base will occur if
cleaned with solvents, sharp tools, a wire brush or wheel, or by sand blasting. Cleaning
by these methods is not recommended.
3.5. Inspect the passage in the water crossover assembly for deposits. Remove all loose
particles.
3.6. Replace EGR valve on the engine using a new gasket. Refer to Exhaust Gas
Recirculation Valve Replacement .

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4. Cleaning the EGR passages in the water crossover assembly.

4.1. Remove the water crossover assembly. Refer to Engine Coolant Crossover Pipe
Replacement in Engine Cooling.
4.2. Remove the 2 plugs (2) and clean the passages with a wire brush. Remove all loose
particles.
4.3. Re-install the water crossover assembly. Refer to Engine Coolant Crossover Pipe
Replacement in Engine Cooling.
5. Wash-up with soap and water after any contact with deposits from the EGR system.

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Exhaust Gas Recirculation Pipe Replacement

Exhaust Gas Recirculation (EGR) Inlet Pipe
Removal Procedure

1. Remove the mounting bolt (2) that attaches the EGR inlet pipe flange to the coolant
crossover assembly (5).
2. Remove the nut that attaches the EGR inlet pipe flare to the rear exhaust manifold.

Installation Procedure

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1. Hand tighten the flange mounting bolt (2) to the coolant crossover assembly (4).

2. Attach the EGR inlet pipe nut (3) to the rear exhaust manifold (4).

Tighten
• Tighten the nut to 60 N·m (44 lb ft).
• Tighten the mounting bolt to 24 N·m (18 lb ft).

Exhaust Gas Recirculation (EGR) Outlet Pipe

Removal Procedure

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1. Remove the mounting nuts (2) from the fuel injector sight shield .
2. Lift the injector sight shield off the mounting studs by lifting at the front (4) of the cover.

3. Remove the mounting bolts (1) retaining the outlet pipe upper flange to the intake manifold.
4. Remove the lower flange mounting bolt (2) from the coolant crossover assembly.
5. Remove the EGR outlet pipe.

Installation Procedure

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1. Install the EGR outlet pipe (3) between the intake manifold and the coolant crossover
assembly.

2. Install the lower flange mounting bolt (2) into the coolant crossover assembly.

Tighten
Tighten the bolt to 24 N·m (18 lb ft).

3. Install the upper flange mounting bolts (1) into the intake manifold.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

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4. Keeping the injector sight shield as level as possible, place the rear (1) of the shield under
the mounting bracket (6).
5. Align and press the injector sight shield (4) onto the mounting studs (5).
6. Install the mounting nuts (2) onto the mounting studs (5).

Tighten
Tighten the nuts to 3 N·m (27 lb in).

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Exhaust Gas Recirculation Valve Replacement

Removal Procedure

1. Remove the fuel lines from the EGR valve bracket.

2. Disconnect the electrical connector from the EGR valve (3).
3. Remove the mounting nuts from the valve bracket studs (4).
4. Remove the EGR valve bracket.
5. Remove the mounting studs (4) from the coolant crossover assembly (1).
6. Remove the EGR valve.

Ensure the valve mounting surface is clean and all gasket material is removed.

Installation Procedure

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1. Install the EGR valve (3) and a NEW gasket (2) to the coolant crossover assembly (1).

2. Install the EGR valve mounting studs.

Tighten
Tighten the studs to 24 N·m (18 lb ft).

3. Install the EGR valve bracket to the mounting studs (4) using the 2 nuts.

Tighten
Tighten the nuts to 19 N·m (14 lb ft).

4. Connect the electrical connector to the EGR valve (3).

5. Install the fuel lines into the EGR valve bracket.

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Filler Tube Replacement

Removal Procedure

1. Drain the fuel tank below the level of the fuel filler hose. Refer to Fuel Tank Draining .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the wheel house filler pipe opening cover (2).
4. Remove the fuel tank filler pipe ground wire bolt (4).

5. Remove the fuel filler©pipe

2014clamp.
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6. Remove the fuel filler pipe (1).

Installation Procedure

1. Install the fuel filler pipe (1).

2. Install the fuel filler pipe clamp.

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N·m (22 lb in).

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3. Install the fuel tank filler pipe ground wire attaching bolt (4).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

4. Install the wheel house filler pipe opening cover (2).

5. Lower the vehicle.
6. Add fuel to the fuel tank.
7. Install the fuel tank filler pipe cap.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
9. Inspect for fuel leaks.
9.1. Turn ON the ignition for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical - 3.5L.

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Fuel Filter Replacement

Removal Procedure

Important:
• There is no service interval for fuel filter replacement. Only replace the fuel filter if
restricted.
• Inspect the fuel tank internally and clean the fuel tank if you find a restricted fuel filter.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Disconnect the quick-connect fitting (4) at the fuel filter inlet. Refer to Plastic Collar Quick
Connect Fitting Service .
4. Disconnect the threaded fitting at the fuel filter outlet.
5. Drain any remaining fuel into an approved gasoline container.
6. Remove the fuel pipe O-ring.

Installation Procedure

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1. Remove the protective caps from the new fuel filter.

2. Install the new plastic connector retainer on the fuel filter inlet. Install the new retainer in the
same position as on the old fuel filter.
3. Lubricate the new fuel pipe O-ring with clean engine oil.
4. Install the fuel pipe O-ring.
5. Slide the fuel filter into place.
6. Connect the quick-connect fitting (4) to the fuel filter inlet. Refer to Plastic Collar Quick
Connect Fitting Service .

7. Connect the threaded fitting to the fuel filter outlet. Use a back-up wrench in order to
prevent the fuel filter from turning.

Tighten
Tighten the fuel filter fitting to 30 N·m (22 lb ft).

8. Lower the vehicle.

9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
10. Inspect for fuel leaks.
10.1. Turn ON the ignition for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition.
10.4. Inspect for fuel leaks.

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Fuel Hose/Pipes Replacement - Filter to Engine

Tools Required
J 37088-A Fuel Line Quick-Connect Tools

Removal Procedure
Caution: In order to reduce the risk of fire and personal injury observe the following items:
• Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not
attempt to repair the sections of the nylon fuel pipes
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
Damage to the nylon pipes may result in a fuel leak.
• Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never
expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or
more than 90°C (194°F) for any extended period.
• Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe
fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal
operation, the O-rings located in the female connector will swell and may prevent proper
reconnection if not lubricated.)

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt
and other contaminants from entering the open pipes and passages.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .

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2. Clean all the engine fuel pipe connections and areas surrounding the connections before
disconnecting the pipes to avoid contamination of the fuel system.
3. Disconnect the fuel feed (1) fuel return (5) quick-connect fittings from the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service .

4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Disconnect the fuel line on the engine-side of the in-line fuel filter. Refer to Plastic Collar
Quick Connect Fitting Service .
6. Cap the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop
any fuel leakage.

Important: Partially lowering the engine cradle may be necessary.

7. Remove the fuel feed, the fuel return, and the evaporative emission (EVAP) pipe attaching

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hardware and pipes. Note the position of the hardware for the installation.
8. Inspect the pipes for bends, kinks, and cracks.
9. Repair or replace the pipes as required.

Installation Procedure
Caution: In order to reduce the risk of fire and personal injury observe the following items:
• Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not
attempt to repair the sections of the nylon fuel pipes
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
Damage to the nylon pipes may result in a fuel leak.
• Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never
expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or
more than 90°C (194°F) for any extended period.
• Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe
fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal
operation, the O-rings located in the female connector will swell and may prevent proper
reconnection if not lubricated.)

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

Notice:
• Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm
(½ inch) clearance around a pipe in order to prevent contact and chafing. Maintain a
minimum of 19 mm (¾ inch) around any moving part.
• Do not allow the fuel pipes to come into contact with the fuel tank or underbody.

1. Install the new fuel feed, fuel return, and EVAP pipes and attaching hardware as noted during

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the removal.
2. Remove the caps from the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe.

3. Install the new plastic connector retainers on the fuel pipes.

4. Connect the line at the in-line fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
5. Lower the vehicle.
6. Connect the fuel feed (1) and fuel return (2) line quick-connect fitting to the fuel rail. Refer
to Metal Collar Quick Connect Fitting Service .
7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
8. Perform the following procedure to check for fuel leaks:
8.1. Turn ON the ignition switch to the position for 2 seconds.
8.2. Turn OFF the ignition switch to the for 10 seconds.
8.3. Turn ON the ignition switch to the position.
8.4. Check for fuel leaks.

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9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Fuel Hoses/Pipes Replacement - Filter to Tank

Removal Procedure
Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt
and other contaminants from entering the open pipes and passages.

Important: Always maintain cleanliness when servicing the fuel system components.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

2. Disconnect the fuel pipes (2,3) at the fuel sender assembly. Refer to Plastic Collar Quick
Connect Fitting Service .
3. Cap the fuel sender fuel pipes and the fuel filter area pipes as needed in order to stop any
fuel leakage.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon
fuel feed or return pipes in order to prevent damage to the vehicle.

4. Remove the fuel pipe-attaching hardware.

5. Remove the fuel feed and the fuel return pipes.
6. Note the position of the fuel pipes and the fuel pipe-attaching hardware for installation.

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• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
Damage to the nylon pipes may result in a fuel leak.
• Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never
expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or
more than 90°C (194°F) for any extended period.
• Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe
fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal
operation, the O-rings located in the female connector will swell and may prevent proper
reconnection if not lubricated.)

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

Notice: Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM
specifications for those parts. The replacement EVAP pipe must have the same type of fittings as
the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the
hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose
within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic
converter.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel
feed or return pipes in order to prevent damage to the vehicle.

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1. Install the new fuel feed and the fuel return pipes and the fuel pipe-attaching hardware as
noted during the removal.
2. Remove the caps from the fuel filter area pipes and from the fuel sender fuel pipes.
3. Connect the fuel feed pipes (2,3) at the fuel sender assembly. Refer to Plastic Collar Quick
Connect Fitting Service .
4. Inspect all the fuel pipe bundle clips and fasteners for correct installation.
5. Install the fuel tank. Refer to Fuel Tank Replacement .

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Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
Notice:
• Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical
connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is
removed in order to avoid damaging the fuel rail components.
• Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and
other contaminants from entering open pipes and passages.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if
necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning
solvent.
3. Disconnect the fuel feed and return pipes (4, 5) from the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service .

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4. Disconnect the fuel pressure regulator vacuum hose (1).

5. Disconnect the fuel injector electrical connectors (1) from each fuel injector.

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6. Release the 4 snap-lock tabs on the fuel rail assembly by pushing toward the camshaft
covers and lifting.
7. Remove the fuel rail (1).
8. Remove the injector lower O-ring seal from the spray tip end of each injector.
9. Discard the O-ring seals.

Installation Procedure
Notice:
• Use care when servicing the fuel system components, especially the fuel injector electrical
connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports
of the fuel rail in order to prevent contamination.
• Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail
components.
• Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the
fuel rail assembly.

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1. Lubricate the new lower injector O-ring seals with clean engine oil.
2. Install the new O-ring seals on the spray tip end of each injector.
3. Install the fuel rail assembly (1) onto the intake manifold. A snap will be heard when the
injectors are properly seated.

4. Connect the fuel injector electrical connectors (1) to each fuel injector.

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5. Connect the fuel pressure regulator vacuum hose (1).

6. Connect the fuel feed and return pipes (4,5) to the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service .
7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
8. Inspect for fuel leaks.
8.1. Turn ON the ignition for 2 seconds.
8.2. Turn OFF the ignition for 10 seconds.
8.3. Turn ON the ignition.
8.4. Inspect for leaks.
9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-3.5 L.

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Fuel Injector Replacement

Tools Required
J 43013 Fuel Injector Removal Tool

Removal Procedure
Notice: Use care in removing the fuel injectors in order to prevent damage to the fuel injector
electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of
cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

Important: If the fuel injectors are leaking, the engine oil may be contaminated with fuel.

1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
2. Remove the fuel injector retaining clip (3).
3. Using J 43013 , remove the fuel injector (5) from the fuel rail.

© 2014 General Motors Corporation. All rights reserved.

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4. Remove and discard the upper O-ring (3).

5. Remove and discard the lower O-ring (2).

Installation Procedure
Important:
• Use the correct part number when ordering replacement fuel injectors.
• The fuel injector O-rings should always be replaced whenever the fuel injectors are serviced.
Install the correct O-ring for the fuel injector. If the O-ring is not seated properly a vacuum
leak is possible, and driveability complaints may occur.

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1. Lubricate the new upper (3) and lower (2) O-rings with clean engine oil.
2. Install the new O-rings on the fuel injector.

3. Install the fuel injector (5) onto the fuel rail.

4. Snap the fuel injector retaining clip (3) onto the injector and fuel rail.
5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .

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Fuel Level Sensor Replacement

Removal Procedure

Important: Always maintain cleanliness when servicing fuel system components.

1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
2. Disconnect the fuel level sensor harness connector from under the top of the fuel sender
assembly.
3. Remove the fuel level sensor (5) from the fuel sender assembly.

Installation Procedure

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1. Install the fuel level sensor (5) to modular fuel sender.

2. Connect the fuel level sensor harness connector.
3. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

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Fuel Pressure Gage Installation and Removal

Tools Required
J 34730-1A Fuel Pressure Gage

Installation Procedure
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-3.5L.

Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk
of fire and personal injury. The towel will absorb any fuel leakage that occurs during the
connection of the fuel pressure gage. Place the towel in an approved container when the
connection of the fuel pressure gage is complete.

Notice: Clean all of the following areas before performing any disconnections in order to
avoid possible contamination in the system:
• The fuel pipe connections
• The hose connections
• The areas surrounding the connections

2. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail.
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3. Turn ON the ignition.

Caution: Do not drain the fuel into an open container. Never store the fuel in an open
container due to the possibility of a fire or an explosion.

4. Place the bleed hose of the J 34730-1A into an approved gasoline container.
5. Open the bleed valve on the J 34730-1A in order to bleed the air from the J 34730-1A .
6. Command the fuel pump ON with a scan tool.
7. Close the bleed valve on the J 34730-1A .
8. Inspect for fuel leaks.

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Fuel Pressure Regulator Replacement

Removal Procedure

1. Relieve the fuel pressure. Refer to Fuel Pressure Relief .

2. Clean any dirt from the fuel pressure regulator.
3. Disconnect the fuel pressure regulator vacuum line.
4. Remove the fuel pressure regulator retainer clip (1).
5. Pull and twist the fuel pressure regulator (6) in order to remove the regulator from the fuel
rail. Use a shop towel to catch any spilled fuel.
6. Remove the regulator lower O-ring (2).
7. Remove the filter (3).
8. Remove the regulator upper O-ring (4).
9. Remove the back-up ring (5).
10. Cover the fuel pressure regulator housing in order to prevent contaminants from entering the
fuel system.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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Notice:
• Do not use compressed air in order to test or clean a fuel pressure regulator as damage
to the fuel pressure regulator may result.
• Clean the fuel pressure regulator filter screen with gasoline if necessary.
• Do not immerse the fuel pressure regulator in a solvent bath in order to prevent
damage to the fuel pressure regulator.

1. Install new O-rings on the fuel pressure regulator if a new regulator is not being installed.
Lubricate the O-rings lightly with clean engine oil.
2. Install the back-up ring (5).
3. Install the upper O-ring (4).
4. Install the filter (3).
5. Install the lower O-ring (2).
6. Install the fuel pressure regulator (6) into the fuel rail.
7. Install the fuel pressure regulator retainer clip (1).
8. Connect the fuel pressure regulator vacuum line.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
10. Inspect for fuel leaks.
10.1. Turn ON the ignition for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition.
10.4. Inspect for fuel leaks.
11. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-3.5 L.

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Fuel Pressure Relief

Tools Required
J 34730-1A Fuel Pressure Gage

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition
source is present. Never drain or store gasoline or diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the
fuel system in order to reduce the risk of personal injury. After you relieve the fuel system
pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel
injection pump, or the connections. In order to reduce the risk of personal injury, cover the
fuel system components with a shop towel before disconnection. This will catch any fuel that
may leak out. Place the towel in an approved container when the disconnection is complete.

1. Turn the ignition OFF.

2. Disconnect the negative battery cable in order to avoid possible fuel discharge if an
accidental attempt is made to start the engine. Refer to Battery Negative Cable
Disconnection and Connection in Engine Electrical.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-3.5 L.

4. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting
while connecting the gauge in order to avoid spillage. Refer to Fuel Pressure Gage Installation
and Removal .
5. Install the bleed hose into an approved container.
6. Open the valve in order to bleed the system pressure. The fuel connections are now safe for
servicing.
7. Drain any fuel remaining in the gauge into an approved container.
© 2014 General Motors Corporation. All rights reserved.

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Fuel Pressure Service Valve Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the fuel pressure connection valve (2) using a standard valve core removal and
installation tool.

Installation Procedure

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1. Install the fuel pressure connection valve assembly (2) using a standard valve core removal
and installation tool.
2. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
3. Inspect for fuel leaks.
3.1. Turn ON the ignition switch for 2 seconds.
3.2. Turn OFF the ignition switch for 10 seconds.
3.3. Turn ON the ignition switch.
3.4. Inspect for fuel leaks.
4. Install the cap (1) on the fuel pressure connection valve.
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-3.5L.

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Fuel Sender Assembly Replacement

Tools Required
J 39765 Fuel Sender Lock Nut Wrench

Removal Procedure
Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a
trunk. To reduce the risk of fire and increased exposure to vapors:
• Use forced air ventilation such as a fan set outside of the trunk.
• Plug or cap any fuel system openings in order to reduce fuel vapor formation.
• Clean up any spilled fuel immediately.
• Avoid sparks and any source of ignition.
• Use signs to alert others in the work area that fuel system work is in process.

1. Relieve the fuel system pressure. Refer to Plastic Collar Quick Connect Fitting Service .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the rear compartment floor trim.
4. Remove the fuel sender access panel bolts.
5. Remove the fuel sender access panel.

© 2014 General Motors Corporation. All rights reserved.

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Notice: In order to prevent damage, cover the fuel pipe fittings with a shop towel before
disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any
fuel that may leak out. Place the towel in an approved container when procedure is
completed.

6. Disconnect the fuel sender quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting
Service .
7. Disconnect the fuel sender electrical connector.
8. Disconnect the fuel tank pressure sensor electrical connector.

Important: The modular fuel sender assembly will spring-up when the locking ring is
removed.

9. Remove the fuel sender retaining ring using the J 39765 .

Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage
generated by handling the fuel pipes could damage the joints.

Important: When removing the fuel sender assembly from the fuel tank, the reservoir
bucket on the fuel sender is full of fuel. The fuel sender must be tipped slightly during
removal in order to avoid damage to the float. Place any remaining fuel into an approved
container once the fuel sender is removed from the fuel tank.

10. Remove the fuel sender assembly.

11. Clean the fuel sender sealing surfaces.
12. Inspect the fuel sender sealing surfaces.

Installation Procedure

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Important: Care should be taken not to fold over or twist the fuel pump strainer when
installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel
pump strainer does not block full travel of the float arm.

Important: Always replace the fuel sender seal when reinstalling the fuel sender.

1. Position the new fuel sender seal on the fuel tank.

2. Install the fuel sender assembly and the fuel sender lock ring using the J 39765 .
3. Connect the quick-connect fittings at the fuel sender. Refer to Plastic Collar Quick Connect
Fitting Service .
4. Connect the fuel sender electrical connector.
5. Connect the fuel tank pressure sensor electrical connector.
6. Add fuel to the fuel tank.
7. Install the fuel tank filler pipe cap.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
9. Inspect for leaks.
9.1. Turn ON the ignition for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.

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10. Install the fuel sender access panel.

11. Install the fuel sender access panel bolts.

Tighten
Tighten the fuel sender access panel bolts to 2 N·m (18 lb in).

12. Install the rear compartment floor trim.

13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Fuel System Cleaning

Important:
• Only use oil-free compressed air in order to blow out the fuel pipes. If the fuel filter is
plugged, the fuel tank should be inspected internally and cleaned if necessary.
• When flushing the fuel tank, handle the fuel and water mixture as a hazardous material.
Handle the fuel and water in accordance with all applicable local, state, and federal laws and
regulations.
• Whenever the fuel tank is cleaned, the fuel pump strainer must be inspected. If the fuel pump
fuel strainer is contaminated, the fuel pump fuel strainer must be replaced, and the fuel pump
must be inspected.
• Always maintain cleanliness when servicing the fuel system components.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

2. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
3. Inspect the fuel pump strainer for dirt and debris. Replace the fuel sender assembly if the
fuel strainer is contaminated.
4. Flush the fuel tank with hot water.
5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in
order to be sure that the removal of the water from the fuel tank is complete.
6. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
7. Install the fuel tank. Refer to Fuel Tank Replacement .
8. Replace the fuel filter. Refer to Fuel Filter Replacement .

© 2014 General Motors Corporation. All rights reserved.

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Fuel Tank Draining

Caution: Never drain or store fuel in an open container. Always use an approved fuel storage
container in order to reduce the chance of fire or explosion.

Caution: Drain the fuel tank to at least 3/4 of a tank before removing the fuel sender retaining
ring or fuel sender access panel in order to avoid possible fuel spillage. Failing to follow this
procedure could result in personal injury.

Notice: Drain the fuel tank with a hose which has a 13 mm (0.5 in) or smaller diameter in order to
prevent the drain hose from getting stuck inside the fuel tank filler neck pipe check valve. Damage
to the check valve may result.

Notice: Drain the fuel from the complete system, including injector nozzle(s), the fuel pump, all
fuel pipes, and the fuel tank if a vehicle is to be stored for any appreciable length of time. Draining
the fuel will prevent the formations of fuel system deposits.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the fuel tank filler pipe cap (1).

3. Drain the fuel through the fuel tank filler pipe by using a hand or air operated fuel pump
device.

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Fuel Tank Pressure Sensor Replacement

Removal Procedure
1. Remove the rear compartment floor trim.

2. Remove the fuel sender access panel bolts.

3. Remove the fuel sender access panel.

4. Disconnect the fuel tank pressure sensor electrical connector.

5. Remove the fuel tank pressure sensor.
© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure

1. Install the fuel tank pressure sensor.

2. Connect the fuel tank pressure sensor electrical connector.

3. Install the fuel sender access panel.

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installing fasteners in order to avoid damage to parts and systems.

4. Install the fuel sender access panel bolts.

Tighten
Tighten the fuel sender access panel bolts to 2 N·m (18 lb in).

5. Install the rear compartment floor trim.

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Fuel Tank Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the wheel house filler pipe opening cover (2).
5. Disconnect the fuel fill hose from the fuel fill pipe.
6. Remove the rear suspension support assembly. Refer to Support Replacement in Rear
Suspension.

© 2014 General Motors Corporation. All rights reserved.

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7. Disconnect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Plastic Collar Quick
Connect Fitting Service .

8. Disconnect the evaporative emission (EVAP) pipe (2) from the EVAP canister.

9. Remove the fuel and EVAP retainer from the frame.

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10. Disconnect the fuel tank electrical connector.

11. Disconnect the fuel tank electrical harness from the retainers.

12. Remove the fuel tank strap bolts (4).

13. Remove the fuel tank (5).

Disassemble Procedure

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1. If the fuel tank is not being replaced refer to the Installation Procedure.
2. Remove the fuel pipes (2, 3) and the EVAP pipe (1).
3. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

4. Remove the fuel filler hose clamp (2).

5. Remove the fuel filler hose from the fuel tank (3).

Assemble Procedure

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1. Install the fuel filler hose to the fuel tank (3). Align the dot on the hose to the parting line on
the fuel tank.

2. Install the fuel filler hose clamp (2).

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).

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3. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
4. Install the fuel pipes (2,3) and the EVAP pipe (1).

Installation Procedure

1. Position and support the fuel tank (5) with the aid of an assistant.
2. Install the fuel tank straps (2).

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

3. Install the fuel tank strap bolts (4).

Tighten
Tighten the fuel tank retaining strap bolts to 47 N·m (35 lb ft).

4. Connect the fuel tank electrical connector.

5. Install the fuel tank electrical harness into the retainers.

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6. Install the fuel and EVAP retainer to the frame.

7. Connect the EVAP pipe (2) to the EVAP canister.

8. Connect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Plastic Collar Quick
Connect Fitting Service .

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9. Install the rear suspension support assembly. Refer to Support Replacement in Rear
Suspension.
10. Connect the fuel filler hose to the fuel tank filler pipe.

Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).

11. Install the wheelhouse filler pipe opening cover (2).

12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel tank filler pipe cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
16. Inspect for leaks.
16.1. Turn ON the ignition for 2 seconds.
16.2. Turn OFF the ignition for 10 seconds.
16.3. Turn ON the ignition.
16.4. Inspect for fuel leaks.
17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Heated Oxygen Sensor Replacement - Sensor 1

Tools Required
J 39194-B Heated Oxygen Sensor Wrench

Removal Procedure
Notice: Remove oxygen sensors with the engine temperature above 48°C (120°F).
Otherwise the oxygen sensors may be difficult to remove.

Notice: Take care when handling oxygen sensors. The electrical connector and louvered end
must be kept free of contaminants. Do not use cleaning solvents on the sensor. Do not drop
or mishandle the sensor.

Important: A special anti-seize compound is used on the oxygen sensor threads. New
service sensors should already have the compound applied to the threads. Coat the threads
of a reused sensor with anti-seize compound GM PN 12377953 or equivalent.

If a sensor is reused, install a new gasket GM PN 01555476 or equivalent .

1. Disconnect the HO2S electrical connector.

2. Remove the electrical connector from the mounting hole.
3. Remove the HO2S from the exhaust manifold using J 39194-B .

Installation Procedure
© 2014 General Motors Corporation. All rights reserved.

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Important: Ensure that the correct replacement HO2S is used. The engine HO2S 1 and the
post-converter HO2S 2 are both 6.6-watt Denso sensors. Due to differences in the pigtail
length, the sensors use different connectors and are not interchangeable.

1. Install the HO2S in the rear exhaust manifold using J 39194-B .

Tighten
Tighten the HO2S to 41 N·m (30 lb ft).

2. Install the electrical connector into the mounting hole.

3. Connect the HO2S electrical connector.

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Heated Oxygen Sensor Replacement - Sensor 2

Tools Required
J 39194-B Heated Oxygen Sensor Wrench

Removal Procedure

1. Raise the vehicle.

2. Remove the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring
Harness Heat Shield Replacement in Engine Exhaust.
3. Disconnect the HO2S electrical connector (1).
4. Remove the electrical connector from the mounting hole.
5. Remove the HO2S from the exhaust pipe using the J 39194-B .

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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Important: Ensure that the correct replacement HO2S is used. The engine HO2S 1 and the
post-converter HO2S 2 are both 6.6-watt Denso sensors. Due to differences in pigtail length,
the sensors use different connectors and are not interchangeable.

1. Install the HO2S in the rear exhaust pipe using the J 39194-B .

Tighten
Tighten the HO2S to 41 N·m (30 lb ft).

2. Install the electrical connector into the mounting hole.

3. Connect the HO2S electrical connector (1).
4. Reinstall the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring
Harness Heat Shield Replacement in Engine Exhaust.
5. Lower the vehicle.

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Idle Air Control Valve Replacement

Removal Procedure
1. Turn OFF the ignition.

2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical.

3. Remove the electrical harness (4) from the idle air control (IAC) valve (1).
4. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve
Replacement . © 2014 General Motors Corporation. All rights reserved.

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5. Remove the IAC valve attaching screws (3) from the IAC valve (2).
6. Remove the IAC valve (2) from the throttle body.
7. Remove the O-ring from the IAC valve.

Installation Procedure
Notice: The IAC valve may be damaged if installed with the cone (pintle) extended more than
28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a new valve.
The distance from the idle air control valve motor housing to the end of the idle air control valve
pintle should be less than 28 mm (1-1/8 in). Manually compress the pintle until the extension is
less than 28 mm (1-1/8 in).

1. Install the new idle air control O-ring on the IAC valve.

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2. Install the IAC valve (2) into the throttle body.

3. Install the IAC valve attaching screws (3).

Tighten
Tighten the screws to 3.0 N·m (27 lb in).

4. Connect the harness connector (4) to the IAC valve (1).

5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .

Important: The PCM will reset the IAC valve whenever the ignition switch is turned ON, then
OFF.

6. Turn ON the ignition with the engine OFF.

7. Turn OFF the ignition for 5 seconds.
8. Start the engine and allow the engine to reach a normal operating temperature and check for
proper operation.

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9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Ignition Coil Replacement

Tools Required
J 43094 Spark Plug Boot Puller

Removal Procedure

1. Remove the mounting nuts retaining the injector sight shield.

2. Lift the injector sight shield off the mounting studs by lifting at the front (4) of the cover.

© 2014 General Motors Corporation. All rights reserved.

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3. Disconnect the electrical connector from the ignition control module.

4. Remove the 7 bolts (2) retaining the ignition cassette to the cam cover.

5. Gently pry the cassette (2) away from the cam cover (3) using a screwdriver. Protect finished
surfaces from scratches with a shop cloth. Pry a small amount in several locations around the
edge of the cassette in order to lift the assembly as evenly as possible. Do not insert the
screwdriver far enough to tear the perimeter seal on the cassette.
6. On some vehicles the oil level indicator tube may interfere with the removal of the front bank
coil cassette. Remove the bolt retaining the oil level indicator tube and move the oil level
indicator tube if necessary.
7. Lift the cassette straight up off the spark plugs.

8. Remove the secondary boots (3) from the spark plugs or the ignition coils using a twisting

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motion to break the seal. Use the J 43094 . Do not use pliers, screwdrivers, or any
unauthorized tool to remove the boots.

9. Remove the cover (4) from the ignition coils (3).

10. Remove the ignition control module retaining screws (1).
11. Remove the ignition control module (2).

Installation Procedure
Important: When servicing the ignition system components, use the following recommended
procedures:
• Do not re-install any component that has visible signs of damage.
• Check the boots for a missing or damaged internal spring.
• Ensure that the boots are installed right-side up.
• Ensure that the ignition cassette-to-cam cover ground spring (2) is in place.
• Repair a torn perimeter seal with an RTV sealant.
• Clean all the mounting surfaces before re-installing any components.

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1. Install the ignition control module (2) on the ignition coils.

2. Install the ignition control module retaining screws (1).

Tighten
Tighten the retaining screws to 1.1 N·m (10 lb in).

3. Install the cover (4) on the ignition coils (3).

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4. Install the boots (3) on the ignition coils until the boots bottom out.

5. Install the cassette assembly (2) straight down onto the spark plugs.

If this is not possible due to space limitations (rear bank), just-start the boots onto the spark
plugs and then align and start the ignition coil towers into the boots. Press the ignition
cassette (2) down on the plugs as straight as possible.

6. Install the 7 bolts (2) that retain the ignition cassette to the cam cover .

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Tighten
Tighten the bolts to 9.5 N·m (84 lb in).

7. Connect the electrical connector to the ignition control module.

8. If the oil level indicator tube was moved during disassembly, move the tube back into
position and install the retaining bolt.

Tighten
Tighten the retaining bolt to 9 N·m (80 lb in).

9. Keeping the injector sight shield as level as possible, place the rear (1) of the shield under
the mounting bracket (6).
10. Align and press the injector sight shield (4) onto the mounting studs (5).
11. Install the mounting nuts (2) onto the mounting studs (5).

Tighten
Tighten the mounting nuts to 3 N·m (27 lb in).

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Ignition Control Module Replacement

Removal Procedure

1. Disconnect the electrical connector from the ignition control module (ICM).

2. Remove the cover (4) from the ignition coils (3).

3. Remove the screws (1) retaining the ICM .
4. Remove the ignition control module (2).
© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure
Important: When servicing the ignition system components, use the following recommended
procedures:
• DO NOT re-install any component that has visible signs of damage.
• Clean all the mounting surfaces before re-installing any components.

1. Install the ignition control module (2) on the ignition coils.

2. Install the ICM retaining screws (1).

Tighten
Tighten the screws to 1.1 N·m (10 lb in).

3. Install the cover (4) on the ignition coils (3).

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4. Connect the electrical connector to the ignition control module (1).

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Intake Air Temperature Sensor Replacement

Removal Procedure

1. Disconnect the electrical connector (2) from the intake air temperature (IAT) sensor (1).
Object Number: 292996 Size: SH

2. Grasp and rotate the IAT counterclockwise to unlock the sensor and remove from the air
cleaner cover.

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Installation Procedure

Object Number: 292996 Size: SH

1. Position and insert the IAT sensor into the air cleaner cover and rotate clockwise to lock.

2. Connect the electrical connector (2) to the IAT sensor (1).

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Knock Sensor Replacement

Removal Procedure

1. Raise the vehicle.

2. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Disconnect and reposition the jumper harness connector.
4. Disconnect the electrical connector from the knock sensor.
5. Remove the knock sensor (1) from the engine block.

Installation Procedure
Important: When replacing the knock sensor, use the following recommended procedures:
• A dropped or over-torqued sensor is considered bad and should be replaced.
• Check all of the connectors for any damaged terminals.
• Clean all of the mounting surfaces before re-installing any components.

© 2014 General Motors Corporation. All rights reserved.

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1. Install the knock sensor (1) into the engine block.

Tighten
Tighten the sensor to 15 N·m (11 lb in).

2. Connect the electrical connector to the knock sensor.

3. Install the jumper harness connector.
4. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
5. Lower the vehicle.

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Manifold Absolute Pressure Sensor Replacement

Removal Procedure

1. Remove the mounting nuts (2) from the injector sight shield .
2. Lift the injector sight shield off the mounting studs by lifting at the front (4) of the cover.

3. Remove the MAP sensor (1) from the intake manifold.

4. Disconnect the electrical connector from the MAP sensor .
5. Inspect the MAP sensor grommet
© 2014 Generalfor wear
Motors or damage,
Corporation. and reserved.
All rights replace as needed.

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Installation Procedure

1. Connect the electrical connector to the MAP sensor .

2. Apply a small amount of lubrication to the MAP sensor grommet.
3. Install the MAP sensor (1) to the intake manifold.

4. Keeping the injector sight shield as level as possible place the rear (1) of the shield under the
mounting bracket (6).
5. Align and press the injector sight shield (4) onto the mounting studs (5).

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

6. Install the mounting nuts (2) onto the mounting studs (5).

Tighten
Tighten the mounting nuts to 3 N·m (27 lb in).

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Mass Airflow Sensor Replacement

Removal Procedure

1. Disconnect the electrical connector (3) from the mass air flow (MAF) sensor .
2. Loosen the 2 band clamps located on either side of the MAF sensor (4).
3. Disconnect the intake air duct of the throttle body from the MAF sensor.

Notice: Do not damage the MAF sensor screen. A damaged screen could restrict airflow and
lead to a driveability concern.

4. Remove the MAF sensor from the air cleaner assembly.

Installation Procedure
Notice: Do not damage the MAF sensor screen. A damaged screen could restrict airflow and
lead to a driveability concern.

Important: The MAF sensor must be mounted with the air flow direction arrow located on
top of the MAF sensor pointing with air flow toward the throttle body. Ensure that the MAF
sensor locating tabs and the locating slots of the intake air ducts line up before connecting
the MAF sensor and the intake air ducts.

1. Insert the MAF sensor into the air cleaner assembly duct.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread
© 2014 locking compound
General Motors or sealant
Corporation. arereserved.
All rights identified in the service

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Connect the intake air duct to the MAF sensor.

Tighten
Tighten the 2 band clamps to 3.5 N·m (31 lb in).

3. Connect the electrical connector to the MAF sensor .

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Metal Collar Quick Connect Fitting Service

Tools Required
J 37088-A Fuel Line Disconnect Tool Set

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the retainer from the quick-connect fitting.

Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause
eye injury.

3. Blow dirt out of the fitting using compressed air.

© 2014 General Motors Corporation. All rights reserved.

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4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into
the female connector, then push inward to release the locking tabs.

5. Pull the connection apart.

Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a
radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections
for dirt and burrs. Clean or replace the components and assemblies as required.

6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as
required.

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Installation Procedure

Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may
prevent proper reconnection if not lubricated.

1. Apply a few drops of clean engine oil to the male pipe end.

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2. Push both sides of the fitting together to cause the retaining tabs to snap into place.

3. Once installed, pull on both sides of the fitting to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.

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Plastic Collar Quick Connect Fitting Service

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

2. Blow dirt out of the fittings using compressed air.

© 2014 General Motors Corporation. All rights reserved.

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3. Squeeze the plastic tabs of the male end connector.

4. Pull the connection apart.

Notice: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial
motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

5. Wipe off the male pipe end using a clean shop towel.
6. Inspect both ends of the fitting for dirt and burrs.
7. Clean or replace the components as required.

Installation Procedure
Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings,
always apply a few drops of clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent
proper reconnection if not lubricated.

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1. Apply a few drops of clean engine oil to the male pipe end.

2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to
snap into place.

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3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.

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Powertrain Control Module Programming (Off-Board

Programming)
Before Programming a Control Module
Important:
• Do NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporation service bulletin. Programming a control module at
any other time will not permanently correct a customer's concern.
• The Off-Board Programming is used in situations where a control module must be
programmed without having the vehicle present. The Off-Board Programming Adapter must
be used to perform the Off-Board Programming procedure. The adapter allows the control
module to power up and allows the Tech 2® to communicate with the control module.
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.

Ensure that all connections are secure at the following locations:

• The Off-Board Programming Adapter

• The Tech 2®
• The control module
• The Techline® terminal

Off-Board Programming
1. Obtain the VIN of the vehicle for which the control module is being programmed.
2. With the Techline® terminal, select Service Programming.
3. Select Tech 2®, Reprogram ECU, and Off-Board Programming Adapter as the ECU location.
4. Connect the control module, Off-Board Programming Adapter, and the Tech 2® as described
on the Techline® terminal. Ensure you use the correct harness connector from the Off-Board
Programming Adapter kit.
5. With the Tech 2®, select Service Programming Request Information function. The Tech 2®
communicates with the control module and receives the access code.
6. With the Tech 2®, exit the Service Programming Request Information.
7. Disconnect the Tech 2® from the Off-Board Programming Adapter.
8. Connect the Tech 2® to the Techline® terminal.
9. Turn ON the Tech 2®.
10. With the Techline® terminal, enter the VIN of the vehicle that will be receiving the control
module.
11. The Techline® terminal will display the message, attaching to database.
12. Identify what type of programming that you are performing.
13. Select the appropriate calibration file.
14. Ensure all connections are secure.
15. The Techline® terminal displays a summary screen that summarizes your selections. After
confirming you choices, the Techline® terminal automatically loads the calibration files to the
Tech 2®.
16. After the download is complete, turn OFF the Tech 2®.
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17. Disconnect the Tech 2® from the Techline® terminal.

18. Connect the Tech 2® to the Off-Board Programming Adapter.
19. With the Tech 2®, select Service Programming.

Important: DO NOT turn OFF the Off-Board Programming Adapter if the programming
procedure is interrupted or unsuccessful. Ensure the control module and the Off-Board
Programming Adapter connections are secure and the Techline® operating software is up to
date. Attempt to reprogram the control module. If the control module cannot be
programmed, replace the control module.

20. With the Tech 2®, select Program.

21. After the download is complete, exit Service Programming.
22. Turn OFF the Off-Board Programming Adapter.

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Powertrain Control Module Programming (Remote

Programming)
Before Programming a Control Module
Important: Do NOT program a control module unless you are directed by a service procedure or
you are directed by a General Motors Corporation service bulletin. Programming a control module
at any other time will not permanently correct a customers concern.

Ensure the following conditions are met before programming a control module:

• Vehicle system voltage

- There is no charging system concern. All charging system concerns must be repaired before
programming a control module.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged
before programming the control module if the battery voltage is low.
- A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or
voltage fluctuations from a battery charger, may cause programming failure or control
module damage.
- Turn OFF or disable any system that may put a load on the vehicle's battery.
• Twilight Sentinel
• Interior Lights
• Daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the DRL
system. Refer to the Owners manual.
• HVAC systems
• Engine cooling fans etc.
• The ignition switch is in the proper position. The scan tool prompts you to turn ON the
ignition, with the engine OFF. Do NOT change the position of the ignition switch during the
programming procedure, unless instructed to do so.
• All tool connections are secure.
- RS-232
- The connection at the DLC is secure.
- Voltage supply circuits
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.

Remote Programming
1. Turn OFF the ignition.
2. Install the Tech 2® to the data link connector (DLC).
3. Turn ON the ignition, with the engine OFF.
4. Turn OFF all vehicle accessories.
5. With the Tech 2®, select Service Programming.
6. Identify vehicle information as requested
© 2014 General by the Tech
Motors Corporation. All 2®.
rights reserved.

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7. Select the type of module you are programming.

8. Select the type of programming to be performed.
9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual
VIN, write down the actual VIN and correct the VIN at the Techline® terminal.
10. When complete, Exit Service Programming.
11. Turn OFF the Tech 2® and disconnect the Tech 2® from the vehicle.
12. Turn OFF the ignition.
13. Connect the Tech 2® to the Techline® terminal.
14. Select Service Programming.
15. Select Tech 2® as the tool you are using.
16. Select the type of programming to be performed.
17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary.
18. Select the type of module you are programming.
19. Identify what type of programming that you are performing.
• Normal--This type of programming is for updating an existing calibration or programming
a new controller.
• Vehicle Configuration Index (VCI)--This selection is used if the vehicle VIN is unavailable
or not recognized by the Techline® terminal. Observe, you will need to contact the
Techline® Customer Support center to use this option.
• Reconfigure--This is to reconfigure a vehicle, such as tire size and axle ratio changes.
20. Select the appropriate calibration file.
21. Ensure all connections are secure.
22. Select Reprog to initiate the download of the new calibration to the Tech 2®.
23. After the download is complete, turn OFF the Tech 2®.
24. Disconnect the Tech 2® from the Techline® terminal.
25. Install the Tech 2® to the data link connector (DLC).
26. Turn ON the Tech 2®.
27. Turn ON the ignition, with the engine OFF.
28. Select Service Programming.

Important: DO NOT turn OFF the ignition if the programming procedure is interrupted or
unsuccessful. Ensure that all the exclaim and DLC connections are secure and the Techline®
operating software is up to date. Attempt to reprogram the control module. If the control
module cannot be programmed, replace the control module. Refer to Powertrain Control
Module Replacement .

29. Select Program.

30. After the download is complete, EXIT Service Programming.
31. Turn OFF the ignition for 30 seconds.
32. Turn OFF the Tech 2®.
33. If a control module is replaced the following service procedures must be performed:
• The Crankshaft Variation Learn Procedure
• The Engine Oil Life Reset Procedure
• The Idle Learn Procedure
• The Inspection/Maintenance Complete System Set Procedure
• The Vehicle Theft Deterrent Password Learn Procedure
• The TP Sensor Learn Procedure

Programming Verification
1. With a scan tool, clear the DTCs.

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2. Attempt to start the engine.

3. Repeat the Service Programming procedure if the engine does not start or operates poorly.
Perform the following procedures before programming the PCM:
• Ensure the control module and DLC connections are OK.
• Ensure the Techline® operating software is up to date.
• Ensure the calibration part number is correct for the vehicle.
4. Attempt to program the control module. If the control module still cannot be programmed
properly, replace the control module. Refer to Powertrain Control Module Replacement . You
must program the replacement control module.

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Powertrain Control Module Replacement

Service of the powertrain control module (PCM) should normally consist of either replacement of
the PCM or electronically eraseable programmable read only memory (EEPROM) programming. If
the diagnostic procedures call for PCM replacement, check the PCM first to see if the PCM is the
correct part. If the PCM is faulty, remove the PCM and install the new service PCM.

The new service PCM will not be programmed. You must program the new PCM. DTC P0602
indicates the EEPROM is not programmed or has malfunctioned.

Notice: In order to prevent possible electrostatic discharge damage to the PCM, do not touch the
connector pins or soldered components on the circuit board.

There are no user serviceable parts in this PCM. The PCM should never be opened for any reason.

Notice: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in
order to prevent internal PCM damage.

Important: When replacing the production PCM with a service PCM, transfer the broadcast code
and production PCM number to the service PCM label. Do not record the information on the PCM
cover. This will allow positive identification of the PCM parts throughout the service life of the
vehicle.

Removal Procedure
Important: It is necessary to record the remaining engine oil life. If the replacement module
is not programed with the remaining engine oil life, the engine oil life will default to 100%. If
the replacement module is not programmed with the remaining engine oil life, the engine oil
will need to be changed at 5000 km (3,000 mi) from the last engine oil change.

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining
engine oil life.

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2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
3. Remove the left strut brace.
4. Loosen the band clamp (2) at the throttle body (1), and disconnect the air duct (3) from the
throttle body.
5. Disconnect the electrical connectors for the intake air temperature (IAT) sensor and the mass
air flow (MAF) sensor .

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6. Loosen the retaining screw (2) for the air cleaner cover .
7. Remove the air cleaner cover (1) and lift the PCM (3) from the housing assembly.

8. Disconnect the harness connectors (2) from the PCM (1).

9. Remove the PCM from the engine compartment.

Installation Procedure
Notice: Refer to Fastener Notice in the Preface section.

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1. Install the connectors (2) to the PCM (1).

Tighten
Tighten the connectors to 8 N·m (71 lb in).

2. Install the PCM (3) into the air cleaner housing assembly.
3. Install the air cleaner housing cover (1).
4. Tighten the retaining screw (2) for the air cleaner cover .

5. Reconnect the air duct (3) to the throttle body (1), and tighten the band clamp (2) at the
throttle body .
6. Reconnect the electrical connectors for the IAT sensor and the MAF sensor .
7. Install the strut brace.

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8. Connect the negative battery cable.

9. If a new PCM is being installed, program the EEPROM. Refer to Powertrain Control Module
Programming .

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Secondary Air Injection Crossover Pipe/Hose

Replacement
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the fasteners from the front portion of the splash shield in the left front wheel well.
Refer to Wheelhouse Panel Replacement in Body and Accessories.
3. Reposition the splash shield in order to gain access to the pump and bracket assembly.
4. Compress the pinch clamp and remove the outlet hose (3) from the pump.
5. Reposition the hose into the engine compartment.
6. Remove the crossover pipe (4) fasteners.
7. Lower the vehicle.
8. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
9. Remove the master cylinder fasteners.
10. Reposition the master cylinder.
11. Remove the crossover pipe fasteners.
12. Remove the crossover pipe from the shut-off valves and the vehicle.

Installation Procedure
1. Install the crossover pipe to the shut-off valves and the vehicle.
2. Install the crossover pipe fasteners.
3. Reposition the master cylinder to the booster.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread
© 2014 locking compound
General Motors or sealant
Corporation. arereserved.
All rights identified in the service

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

4. Install the master cylinder fasteners.

Tighten
Tighten the fasteners to 23 N·m (17 lb ft).

5. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement .
6. Raise the vehicle.

7. Install the crossover pipe fasteners.

Tighten
Tighten all of the fasteners to 9 N·m (80 lb in).

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8. Compress the pinch clamp and install the outlet hose to the pump.
9. Raise the wheel well splash shield into position.
10. Install the fasteners to the wheel well splash shield.
11. Lower the vehicle.

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Secondary Air Injection Manifold/Pipe Replacement -

Bank 1
Removal Procedure

1. Remove the coolant recovery tank.

2. Loosen the shut-off valve bracket fasteners (3).
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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4. Remove the shut-off valve outlet pipe (1) to the AIR manifold fasteners.

5. Remove the AIR manifold fasteners (4).

6. Remove the AIR manifold from the outlet pipe and vehicle (3).
7. Clean gasket surfaces as necessary.

Installation Procedure

1. Install the AIR manifold to the outlet pipe and vehicle (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners

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2. Install the AIR manifold bolts (4).

Tighten
Tighten the bolts to 10 N·m (89 lb in).

3. Install the shut-off valve outlet pipe (1) to the AIR manifold fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Lower the vehicle.

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5. Tighten the shut-off valve bracket fasteners (3)

Tighten
Tighten the shut-off valve bracket fasteners to 25 N·m (18 lb ft).

6. Install the coolant recovery tank.

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Secondary Air Injection Manifold/Pipe Replacement -

Bank 2
Removal Procedure

1. Loosen the shut-off valve bracket fasteners (2).

2. Remove the oil indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine
Mechanical.

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3. Remove the shut-off valve outlet pipe to the AIR manifold fasteners (3).

4. Remove the AIR manifold fasteners (4).

5. Remove the AIR manifold (3) from the outlet pipe and vehicle.
6. Clean gasket surfaces as necessary.

Installation Procedure

1. Install the AIR manifold (3) to the outlet pipe and vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners

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2. Install the AIR manifold bolts (4).

Tighten
Tighten the bolts to 10 N·m (89 lb in).

3. Install the shut-off valve outlet pipe to the AIR manifold fasteners (2).

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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4. Tighten the shut-off valve bracket fasteners.

Tighten
Tighten the shut-off valve bracket fasteners to 25 N·m (18 lb ft).

5. Install the oil indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine
Mechanical.

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Secondary Air Injection Pump Inlet Filter Replacement

Removal Procedure

Installation Procedure

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1. Install the filter (2) to hose (1).

2. Install the band clamp.
3. Raise the wheel well splash shield into position.
4. Install the fasteners to the wheel well splash shield.
5. Lower the vehicle.

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Secondary Air Injection Pump Inlet Hose/Duct

Replacement
Removal Procedure

Installation Procedure

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1. Install the inlet hose (3) to the pump.

2. Install the band clamp.
3. Raise the wheel well splash shield into position.
4. Install the fasteners to the wheel well splash shield .
5. Lower the vehicle.

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Secondary Air Injection Pump Outlet Pipe/Hose

Replacement
Removal Procedure

Compress the pinch clamp and remove the outlet hose from the crossover pipe.

Installation Procedure

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1. Compress the pinch clamp and install the outlet hose (3) to the crossover pipe.
2. Raise the vehicle.
3. Compress the pinch clamp and install the outlet hose to the pump.
4. Raise the wheel well splash shield into position.
5. Install the fasteners to the wheel well splash shield .
6. Lower the vehicle.

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Secondary Air Injection Pump Replacement

Removal Procedure

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7. Reposition pump to gain access to the electrical connector.

8. Disconnect the pump electrical connector.
9. Remove the pump from the vehicle.
10. Transfer parts as necessary.

Installation Procedure

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1. Connect the pump electrical connector.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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2. Attach the pump to the bracket using the fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

3. Install the inlet hose to the pump.

4. Compress the pinch clamp and install the outlet hose to the pump (3).
5. Raise the wheel well splash shield into position. Refer to Wheelhouse Panel Replacement in
Body front end.
6. Install the fasteners to the wheel well splash shield.
7. Lower the vehicle.

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Secondary Air Injection Shut-Off Valve Outlet

Pipe/Hose Replacement - Bank 1
Removal Procedure

1. Remove the power steering hose to the shut-off valve bracket fastener.
2. Remove the shut-off valve to the outlet pipe fasteners.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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4. Remove the shut-off valve outlet pipe (1) to the AIR manifold fasteners (2).
5. Remove the outlet pipe (1) from the vehicle.
6. Clean the gasket surfaces as necessary.

Installation Procedure

1. Install the outlet pipe (1) to the vehicle.

2. Install the outlet pipe (1) to the AIR manifold fasteners (2).

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

3. Lower the vehicle.

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4. Install the shut-off valve to outlet pipe fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

5. Install the power steering hose retainer to the shut-off valve bracket bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

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Secondary Air Injection Shut-Off Valve Outlet

Pipe/Hose Replacement - Bank 2
Removal Procedure

1. Remove the shut-off valve to the outlet pipe fasteners.

2. Remove the shut-off valve outlet pipe to AIR manifold fasteners (2).
3. Remove the outlet pipe from the vehicle.
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4. Clean gasket surfaces as necessary.

Installation Procedure

1. Install the outlet pipe to the vehicle (1) .

2. Install the outlet pipe to the AIR manifold fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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3. Install the shut-off valve to outlet pipe fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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Secondary Air Injection Shutoff Valve Replacement -

Bank 1
Removal Procedure

1. Remove the coolant recovery tank.

2. Remove the vacuum line (6) from shut-off valve.

3. Remove the shut-off valve to the outlet pipe and bracket fasteners.
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4. Remove the shut-off valve (2) from the bracket and hose.
5. Clean the gasket surfaces as necessary.

Installation Procedure

1. Install the shut-off valve (2) to the bracket and hose.

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2. Install the shut-off valve to outlet pipe fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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3. Install the vacuum line (6) to the shut-off valve.

4. Install the coolant recovery tank.

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Secondary Air Injection Shutoff Valve Replacement -

Bank 2
Removal Procedure

1. Remove the vacuum line (3) from shut-off valve.

2. Remove the shut-off valve to the outlet pipe and bracket fasteners.
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3. Remove the shut-off valve (1) from the bracket and hose.
4. Clean gasket surfaces as necessary.

Installation Procedure

1. Install the shut-off valve (1) to the bracket and hose.

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2. Install the shut-off valve to outlet pipe fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

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3. Install the vacuum line (3) to the shut-off valve.

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Secondary Air Injection Vacuum Check Valve

Replacement
Removal Procedure

1. Remove the injector sight shield (4) fasteners.

2. Remove the injector sight shield from the vehicle.

3. Remove the vacuum lines from the check valve (5).

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4. Remove the check valve.

Installation Procedure

1. Install the injector sight shield to the vehicle.

2. Install the injector sight shield (4) nuts.

Tighten
Tighten the nuts to 3 N·m (27 lb in).

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Secondary Air Injection Vacuum Control Solenoid Valve

Replacement
Removal Procedure

1. Remove the injector sight shield fasteners (2).

2. Remove the injector sight shield (4) from the vehicle.
3. Disconnect the electrical connector from the solenoid.

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4. Remove the vacuum lines (1) from the solenoid.

5. Remove the solenoid bracket fasteners.
6. Remove the solenoid and bracket assembly from the vehicle.
7. Remove the solenoid to bracket fastener.
8. Remove the solenoid from the bracket.

Installation Procedure

1. Install the solenoid to the bracket.

2. Install the solenoid to bracket screws.

Tighten
Tighten the screws to 10 N·m (89 lb in).

3. Install the bracket and solenoid assembly to the vehicle.

4. Install the bracket and solenoid assembly bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

5. Install the vacuum lines to the solenoid (1).

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6. Install the electrical connector to the solenoid.

7. Install the injector sight shield (4) to the vehicle.
8. Install the injector sight shield nuts.

Tighten
Tighten the nuts to 3 N·m (27 lb in).

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Spark Plug Inspection

Spark Plug Usage
• l Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Ignition System Specifications for the correct spark plug.
• l Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling--Colder plug
- Pre-ignition causing spark plug and/or engine damage--Hotter plug

Spark Plug Inspection

•

l Inspect the terminal post (1) for damage.

- Inspect for a bent or broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1)
should NOT move.
•

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l Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the
electrical charge traveling across the insulator (2) between the terminal post (1) and ground.
Inspect for the following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
•

l Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the
crack instead of the electrodes (3, 4).
•

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l Inspect for evidence of improper arcing.

• l Measure the gap between the center electrode (4) and the side electrode (3) terminals.
Refer to Ignition System Specifications . An excessively wide electrode gap can prevent
correct spark plug operation.
• l Inspect for the correct spark plug torque. Refer to Ignition System Specifications .
Insufficient torque can prevent correct spark plug operation. An over torqued spark plug,
causes the insulator (2) to crack.
• l Inspect for signs of tracking that occurred near the insulator tip instead of the center
electrode (4).
• l Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
• A rattling sound indicates internal damage.
• A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates
the gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), If equipped.
- Inspect for excessive fouling.
• l Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged
threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

• l Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
• l Carbon Fouled--Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
• Leaking fuel injectors

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• Excessive fuel pressure

• Restricted air filter element
• Incorrect combustion
- Reduced ignition system voltage output
• Weak coils
• Worn ignition wires
• Incorrect spark plug gap
- Excessive idling or slow speeds under light loads can keep spark plug temperatures so low
that normal combustion deposits may not burn off.
• l Deposit Fouling--Oil, coolant, or additives that include substances such as silicone, very
white coating, reduces the spark intensity. Most powdery deposits will not effect spark
intensity unless they form into a glazing over the electrode.

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Spark Plug Replacement

Tools Required
J 43094 Spark Plug Boot Puller

Removal Procedure
1. Turn OFF the ignition switch.
2. Remove the ignition coil assembly. Refer to Ignition Coil Replacement in Engine Controls-
3.5L.
3. Use the J 43094 in order to remove the spark plug boots from the spark plugs.

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 of any
contamination.

4. Remove the spark plugs from the engine.

Installation Procedure
Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs
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that are either hotter or colder than those specified for the vehicle. Installing spark plugs of
another type can severely damage the engine.

Notice: Check the gap of all new and reconditioned spark plugs before installation. The pre-
set gaps may have changed during handling. Use a round feeler gage to ensure an accurate
check. Installing the spark plugs with the wrong gap can cause poor engine performance and
may even damage the engine.

1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to
the gap specifications. Refer to Ignition System Specifications . Correct as necessary.

Notice: Be sure that the spark plug threads smoothly into the cylinder head and the spark
plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head.
Cross-threading or failing to fully seat the spark plug can cause overheating of the plug,
exhaust blow-by, or thread damage.

2. Install the spark plugs to the engine.

Tighten
Tighten the spark plug to 20 N·m (15 lb ft).

3. Install the spark plug boots to the ignition coil assembly.

4. Install the ignition coil assembly. Refer to Ignition Coil Replacement in Engine Controls-3.5L.

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Throttle Body Assembly Replacement

Removal Procedure
Notice: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold
and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may
result.

Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as
sharp tools may damage the gasket surfaces.

1. Turn OFF the ignition.

2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical.

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3. Drain the radiator coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the air cleaner intake duct (3). Refer to Air Cleaner Inlet Duct Replacement .

5. Disconnect the idle air control (IAC) valve sensor electrical connector (4).
6. Disconnect the throttle position (TP) sensor electrical connector (3).

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7. Disconnect the cruise control cable from the throttle body lever. Refer to Cruise Control Cable
Replacement in Cruise Control.

8. Disconnect the accelerator control cable from the throttle body lever. Refer to Cruise Control
Cable Replacement in Cruise Control.

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9. Disconnect the fuel pressure regulator vacuum hose (1).

10. Disconnect the positive crankcase ventilation (PCV) valve hose (1).
11. Disconnect the throttle body vacuum port hose (2).

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12. Disconnect the throttle body coolant hoses.

13. Remove the accelerator controls cable bracket, leaving the accelerator and cruse cables
connected. Refer to Accelerator Control Cable Bracket Replacement .
14. Remove the upper nut holding the throttle body to the intake manifold (1).
15. Remove the throttle body assembly (3).
16. Clean the gasket surface on the intake manifold (1) and the throttle body assembly.

Installation Procedure
Important: The throttle should operate freely without binding between full closed and wide open
throttle.

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1. Install a new gasket (2), and new studs if necessary.

2. Install the throttle body assembly (3).
3. Finger start the top nut.
4. Connect the throttle body coolant hoses.
5. Position the accelerator controls bracket (4).

6. Finger start the accelerator controls bracket retaining nuts and bolt.

Tighten
• Tighten the three throttle body retaining nuts to 10 N·m (89 lb in).
• Tighten the accelerator bracket retaining bolt to 13 N·m (115 lb in).

7. Connect the throttle body vacuum port hose (2).

8. Connect the PCV valve hose (1).

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9. Connect the fuel pressure regulator vacuum hose (1).

10. Connect the accelerator controls cable to the throttle body lever. Refer to Accelerator Control
Cable Replacement .

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11. Connect the cruise control cable to the throttle body lever. Refer to Cruise Control Cable
Replacement in Cruise Control.

12. Connect the IAC valve sensor electrical connector (4).

13. Install the TP sensor electrical connector (3).

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14. Install the air intake duct (3). Refer to Air Cleaner Inlet Duct Replacement .
15. Refill the radiator to replace the lost coolant. Refer to Cooling System Draining and Filling in
Engine Cooling.

16. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Throttle Body Inspection and Cleaning

Removal Procedure

1. Remove the air cleaner intake duct (3). Refer to Air Cleaner Inlet Duct Replacement .
2. Open and inspect the throttle body bore and the throttle valve plate for surface deposits.

Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may
damage fuel system components.

3. Clean the throttle body bore and the throttle valve plate with GM PN 1052626 Top Engine
Cleaner or AC-Delco PN X66-P Carburetor Tune-Up Conditioner, or equivalent, using a clean
shop towel .

Installation Procedure

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1. Install the intake duct assembly (3) to the air cleaner . Refer to Air Cleaner Inlet Duct
Replacement .

2. Install the air cleaner intake duct clamps.

Tighten
Tighten the clamp to 2 N·m (18 lb in).

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Throttle Position Sensor Replacement

Removal Procedure
1. Turn OFF the ignition.

2. Remove the electrical connector (3) from the throttle position (TP) sensor (2).
3. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve
Replacement .

4. Remove the 2 throttle position (TP) sensor mounting bolts (4) from the TP sensor (5).
5. Remove the TP sensor© (5)
2014from theMotors
General throttle body (7).
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6. Remove the O-ring (6) from the TP sensor (5).

7. Discard the O-ring.

Installation Procedure

1. Install the new O-ring (6) onto the TP sensor (5).

2. Install the TP sensor (5) on to the throttle body (7).

3. Install the 2 TP sensor screws.

Tighten
Tighten the screws to 2.3N·m (20 lb in).

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4. Install the electrical connector (3) to the TP sensor (2).

5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .

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Fastener Tightening Specifications

Specification
Application Metric English
Accelerator Controls Cable Bracket Bolts 12 N·m 106 lb in
Air Cleaner Element / PCM Housing Cover Screws 4 N·m 35 lb in
Camshaft Position Sensor 10 N·m 89 lb in
Crankshaft Position (CKP) Sensors 10 N·m 89 lb in
EGR Crossover Pipe Bolt 24 N·m 18 lb ft
EGR Pipe Nut 60 N·m 44 lb in
Engine Coolant Temperature (ECT) Sensor 20 N·m 15 lb ft
Exhaust Gas Recirculation (EGR) Valve Bolt 24 N·m 18 lb ft
EVAP Canister 6 N·m 53 lb in
EVAP Canister Purge Valve Bolt 12 N·m 106 lb in
EVAP Vent Valve Bolt 6 N·m 53 lb in
Fuel Filler Pipe Attaching Ground Bolt 9 N·m 80 lb in
Fuel Filler Pipe Hose Clamps 3.5N·m 31 lb in
Fuel Injector Sight Shield Nuts 2.3 N·m 20 lb in
Fuel Rail Assembly Studs 10 N·m 89 lb in
Fuel Rail End-Point Bracket Bolt 10 N·m 89 lb in
Fuel Sender Access Panel 2 N·m 18 lb in
Fuel Sender Access Panel Bolts 2 N·m 18 lb in
Fuel Tank Filler Pipe Ground Wire Bolt 9 N·m 80 lb in
Fuel Tank Retaining Strap Bolts 42 N·m 31 lb ft
Heated Oxygen Sensor (HO2S) 41 N·m 30 lb ft
Idle Air Control Valve Attaching Bolts 3 N·m 27 lb in
Ignition Coil Cassette 9 N·m 80 lb in
Ignition Control Module Screws 0.8 N·m 7 lb in
In-Line Fuel Filter Outlet Nut 30 N·m 22 lb ft
Intake Air Duct Clamps 3 N·m 27 lb in
Knock Sensor (KS) 25 N·m 18 lb ft
MAF/IAT Sensor Clamps 3 N·m 27 lb in
MAP Sensor Retaining Bracket 12 N·m 106 lb in
PCM Connector Screws 8 N·m 71 lb in
Rear Frame Bolts 100 N·m 74 lb ft
Secondary Air Injection (AIR) System (if equipped) Bolts/Nuts (pumps,
9 N·m 80 lb in
Shutoff valves, etc.)
17- 13-
Spark Plugs
23 N·m 16 lb ft
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Throttle Body Attaching Bolts 12 N·m 106 lb in

Throttle Position (TP) Sensor Attaching Screws 3 N·m 27 lb in

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Fuel System Specifications

Fuel (Premium Required)
The following information appears in the General Motors Owner's Manual for this vehicle.

Use premium unleaded gasoline rated at 91 octane or higher. At a minimum, it should meet
specifications ASTM D4814 in the United States and CGSB 3.5-M93 in Canada. Improved gasoline
specifications have been developed by the American Automobile Manufacturers Association (AAMA)
for better vehicle performance and engine protection. Gasolines meeting the AAMA specification
could provide improved driveability and emission control system protection compared to other
gasolines.

Be sure the posted octane for premium is at least 91. If the octane is less than 91, you may get a
heavy knocking noise when you drive. (In an emergency, you may be able to use a lower octane --
as low as 87 - if heavy knocking does not occur. If you are using 91 or higher octane unleaded
gasoline and you still hear heavy knocking, your engine needs service.

If your vehicle is certified to meet California Emission Standards (indicated on the underhood tune-
up label), it is designed to operate on fuels that meet California specifications. If such fuels are not
available in states adopting California emissions standards, your vehicle will operate satisfactorily
on fuels meeting federal specifications, but emission control system performance may be affected.
The malfunction indicator lamp on your instrument panel may turn on and/or your vehicle may fail
a smog-check test. If this occurs, return to a qualified service outlet for diagnosis to determine the
cause of failure. In the event it is determined that the cause of the condition is the type of fuels
used, repairs may not be covered by your warranty.

Some gasolines that are not reformulated for low emissions contain an octane-enhancing additive
called methylcyclopentadlenyl manganese tricarbonyl (MMT); ask your service station operator
whether or not this fuel contains MMT. General Motors does not recommend the use of such
gasolines. If fuels containing MMT are used, spark plug life may be reduced and your emission
control system performance may be affected. The malfunction indicator lamp on your instrument
panel may turn on. If this occurs, return to a qualified service outlet for service.

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Ignition System Specifications

Ignition System Specifications
Specification
Application Metric English
Firing Order 1-2-7-3-4-5-6-8
Spark Plug Gap 1.27 mm 0.050 in
Spark Plug Torque 17-23 N·m 13-16 lb ft
Spark Plug Type Denso

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Temperature Versus Resistance

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Vacuum Hose Routing

(1) PCV Valve

(2) AIR Control Valve
(3) AIR Vacuum Solenoid Valve
(4) Fuel Pressure Regulator
(5) EVAP Purge Pipe to EVAP Canister
(6) EVAP Canister Purge Valve
(7) Throttle Body
(8) AIR Control Valve
(9) Intake Manifold

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EVAP System Overview

(1) EVAP Canister Purge Solenoid

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AIR Pump Relays and Motors

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EVAP Vent Valve, EVAP Purge Solenoid, and EGR Valve

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Fuel Injectors

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Fuel Pump and Sender Assembly and Controls

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Ignition Control Modules

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MAF Sensor and IAC Valve

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Oxygen Sensors

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PCM Controls (1 of 2)

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PCM Controls (2 of 2)

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PCM Inputs

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Power to the PCM and Ignition Switch Circuits

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Sensors

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Single Air Pump System

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Accelerator Control Cable Bracket Replacement

Removal Procedure

1. Remove the cruise control cable (2) from the accelerator controls cable bracket (1).
2. Remove the accelerator cable (3) from the accelerator controls cable bracket (1).

3. Remove the fuel feed and return pipes from the accelerator controls cable bracket (1)
retainer.
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4. Remove the transaxle vent hose (2) clip from the accelerator controls cable bracket (1).

5. Remove the transaxle shift cable clip from the accelerator controls cable bracket.

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6. Remove the bolts from the accelerator controls cable bracket.

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1. Install the accelerator controls cable bracket.

Tighten
Tighten the bolts to 12 N·m (106 lb in).

2. Install the transaxle shift cable clip to the accelerator controls cable bracket.

3. Install the transaxle vent hose (2) clip to the accelerator controls cable bracket (1).

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4. Install the fuel feed and return pipes to the accelerator controls cable bracket (1) retainer.

5. Install the accelerator cable (3) to the accelerator controls cable bracket (1).

Important: Ensure that cables are not rubbing or binding in any manner. The throttle should
operate freely without bind between full closed and wide open throttle.

6. Install the cruise control cable (2) to the accelerator controls cable bracket (1).

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Accelerator Control Cable Replacement

Removal Procedure

1. Remove the left closeout/insulator panel replacement. Refer to Instrument Panel Insulator
Panel Replacement - Left Side in Instrument Panel, Gages and Console.
2. Remove the accelerator controls cable (1) from accelerator pedal (2).
3. Squeeze the accelerator controls cable cover tangs and push cable through the bulkhead.

4. Remove the accelerator controls

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5. Remove the accelerator controls cable (3) from the throttle body lever (2).

Installation Procedure
Notice: In order to prevent possible interference and damage, flexible components (hoses, wires,
conduits, etc.) must not be routed within 50 mm (2 in) of moving parts, unless the routing is
positively controlled.

Important: Accelerator controls cable must be routed through groove in throttle body lever
and seated securely.

1. Install the accelerator controls cable (3) to the throttle body lever (2).
2. Install the accelerator controls cable (3) at the accelerator controls cable bracket (1).

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3. Route the accelerator controls cable under brake master cylinder and through dash.
4. Install the retainer to the accelerator controls pedal.
5. Install the accelerator controls cable (1) to the accelerator controls pedal (3).

Important: Check for complete throttle opening and closing positions by operating the
accelerator controls pedal. Also check for poor carpet fit under the accelerator controls pedal.
The throttle should operate freely without binding between full closed and wide open throttle
(WOT).

6. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gages and Console.

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Accelerator Pedal Replacement

Removal Procedure
1. Remove the left instrument panel sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.

2. Remove the accelerator controls cable (1) from accelerator controls pedal (2).

3. Remove the accelerator controls pedal retainer (1) from the accelerator controls pedal.
4. Remove the accelerator controls pedal (2).
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Installation Procedure

1. Install the accelerator controls pedal (2).

2. Install the accelerator controls pedal retainer (3).

Important: Check for complete throttle opening and closing positions by operating the
accelerator pedal. Also check for poor carpet fit under the accelerator pedal.

The throttle should operate freely without binding between full closed and wide open throttle
(WOT).

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3. Install the accelerator controls cable (1) to accelerator controls pedal (2).
4. Install the left instrument panel sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.

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Air Cleaner Assembly Replacement

Removal Procedure
1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector.
2. Loosen the intake air duct clamp at the throttle body.
3. Lift the air cleaner element assembly off of the air inlet assembly locating pins.
4. Slide the air cleaner element assembly toward the fender in order to separate the air cleaner
element assembly from the air inlet assembly.
5. Remove the air cleaner element assembly and remove the intake air ducting from the throttle
body.
6. Loosen the clamp connecting the air cleaner element to the MAF/IAT sensor assembly.

Notice:
• Handle the MAF sensor carefully.
• Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
• Do not damage the screen located on the air inlet end of the MAF.
• Do not touch the sensing elements.
• Do not allow solvents and lubricants to come in contact with the sensing elements.
• Use a small amount of a soap based solution in order to aid in the installation.

7. Carefully separate the air cleaner element assembly from the MAF/IAT sensor assembly.

Installation Procedure
1. Install the air cleaner element.
2. Ensure the rubber locating grommets are secure in the bottom of the air cleaner element
assembly.
3. Slide the locating tab on bottom of the air cleaner element assembly down into the slot in the
air inlet assembly.
4. Press the air cleaner element assembly down onto the locating pins ensuring the locating
grommets are secure in the bottom of the air cleaner element assembly.

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5. Install the MAF/IAT sensor and intake air ducting along with the clamps between the air
cleaner element assembly and the throttle body.

Tighten
Tighten the clamps to 3 N·m (27 lb in).

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Air Cleaner Element Replacement

Removal Procedure
1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector.
2. Loosen the clamp connecting the intake air duct to the throttle body.
3. Disconnect the intake air from the throttle body.
4. Disengage both air cleaner cover latches.
5. Remove the air cleaner cover.

Important: Inspect the air cleaner housing assembly for damage. If a problem is found,
replace the assembly as necessary.

6. Remove the air filter element.

Installation Procedure
1. Install the new air cleaner element.
2. Install the air cleaner housing cover.
3. Engage the 2 latches connecting the cover to the air cleaner base.
4. Inspect to be sure that both latches are secured properly.

5. Install the intake air duct to the throttle body.

Tighten
Tighten the clamp assembly to 3 N·m (27 lb in).

6. Connect the MAF/IAT sensor electrical connector.

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Air Cleaner Inlet Duct Replacement

Removal Procedure
1. Disconnect the Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor electrical connector.
2. Loosen the air cleaner intake and MAF/IAT assembly clamps from the throttle body side and
from the air cleaner cover side.
3. Remove the air cleaner intake and MAF/IAT assembly from the vehicle.
4. Separate the air cleaner intake duct from the MAF/IAT sensor.

Installation Procedure
1. Combine the air cleaner intake duct and the mass air flow/intake air temperature (MAF/IAT)
sensor.
2. Install the air cleaner intake and the MAF/IAT assembly on the throttle body and on the air
cleaner cover.

3. Inspect for proper alignment of the air cleaner intake and MAF/IAT assembly and tighten the
hose clamps.

Tighten
Tighten the air cleaner intake and MAF/IAT assembly clamps to 3 N·m (27 lb in).

4. Connect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector.

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Camshaft Position Sensor Replacement

Removal Procedure

1. Remove the camshaft sensor electrical connector.

2. Remove the camshaft retaining bolt.
3. Remove the camshaft sensor.

Installation Procedure

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Important: Inspect the camshaft sensor O-ring for wear or damage. If a problem is found,
replace the O-ring.

1. Lubricate the camshaft O-ring with engine oil.

2. Install the camshaft sensor and sensor retaining bolt.

Tighten
Tighten the retaining bolt between 10 N·m (89 lb in).

3. Reconnect the camshaft sensor electrical connector.

4. Operate the engine, and inspect the camshaft sensor for engine oil leaks.

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Crankshaft Position Sensor Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the oil filter adaptor. Refer to Oil Filter Adapter Replacement in Engine Mechanical
4.0L.
3. Remove the crankshaft sensor electrical connector. For specific CKP sensor identification,
refer to Front of the Engine in Engine Controls Component Views .
4. Remove the crankshaft sensor retaining bolt.
5. Remove the crankshaft sensor.

Installation Procedure

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Important: Inspect the crankshaft sensor O-ring for wear or damage. If a problem is found,
replace the O-ring.

1. Lubricate the crankshaft sensor O-ring with clean engine oil.

2. Install the crankshaft sensor and the retaining bolt.

Tighten
Tighten the retaining bolt to 10 N·m (89 lb in).

3. Install the crankshaft sensor electrical connector.

4. Install the oil filter adaptor. Refer to Oil Filter Adapter Replacement in Engine Mechanical
4.0L.
5. Lower the vehicle.
6. Operate the engine and inspect crankshaft sensor for engine oil leaks.
7. Perform the Crankshaft Position System Variation Learn .

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Crankshaft Position System Variation Learn

After the powertrain control module (PCM) learns the amount of crankshaft position (CKP) system
variation, the PCM stores the compensating values in the non-volatile area of the electrically
erasable programmable read only memory (EEPROM). If the amount of crankshaft variation is
outside the stored values, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300.

Perform the Crankshaft Position System Variation Learn Procedure for any of the following
conditions:

• DTC P1336 is set

• PCM replacement
• Engine replacement
• Crankshaft replacement
• Crankshaft position sensor replacement
• Any engine repairs which disturbs the crankshaft to crankshaft position sensor relationship

1. Set the parking brake.

2. Block the drive wheels.
3. Ensure the hood is closed.
4. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F).
5. Turn OFF the ignition .
6. Select and enable the crankshaft position variation learn procedure with the scan tool.
7. Start the vehicle.
8. Apply and hold the service brake pedal firmly.
9. Ensure that the transaxle is in park.
10. Increase the accelerator pedal position until the fuel cutoff is reached at 5150 RPM.
Immediately release the accelerator pedal after fuel cutoff is reached.

The crankshaft position system variation compensating values are learned when the RPM
decreases back to idle.

11. Observe the DTC status for DTC P1336.

12. If the scan tool indicates that DTC P1336 ran and passed, the crankshaft position system
variation learn procedure is complete. If the scan tool indicates that DTC P1336 failed or did
not run, check for other DTCs. If no DTCs other than P1336 are set, repeat the crankshaft
position system variation learn procedure as necessary.

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Engine Coolant Temperature Sensor Replacement

Removal Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.

1. Turn OFF the ignition.

2. Drain the coolant to below the level of the engine coolant temperature (ECT) sensor. Refer to
Cooling System Draining and Filling in Engine Cooling.
3. Disconnect the ECT sensor (1).
4. Remove the ECT sensor.

Installation Procedure
Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the
operation of the fuel control system.

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1. Coat the sensor threads with sealer GM P/N 1050805, or equivalent.

2. Install the ECT sensor (1).

Tighten
Tighten the ECT sensor to 20 N·m (15 lb ft).

3. Connect the ECT connector to the ECT sensor.

4. Refill the coolant system. Refer to Cooling System Draining and Filling .

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Evaporative Emission Canister Purge Solenoid Valve

Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-4.0L.

2. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector (5).
3. Disconnect the EVAP purge pipe (4) from the EVAP canister purge valve (3).
4. Partially open the throttle.

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5. Remove the EVAP canister purge valve retaining bolt (2).

6. Remove the EVAP canister purge valve (3) from the intake manifold (1).

Installation Procedure
Important: You must install a new O-ring on the EVAP purge valve.

1. Partially open the throttle.

2. Position the EVAP canister purge valve (3) on the intake manifold (1).

3. Install the EVAP canister purge valve retaining bolt (2).

Tighten
Tighten the bolt to 12 N·m (106 lb in).

4. Allow the throttle to close.

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5. Connect the EVAP purge pipe (4) to the EVAP canister purge valve (3).
6. Connect the EVAP canister purge valve electrical connector (5).
7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Evaporative Emission Canister Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect EVAP purge pipe (3), vapor pipe (2) and vent hose/pipe (1) from the EVAP
canister.

3. Remove the EVAP canister bracket retaining nuts (2).

4. Remove the canister ©
(1)2014
from the EVAP
General Motorscanister bracket
Corporation. (3).
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Installation Procedure

1. Install the EVAP canister (1) to the EVAP canister bracket (3) and position the canister on the
underbody.

2. Install the EVAP canister bracket retaining nuts (2).

Tighten
Tighten the nuts to 6 N·m (53 lb in).

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3. Connect the EVAP purge pipe (3), vapor pipe (2) and vent hose/pipe (1) to the EVAP
canister.
4. Lower the vehicle.

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Evaporative Emission Canister Vent Solenoid Valve

Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the EVAP canister vent valve harness connector.

3. Disconnect the hose from the EVAP canister vent valve.
4. Remove the EVAP canister vent valve bolt.
5. Remove the EVAP canister vent valve from the vehicle.

Installation Procedure

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1. Position the EVAP canister vent valve on the vehicle.

2. Install the EVAP canister vent valve retaining bolt.

Tighten
Tighten the bolt to 6 N·m (53 lb in).

3. Connect the hose to the EVAP canister vent valve.

4. Connect the EVAP vent valve harness connector.
5. Lower the vehicle.

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Evaporative Emission Hoses/Pipes Replacement -

Canister/Fuel Tank
Removal Procedure
Notice:
• Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to
prevent damage to the vehicle.
• Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
• Replace the vapor pipes with original equipment or parts that meet GM specifications.
• Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only
reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the
hose.

1. Remove the fuel tank (5). Refer to Fuel Tank Replacement .

2. Disconnect the EVAP vent hose/pipe (1) from the fill limiter vent valve.
3. Remove the EVAP vent hose/pipe from the fuel tank (5).

Installation Procedure

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1. Position the EVAP vent hose/pipe (1) on the fuel tank (5).
2. Connect the EVAP vent hose/pipe (1) to the fuel limiter vent valve.
3. Install the fuel tank. Refer to Fuel Tank Replacement .
4. Lower the vehicle.

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Evaporative Emission Hoses/Pipes Replacement -

Engine/Chassis
Removal Procedure
1. Remove the chassis fuel pipe bundle. Refer to Fuel Hose/Pipes Replacement - Filter to
Engine .

2. Separate the purge pipe from the fuel pipe bundle.

Installation Procedure

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1. Install the EVAP purge pipe in the fuel pipe bundle.

2. Install the fuel pipe bundle. Refer to Fuel Hose/Pipes Replacement - Filter to Engine .

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Evaporative Emission System Cleaning

Tools Required
J 41413 EVAP Pressure/Purge Diagnostic Station

Important: Do not perform this procedure unless instructed by an EVAP diagnostic.

1. Turn OFF the ignition.

2. Remove the EVAP canister purge valve. Refer to Evaporative Emission Canister Purge
Solenoid Valve Replacement .
3. Lightly tap the EVAP canister purge valve on a clean hard surface.
4. Inspect for carbon particles exiting either of the vacuum ports.
• If no carbon particles are found reinstall the EVAP canister purge valve and continue with
the EVAP cleaning procedure.
• If carbon particles are found during the inspection procedure, replace the EVAP canister
purge valve and continue with the EVAP cleaning procedure. Refer to Evaporative
Emission Canister Purge Solenoid Valve Replacement .
• If you were instructed to replace the EVAP canister purge valve, and no carbon particles
are found, return to the EVAP diagnostic procedure. Do not perform the EVAP cleaning
procedure.

Cleaning Procedure
1. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
2. Turn OFF the main valve on the J 41413 EVAP pressure/purge diagnostic station.
3. Disconnect the hose from the diagnostic station pressure regulator.
4. Using a section of vacuum hose, connect 1 end to the diagnostic station pressure regulator.
5. Connect the other end of the vacuum hose to the canister side of the EVAP purge pipe.
6. Turn on the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
7. If the EVAP purge pipe is plugged and the nitrogen does not dislodge the carbon particles,
replace the EVAP purge pipe. Refer to Evaporative Emission Hoses/Pipes Replacement -
Engine/Chassis .
8. Return the EVAP Pressure/Purge Diagnostic Station to its original condition.
9. Install a new EVAP canister. Refer to Evaporative Emission Canister Replacement .
10. Lower the vehicle.
11. Continue with the published service manual diagnostic DTC procedure.

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Exhaust Gas Recirculation (EGR) System Cleaning

Caution: Avoid breathing fumes and swallowing EGR exhaust deposits when removing components
for cleaning as bodily injury may result.

Whenever the EGR valve is removed, the EGR system should be inspected and cleaned if
necessary. This will ensure that the EGR system will function properly during all operating
conditions. Proper EGR system service consists of the following 5 steps:

1. EGR system diagnosis--Diagnosis of the EGR system should be performed if PCM DTCs are
set . Refer to Diagnostic Trouble Code (DTC) List .
2. EGR valve pipe cleaning and checking for leaks--Clean and check the EGR pipe from the
exhaust manifold to the EGR valve and the EGR pipe from the water pump crossover to the
throttle body spacer. Refer to Exhaust Gas Recirculation Pipe Replacement .
3. EGR valve cleaning--If the EGR system is operating correctly, the EGR valve can be removed,
checked for deposits, cleaned, and re-installed. Use the procedure below for this operation:
3.1. Remove the EGR valve from the engine. Refer to Exhaust Gas Recirculation Valve
Replacement .
3.2. While holding the EGR valve in your hand, use a pencil eraser or other suitable soft
instrument to depress the pintle several times. The pintle should move in and out
smoothly. Replace any valve that exhibits tendencies to stick.
3.3. While holding the EGR valve base in your hand, try to rotate the connector housing.
Repeat this procedure for the coil housing. Replace any valve that exhibits looseness.
3.4. Inspect the EGR valve pintle and the valve seat for deposits. Use a cloth or other
suitable soft device in order to remove the deposits. Remove all loose particles. If the
deposits are such that pintle/base interface cannot be cleaned adequately to allow the
pintle to seal against the seat, replace the valve. Damage to the powdered metal EGR
valve base will occur if the valve base is cleaned with solvents, sharp tools, a wire
brush or wheel, or by sand blasting. Cleaning by these methods is not recommended.
3.5. Inspect the passage in the water crossover assembly for deposits. Remove all loose
particles.
3.6. Replace EGR valve on the engine using a new gasket. Refer to Exhaust Gas
Recirculation Valve Replacement .

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4. Cleaning the EGR passages in the water crossover assembly.

4.1. Remove the water crossover assembly. Refer to Engine Coolant Crossover Pipe
Replacement in Engine Cooling.
4.2. Remove the 2 plugs (2) and clean the passages with a wire brush. Remove all loose
particles.
4.3. Install the water crossover assembly. Refer to Engine Coolant Crossover Pipe
Replacement in Engine Cooling.
5. Wash your hands with soap and water after any contact with deposits from the EGR system.

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Exhaust Gas Recirculation Pipe Replacement

Removal Procedure

1. Remove the bolt at the water pump housing.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the nut from the crossover exhaust pipe.
4. Remove the exhaust gas recirculation (EGR) valve pipe.

Installation Procedure

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1. Loosely install the EGR pipe nut to the crossover exhaust pipe.

Tighten
Tighten the EGR pipe nut to 60 N·m (44 lb ft).

2. Lower the vehicle.

3. Install the bolt at the waterpump housing.

Tighten
Tighten the bolt to 24 N·m (18 lb ft).

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Exhaust Gas Recirculation Valve Replacement

Removal Procedure

1. Disconnect the exhaust gas recirculation (EGR) electrical connector.

2. Remove the EGR valve retaining nuts and bolts.

Important: Inspect the EGR passages in the crossover water pump housing for deposits.
Clean the EGR passages as needed. Refer to Exhaust Gas Recirculation (EGR) System
Cleaning .

3. Remove the EGR valve.

4. Clean the EGR valve mounting surface.

Installation Procedure

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1. Install the cleaned or the replacement EGR valve using a new gasket.

2. Install the EGR valve retaining nuts and bolts.

Tighten
Tighten the retaining nuts and bolts to 24 N·m (18 lb ft).

3. Reconnect the EGR valve electrical connector.

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Filler Tube Replacement

Removal Procedure

5. Remove the fuel filler©pipe

2014clamp.
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6. Remove the fuel filler pipe (1).

Installation Procedure

1. Install the fuel filler pipe (1).

2. Install the fuel filler pipe clamp.

Tighten
Tighten the fuel filler pipe clamp to 3.5 N·m (31 lb in).

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3. Install the fuel tank filler pipe ground wire attaching bolt (4).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

4. Install the wheel house filler pipe opening cover (2).

5. Lower the vehicle.
6. Add fuel to the fuel tank.
7. Install the fuel tank filler pipe cap.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
9. Inspect for fuel leaks.
9.1. Turn ON the ignition, with the engine OFF for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition, with the engine OFF.
9.4. Inspect for fuel leaks.
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel Filter Replacement

Removal Procedure

Important:
• There is no service interval for fuel filter replacement. Only replace the fuel filter if the
filter is restricted.
• Inspect the fuel tank internally and clean the fuel tank if you find a restricted fuel filter.

Installation Procedure

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1. Remove the protective caps from the new fuel filter.

7. Connect the threaded fitting to the fuel filter outlet. Use a back-up wrench in order to
prevent the fuel filter from turning.

Tighten
Tighten the fuel filter fitting to 30 N·m (22 lb ft).

8. Lower the vehicle.

9. Tighten the fuel tank filler pipe cap.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
11. Inspect for fuel leaks.
11.1. Turn ON the ignition, with the engine OFF for 2 seconds.
11.2. Turn OFF the ignition for 10 seconds.
11.3. Turn ON the ignition, with the engine OFF.
11.4. Inspect for fuel leaks.
12. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine

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Mechanical-4.0L.

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Fuel Hose/Pipes Replacement - Filter to Engine

Removal Procedure

Caution: In order to reduce the risk of fire and personal injury observe the following items:
• Replace all nylon fuel pipes that are nicked, scratched or damaged during installation,
do not attempt to repair the sections of the nylon fuel pipes
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
Damage to the nylon pipes may result in a fuel leak.
• Always cover nylon vapor pipes with a wet towel before using a torch near them. Also,
never expose the vehicle to temperatures higher than 115°C (239°F) for more than one
hour, or more than 90°C (194°F) for any extended period.
• Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe
fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During
normal operation, the O-rings located in the female connector will swell and may
prevent proper reconnection if not lubricated.)

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Clean all the fuel pipe connections and areas surrounding the fuel pipe connections before
disconnecting the fuel pipe connections in order to avoid possible contamination of the fuel
system.
3. Disconnect the fuel pipes (2, 3) at the fuel rail. Refer to Metal Collar Quick Connect Fitting
Service .
4. Disconnect the evaporative emissions (EVAP) purge pipe (4) at the EVAP canister purge
valve.
5. Remove the fuel and EVAP pipes from the retainers (1).
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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7. Disconnect the fuel return pipe quick-connect fitting (1). Refer to Plastic Collar Quick Connect
Fitting Service .
8. Disconnect the EVAP purge pipe (2) at the EVAP canister.
9. Disconnect the threaded fitting from the fuel filter (3) outlet.
10. Cap the fuel filter, the fuel feed pipe and the fuel return pipe as needed in order to stop any
fuel leakage.

11. Remove the fuel and the EVAP pipe bundle.

Installation Procedure

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1. Install the fuel and the EVAP pipe bundle.

2. Remove the caps from the fuel filter, the fuel feed pipe, and the fuel return pipe.

3. Connect the fuel return pipe quick-connect fitting (1). Refer to Plastic Collar Quick Connect
Fitting Service .
4. Connect the EVAP purge pipe (2) at the EVAP canister.

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5. Connect the threaded fitting to the fuel filter (3) outlet. Use a back-up wrench in order to
prevent the fuel filter from turning.

Tighten
Tighten the fuel filter fitting to 30 N·m (22 lb ft).

6. Lower the vehicle.

7. Connect the fuel pipes (2, 3) at the fuel rail. Refer to Metal Collar Quick Connect Fitting
Service .
8. Connect the EVAP purge pipe (4) at the EVAP canister purge valve.
9. Install the fuel and EVAP pipes into the retainers (1).
10. Tighten the fuel tank filler pipe cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
12. Inspect for leaks.
12.1. Turn ON the ignition, with the engine OFF for 2 seconds.
12.2. Turn OFF the ignition for 10 seconds.
12.3. Turn ON the ignition, with the engine OFF.
12.4. Inspect for fuel leaks.
13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel Hoses/Pipes Replacement - Filter to Tank

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

2. Remove the fuel pipes (2, 3) from the fuel sender and from the fuel tank.

Installation Procedure

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1. Install the fuel pipes (2, 3) to the fuel tank and to the fuel sender.
2. Install the fuel tank. Refer to Fuel Tank Replacement .

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Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
Notice:
• Use care when servicing the fuel system components, especially the fuel injector
electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and
the outlet ports of the fuel rail in order to prevent contamination.
• Do not use compressed air to clean the fuel rail assembly as this may damage the fuel
rail components.
• Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to
the fuel rail assembly.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if
necessary. Follow the package instructions.
3. Disconnect the fuel feed and return pipes (2, 3) from the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service .

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4. Disconnect the fuel pressure regulator vacuum hose.

5. Disconnect the positive crankcase ventilation (PCV) air tube from the cam cover.

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6. Disconnect the PCV valve (1) from the cam cover.

7. Reposition the coolant surge tank inlet pipe. Refer to Surge Tank Pipe Replacement - Inlet in
Engine Cooling.

8. Remove the fuel rail bracket retainer nut.

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9. Disconnect the fuel injector electrical connectors (1) from each fuel injector (2).
10. Lay the harness aside.

11. Remove the fuel rail attaching studs (2).

12. Remove the fuel rail (1).
13. Remove the injector lower O-ring seal from the spray tip end of each injector.
14. Discard the O-ring seals.

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the outlet ports of the fuel rail in order to prevent contamination.

• Do not use compressed air to clean the fuel rail assembly as this may damage the fuel
rail components.
• Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to
the fuel rail assembly.

1. Lubricate the new lower injector O-ring seals with clean engine oil.
2. Install the new O-ring seals on the spray tip end of each injector.
3. Install the fuel rail (1).

4. Install the fuel rail attaching studs (2).

Tighten
Tighten the studs to 10 N·m (89 lb in).

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5. Connect the fuel injector electrical connectors (1) to each fuel injector (2).

6. Install the fuel rail bracket retainer nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).

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7. Install the PCV valve to the cam cover (2).

8. Install the coolant surge tank inlet pipe (1). Refer to Surge Tank Pipe Replacement - Inlet in
Engine Cooling.

9. Install the PCV air tube to the cam cover.

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10. Connect the fuel pressure regulator vacuum hose.

11. Connect the fuel feed and return pipes (2, 3) to the fuel rail. Refer to Metal Collar Quick
Connect Fitting Service .
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
13. Inspect for fuel leaks.
13.1. Turn ON the ignition for 2 seconds.
13.2. Turn OFF the ignition for 10 seconds.
13.3. Turn ON the ignition.
13.4. Inspect for fuel leaks.
14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel Injector Replacement

Removal Procedure
Important: If the fuel injectors are leaking, the engine oil may be contaminated with fuel.

1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
2. Remove the fuel injector (5) by pushing the locking tab on the fuel rail toward the center of
the fuel rail.
3. Remove the fuel injector upper O-ring (6).
4. Remove the fuel injector lower O-ring (4).
5. Discard the injector O-ring seals.

Installation Procedure
Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak,
always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are
different colors (black and blue), be sure to install the blue O-ring in the upper position and the
black O-ring in the lower position on the fuel injector. The O-rings are the same size but are made
of different materials.

Important:
• You must use the correct part number when ordering replacement fuel injectors.
• The fuel injector O-rings should always be replaced whenever the fuel injectors are serviced.
Be sure to install the correct O-ring for the fuel injector. If the O-ring is not seated properly, a
vacuum leak is possible and poor driveability conditions may occur.

© 2014 General Motors Corporation. All rights reserved.

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1. Lubricate the new upper (6) and lower (4) O-rings with clean engine oil.
2. Install the new upper and lower injector O-rings on the fuel injector.
3. Install the fuel injector on to the fuel rail.
4. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .

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Fuel Level Sensor Replacement

1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
2. Disconnect the fuel pump electrical connector.
3. Remove the fuel level sensor electrical connector retaining clip.
4. Disconnect the fuel level sensor electrical connector from under the fuel sender cover.
5. Remove the fuel level sensor retaining clip.
6. Squeeze the locking tangs and remove the fuel level sensor.

Installation Procedure

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1. Install the fuel level sensor.

2. Install the fuel level sensor retaining clip.
3. Connect the fuel level sensor electrical connector.
4. Install the fuel level sensor electrical connector retaining clip.
5. Connect the fuel pump electrical connector.
6. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

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Fuel Pressure Gage Installation and Removal

Tools Required
J 34730-1A Fuel Pressure Gage

Notice: Clean all of the following areas before performing any disconnections in order to avoid
possible contamination in the system:
• The fuel pipe connections
• The hose connections
• The areas surrounding the connections

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical 4.0L.

2. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail.
3. Turn ON the ignition, with the engine OFF.
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Caution: Do not drain the fuel into an open container. Never store the fuel in an open
container due to the possibility of a fire or an explosion.

4. Place the bleed hose of the fuel pressure gage into an approved gasoline container.
5. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel
pressure gage.
6. Command the fuel pump ON with a scan tool.
7. Close the bleed valve on the fuel pressure gage.
8. Command the fuel pump ON with a scan tool.
9. Inspect for fuel leaks.

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Fuel Pressure Regulator Replacement

Removal Procedure

1. Relieve the fuel pressure. Refer to Metal Collar Quick Connect Fitting Service .
2. Clean any dirt from the fuel pressure regulator.
3. Disconnect the fuel pressure regulator vacuum line.
4. Remove the fuel pressure regulator retainer clip (7).
5. Lift and twist the fuel pressure regulator (10) in order to remove the regulator from the fuel
rail. Use a shop towel in order to catch any spilled fuel.
6. Remove the regulator seal lower O-ring (8).
7. Remove the regulator assembly filter.
8. Remove the regulator seal upper O-ring (9).
9. Remove the regulator seal back-up ring.
10. Cover the fuel pressure regulator housing in order to prevent contaminates from entering the
fuel system.

Installation Procedure

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1. Install new O-rings on the fuel pressure regulator if a new regulator is not being installed.
Lubricate the O-rings lightly with clean engine oil.
2. Install the back-up ring.
3. Install the upper O-ring (9).
4. Install the filter.
5. Install the lower O-ring (8).
6. Install the fuel pressure regulator retainer clip (7).
7. Connect the fuel pressure regulator vacuum line.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
9. Inspect for fuel leaks using the following procedure:
9.1. Turn ON the ignition, with the engine OFF for 2 seconds.
9.2. Turn OFF the ignition for 10 seconds.
9.3. Turn ON the ignition, with the engine OFF.
9.4. Inspect for fuel leaks.
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel Pressure Relief

Tools Required
J 34730-1A Fuel Pressure Gauge

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of
fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Relieve the fuel system pressure before servicing fuel system components in order to
reduce the risk of fire and personal injury.

After relieving the system pressure, a small amount of fuel may be released when servicing the
fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and
the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak
out. Place the towel in an approved container when the disconnection is complete.

1. Turn the ignition OFF.

3. Loosen the fuel tank filler pipe cap (1) in order to relieve the fuel tank vapor pressure.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-4.0L.

© 2014 General Motors Corporation. All rights reserved.

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5. Connect the J 34730-1A fuel pressure gauge to the fuel pressure valve. Wrap a shop towel
around the fitting while connecting the gauge in order to avoid spillage.
6. Install the bleed hose into an approved container.
7. Open the valve in order to bleed the system pressure. Fuel connections are now safe for
servicing.
8. Drain any fuel remaining in the gauge into an approved container.

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Fuel Pressure Service Valve Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the fuel pressure connection valve (2) using a standard valve core removal and
installation tool.

Installation Procedure

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1. Install the fuel pressure connection valve assembly (2) using a standard valve core removal
and installation tool.
2. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
3. Inspect for fuel leaks.
3.1. Turn ON the ignition switch for 2 seconds.
3.2. Turn OFF the ignition switch for 10 seconds.
3.3. Turn ON the ignition switch.
3.4. Inspect for fuel leaks.
4. Install the cap (3) on the fuel pressure connection valve.
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel Sender Assembly Replacement

Tools Required
J 39765 Fuel Sender Locknut Wrench

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the rear compartment floor trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.
4. Remove the fuel sender access panel bolts.
5. Remove the fuel sender access panel.

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Important: The modular fuel sender assembly will spring-up when the locking ring is
removed.

9. Remove the fuel sender retaining ring using the J 39765 .

Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage
generated by handling the fuel pipes could damage the joints.

10. Remove the fuel sender assembly.

11. Clean the fuel sender sealing surfaces.
12. Inspect the fuel sender sealing surfaces.

Installation Procedure

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Important: DO NOT fold over or twist the fuel pump strainer when installing the fuel sender
assembly, as this will restrict fuel flow. Ensure that the fuel pump strainer does not block the
full travel of the float arm.

Important: Always replace the fuel sender seal when reinstalling the fuel sender.

1. Position the new fuel sender seal on the fuel tank.

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10. Install the fuel sender access panel.

11. Install the fuel sender access panel bolts.

Tighten
Tighten the fuel sender access panel bolts to 2 N·m (18 lb in).

12. Install the rear compartment floor trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.
13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Fuel System Cleaning

Important: Only use oil-free compressed air in order to blow out the fuel pipes. If the fuel filter is
plugged, the fuel tank should be inspected internally and cleaned if necessary.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

2. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
3. Inspect the fuel sender strainer. Replace the fuel sender assembly if the fuel strainer is
contaminated.

Important: When flushing the fuel tank, handle the fuel and water mixture as a hazardous
material. Handle the fuel and water in accordance with all applicable local, state, and federal
laws and regulations.

4. Flush the fuel tank with hot water.

5. Pour the water from the fuel sender assembly opening in the fuel tank. Rock the fuel tank in
order to ensure that the removal of the water from the fuel tank is complete.
6. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
7. Install the fuel tank. Refer to Fuel Tank Replacement .

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Fuel Tank Draining

Caution: Never drain or store fuel in an open container. Always use an approved fuel storage
container in order to reduce the chance of fire or explosion.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the fuel tank filler pipe cap (1).

3. Drain the fuel through the fuel tank filler pipe by using a hand or air operated fuel pump
device.

© 2014 General Motors Corporation. All rights reserved.

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Fuel Tank Filler Hose Replacement

Removal Procedure

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

2. Remove the fuel filler hose (1) from the fuel tank (3).

Installation Procedure

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1. Install the fuel filler hose (1) to the fuel tank (3).

Tighten
Tighten the fuel filler hose clamp to 3.5 N·m (31 lb in).

2. Install the fuel tank. Refer to Fuel Tank Replacement .

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Fuel Tank Fuel Pump Module Replacement

1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
2. Remove the fuel tank pressure sensor (1).
3. Disconnect the fuel pump electrical connector.
4. Remove the fuel level sensor electrical connector retaining clip.
5. Disconnect the fuel level sensor electrical connector from under the fuel sender cover.
6. Remove the fuel level sensor retaining clip.
7. Squeeze the locking tangs and remove the fuel level sensor (3).

Installation Procedure

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1. Install the fuel level sensor (3).

2. Install the fuel level sensor retaining clip.
3. Connect the fuel level sensor electrical connector.
4. Install the fuel level sensor electrical connector retaining clip.
5. Connect the fuel pump electrical connector.
6. Install the fuel tank pressure sensor (1).
7. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

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Fuel Tank Pressure Sensor Replacement

Removal Procedure
1. Remove the rear compartment floor trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.

2. Remove the fuel sender access panel bolts.

3. Remove the fuel sender access panel.

4. Disconnect the fuel tank pressure sensor electrical connector.

5. Remove the fuel tank©pressure sensor.
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Installation Procedure

1. Install the fuel tank pressure sensor.

2. Connect the fuel tank pressure sensor electrical connector.

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3. Install the fuel sender access panel.

4. Install the fuel sender access panel bolts.

Tighten
Tighten the fuel sender access panel bolts to 2 N·m (18 lb in).

5. Install the rear compartment floor trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.

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Fuel Tank Replacement

Removal Procedure

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7. Disconnect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Plastic Collar Quick
Connect Fitting Service .

8. Disconnect the EVAP pipe (2) from the EVAP canister.

9. Remove the fuel and EVAP retainer from the frame.

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10. Disconnect the fuel tank electrical connector.

11. Disconnect the fuel tank electrical harness from the retainers.

12. Remove the fuel tank strap bolts (4).

13. Remove the fuel tank (5).

Disassemble Procedure

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4. Remove the fuel filler hose clamp (2).

5. Remove the fuel filler hose from the fuel tank (3).

Assemble Procedure

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1. Install the fuel filler hose to the fuel tank (3). Align the dot on the hose to the parting line on
the fuel tank.

2. Install the fuel filler hose clamp (2).

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).

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3. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
4. Install the fuel pipes (2, 3) and the EVAP pipe (1).

Installation Procedure

1. Position and support the fuel tank (5) with the aid of an assistant.

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2. Install the fuel tank straps (2).

3. Install the fuel tank strap bolts (4).

Tighten
Tighten the fuel tank strap bolts to 42 N·m (31 lb ft).

4. Connect the fuel tank electrical connector.

5. Install the fuel tank electrical harness into the retainers.

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6. Install the fuel and EVAP retainer to the frame.

7. Connect the EVAP pipe (2) to the EVAP canister.

8. Connect the fuel feed pipe (4) and the fuel return pipe (1). Refer to Plastic Collar Quick
Connect Fitting Service .

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9. Install the rear suspension support assembly. Refer to Support Replacement in Rear
Suspension.
10. Connect the fuel filler hose to the fuel filler pipe.

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).

11. Install the wheelhouse filler pipe opening cover (2).

12. Lower the vehicle.
13. Add fuel to the fuel tank.
14. Install the fuel tank filler pipe cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
16. Inspect for leaks.
16.1. Turn ON the ignition, with the engine OFF for 2 seconds.
16.2. Turn OFF the ignition for 10 seconds.
16.3. Turn ON the ignition, with the engine OFF.
16.4. Inspect for fuel leaks.
17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Heated Oxygen Sensor Replacement - Bank 1 Sensor 1

Removal Procedure
Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep
the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning
solvents on the sensor. Do not drop or mishandle the sensor.

Important: Remove the oxygen sensors with the engine temperature above 48°C (120°F).
Otherwise the oxygen sensors may be difficult to remove.

Important: A special anti-seize compound is used on the oxygen sensor threads. New service
sensors should already have the compound applied to the threads. Coat the threads of a reused
sensor with anti-seize compound P/N 5613695 or equivalent.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the rear of powertrain frame.
3. Remove the 4 rear frame bolts.
4. Lower the frame no more than 3 inches.
5. Disconnect the rear oxygen sensor electrical connector.
6. Remove the rear oxygen sensor from the rear exhaust manifold.

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1. Install the rear oxygen sensor in the rear exhaust manifold.

Tighten
Tighten the rear heated oxygen sensor (HO2S) sensor to 41 N·m (30 lb ft).

2. Connect the rear oxygen sensor connector.

3. Raise the frame.
4. Install the 4 rear frame bolts.

Tighten
Tighten the frame bolts to 100 N·m (74 lb ft).

5. Lower the vehicle.

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Heated Oxygen Sensor Replacement - Bank 1 Sensor 2

Important: Remove the oxygen sensors with the engine temperature above 48°C (120°F).
Otherwise the oxygen sensors may be difficult to remove.

Important: A special anti-seize compound is used on the oxygen sensor threads. New service
sensors should already have the compound applied to the threads. Coat the threads of a reused
sensor with anti-seize compound P/N 5613695 or equivalent.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the pre- or post-converter oxygen sensor electrical connector.
3. Remove the pre- or post-converter oxygen sensor.

Installation Procedure

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1. Install the pre- or post-converter oxygen sensor.

Tighten
Tighten the Pre or Post heated oxygen sensor (HO2S) sensor to 41 N·m (30 lb ft).

2. Connect the pre- or post-converter oxygen sensor electrical connector.

Important: Ensure that the connectors are securely installed beneath the harness heat
shield in order to prevent connector damage.

3. Lower the vehicle.

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Heated Oxygen Sensor Replacement - Bank 2 Sensor 1

Important: Remove the oxygen sensors with the engine temperature above 48°C (120°F).
Otherwise the oxygen sensors may be difficult to remove.

Important: A special anti-seize compound is used on the oxygen sensor threads. New service
sensors should already have the compound applied to the threads. Coat the threads of a reused
sensor with anti-seize compound P/N 5613695 or equivalent.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front splash shield.
3. Disconnect the front oxygen sensor electrical connector.
4. Remove the front oxygen sensor from the front exhaust manifold.

© 2014 General Motors Corporation. All rights reserved.

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1. Install the front oxygen sensor in the front exhaust manifold.

Tighten
Tighten the front HO2S to 41 N·m (30 lb ft).

2. Connect the front oxygen sensor electrical connector.

3. Install the front splash shield.
4. Lower the vehicle.

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Idle Air Control Valve Replacement

Removal Procedure

1. Remove the electrical connector (1) from the idle air control valve (4).

2. Remove the idle air control valve attaching screws (2) from the idle air control valve (1).

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3. Remove the idle air control valve from the throttle body.
4. Remove the idle air control valve O-ring.

Installation Procedure

Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC valve pintle.
The force required to move the pintle may damage the threads on the worm drive. Also, DO
NOT soak the IAC valve in any liquid cleaner or solvent, as damage may result.

1. Clean the IAC valve O-ring sealing surface, the pintle valve seat, and the air passage.

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• Clean the IAC valve using GM cleaner P/N 1052626 or GM X 66A. Use a shop towel or
parts brush to remove heavy deposits.
• If the air passage has heavy deposits, remove the throttle body for complete cleaning.
• Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent
pintle shaft.
2. Inspect the IAC valve O-ring for cuts, cracks, or distortion. Replace the O-ring if the O-ring is
damaged.
3. Install the new idle air control valve O-ring.

Notice: The IAC valve may be damaged if installed with the cone (pintle) extended more
than 28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a
new valve. The distance from the idle air control valve motor housing to the end of the idle
air control valve pintle should be less than 28 mm (1-1/8 in). Manually compress the pintle
until the extension is less than 28 mm (1-1/8 in).

4. Install the idle air control valve (1) into the throttle body.

5. Install the idle air control valve attaching screws (2) into the IAC valve.

Tighten
Tighten the idle air control valve attaching screws to 3 N·m (27 lb in).

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6. Install the electrical connector (1) into the idle air control valve (4).
7. The powertrain control module (PCM) will reset the idle air control valve whenever the
ignition switch is turned ON, then OFF.
8. Turn the ignition switch ON.
9. Turn the ignition switch OFF.
10. Perform the IAC Valve learn procedure.

IAC Valve Learn Procedure

10.1. Start and idle the engine for 15 seconds.
10.2. Turn the ignition switch to the LOCK/OFF position.
10.3. Wait 15 seconds.
10.4. Restart the engine and check for proper idle operation.

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Ignition Coil Replacement - Bank 1

Removal Procedure

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical.
2. Disconnect the ignition control module electrical connector.
3. Disconnect the AIR vacuum control solenoid valve electrical connector.
4. Remove the AIR Control Valve. Refer to Secondary Air Injection Control Valve Replacement -
Bank 1 .

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5. Using the removal sequence (1, 2, 3, 4, 5, 6, 7, 8) , remove the ignition cassette retaining
bolts.
6. Carefully remove the ignition cassette.

Installation Procedure

Important: Ensure the ignition cassette grounding spring and the insulator are in place
when installing the ignition cassette.

1. Connect the spark plug boots to the spark plugs.

Carefully install the ignition cassette.

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2. Install the ignition cassette retaining bolts.

Tighten
Using the installation torque sequence (1, 2, 3, 4, 5, 6, 7, 8), tighten the ignition cassette
retaining bolts to 9 N·m (80 lb in).

3. Install the AIR Control Valve. Refer to Secondary Air Injection Control Valve Replacement -
Bank 1 .
4. Reconnect the AIR vacuum control solenoid valve electrical connector.
5. Reconnect the ignition cassette electrical connector.
6. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Ignition Coil Replacement - Bank 2

Removal Procedure

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical.
2. Disconnect the ignition control module electrical connector.

3. Using the removal sequence (1, 2, 3, 4, 5, 6, 7, 8), remove the ignition cassette retaining
bolts. © 2014 General Motors Corporation. All rights reserved.

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4. Carefully remove the ignition cassette.

Installation Procedure

Important: Be sure the ignition cassette grounding spring and insulator are in place when
installing the ignition cassette.

1. Connect the spark plug boots to the spark plugs.

Carefully install the ignition cassette.

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2. Install the ignition cassette retaining bolts.

Tighten
Using the installation torque sequence (1, 2, 3, 4, 5, 6, 7, 8), tighten the ignition cassette
retaining bolts to 9 N·m (80 lb in).

3. Reconnect the ignition cassette electrical connector.

4. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.

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Ignition Control Module Replacement - Bank 1

Removal Procedure

1. Remove the ignition coil cassette. Refer to Ignition Coil Replacement - Bank 1 .
2. Remove the ignition control module retaining screws.
3. Remove the ignition control module.

Installation Procedure

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1. Install the ignition control module.

Tighten
Tighten the ignition control module retaining screws to 0.8 N·m (7 lb in).

Important: Ensure that the ignition cassette grounding spring and insulator are in place
when installing the ignition cassette.

2. Connect the spark plug boots to the spark plugs.

3. Carefully install the ignition cassette. Refer to Ignition Coil Replacement - Bank 1 .

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Ignition Control Module Replacement - Bank 2

Removal Procedure

1. Remove the ignition cassette. Refer to Ignition Coil Replacement - Bank 2 .

2. Remove the ignition control module retaining screws.
3. Remove the ignition control module.

Installation Procedure

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1. Install the ignition control module.

2. Install the ignition control module retaining screws

Tighten
Tighten the ignition control module retaining screws to 0.8 N·m (7 lb in).

Important: Ensure that the ignition cassette grounding spring and the insulator are in place
when installing the ignition cassette.

3. Connect the spark plug boots to the spark plugs.

4. Install the ignition cassette. Refer to Ignition Coil Replacement - Bank 2 .

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Knock Sensor Replacement

Removal Procedure

1. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.
2. Disconnect the knock sensor electrical connector.
3. Remove the knock sensor.

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1. Install the knock sensor.

Tighten
Tighten the knock sensor to 25 N·m (18 lb ft).

2. Connect the knock sensor electrical connector.

3. Reinstall the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.

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Manifold Absolute Pressure Sensor Replacement

Removal Procedure

1. Turn the ignition OFF.

2. Disconnect the MAP sensor electrical connector.
3. Remove the cable bracket bolts and bracket.
4. Remove the MAP (1) sensor from the intake manifold.
5. Inspect the MAP sensor grommet for wear or damage. If a problem is found, replace the
sensor as necessary.

Installation Procedure

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1. Install the MAP sensor (1) into the intake manifold.

2. Install the cable bracket and bolts.

Tighten
Tighten the bracket bolts to 12 N·m (106 lb in).

3. Connect the MAP sensor electrical connector.

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Mass Airflow Sensor with Intake Air Temperature

Sensor Replacement
Removal Procedure
Notice:
• Handle the MAF sensor carefully.
• Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
• Do not damage the screen located on the air inlet end of the MAF.
• Do not touch the sensing elements.
• Do not allow solvents and lubricants to come in contact with the sensing elements.
• Use a small amount of a soap based solution in order to aid in the installation.

1. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector.
2. Remove the clamps securing the MAF/IAT sensor assembly to the air cleaner and intake air
duct.
3. Carefully remove the MAF/IAT sensor from the air cleaner and intake air duct.

Installation Procedure
Notice:
• Handle the MAF sensor carefully.
• Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
• Do not damage the screen located on the air inlet end of the MAF.
• Do not touch the sensing elements.
• Do not allow solvents and lubricants to come in contact with the sensing elements.
• Use a small amount of a soap based solution in order to aid in the installation.

1. Carefully install the MAF/IAT sensor into the air cleaner and intake air duct.

2. Install the clamps securing the MAF/IAT sensor assembly to the air cleaner and intake air
duct.

Tighten
Tighten the clamps to 3 N·m (27 lb in).

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3. Reconnect the MAF/IAT sensor electrical connector.

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Metal Collar Quick Connect Fitting Service

Tools Required
J 37088-A Fuel Line Disconnect Tool Set

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

2. Remove the retainer from the quick-connect fitting.

Caution: Wear safety glasses when using compressed air, as flying dirt particles may cause
eye injury.

3. Blow any dirt from the fitting using compressed air.

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4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into
the female connector, then push inward in order to release the locking tabs.

5. Pull the connection apart.

6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as
required.

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Installation Procedure

Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may
prevent proper reconnection if not lubricated.

1. Apply a few drops of clean engine oil to the male pipe end.

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2. Push both sides of the fitting together in order to cause the retaining tabs to snap into place.

3. Once installed, pull on both sides of the fitting in order to make sure the connection is
secure.
4. Install the retainer to the quick-connect fitting.

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Plastic Collar Quick Connect Fitting Service

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

2. Blow any dirt from the fitting using compressed air.

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3. Squeeze the plastic tabs of the male end connector.

4. Pull the connection apart.

Notice: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial
motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

5. Wipe off the male pipe end using a clean shop towel.
6. Inspect both ends of the fitting for dirt and burrs.
7. Clean or replace the components as required.

Installation Procedure
Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings,
always apply a few drops of clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent
proper reconnection if not lubricated.

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1. Apply a few drops of clean engine oil to the male pipe end.

2. Push both sides of the quick-connect fitting together in order to cause the retaining
tabs/fingers to snap into place.

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3. Pull on both sides of the quick connect fitting in order to ensure that the connection is secure.

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Powertrain Control Module Programming (Off-Board)

Before Programming a Control Module
Important:
• Do NOT program a control module unless you are directed by a service procedure or you are
directed by a General Motors Corporation service bulletin. Programming a control module at
any other time will not permanently correct a customer's concern.
• The Off-Board Programming is used in situations where a control module must be
programmed without having the vehicle present. The Off-Board Programming Adapter must
be used to perform the Off-Board Programming procedure. The adapter allows the control
module to power up and allows the Tech 2 to communicate with the control module.
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.

Ensure that all connections are secure at the following locations:

• The Off-Board Programming Adapter

• The Tech 2
• The control module
• The Techline terminal

Off-Board Programming
1. Obtain the VIN of the vehicle for which the control module is being programmed.
2. With the Techline terminal, select Service Programming.
3. Select Tech 2, Reprogram ECU, and Off-Board Programming Adapter as the ECU location.
4. Connect the control module, Off-Board Programming Adapter, and the Tech 2 as described
on the Techline terminal. Ensure you use the correct harness connector from the Off-Board
Programming Adapter kit.
5. With the Tech 2, select Service Programming Request Information function. The Tech 2
communicates with the control module and receives the access code.
6. With the Tech 2, exit the Service Programming Request Information.
7. Disconnect the Tech 2 from the Off-Board Programming Adapter.
8. Connect the Tech 2 to the Techline terminal.
9. Turn ON the Tech 2.
10. With the Techline terminal, enter the VIN of the vehicle that will be receiving the control
module.
11. The Techline terminal will display the message, attaching to database.
12. Identify what type of programming that you are performing.
13. Select the appropriate calibration file.
14. Ensure all connections are secure.
15. The Techline terminal displays a summary screen that summarizes your selections. After
confirming you choices, the Techline terminal automatically loads the calibration files to the
Tech 2.
16. After the download is complete, turn OFF the Tech 2.
17. Disconnect the Tech 2 from the Techline terminal.
18. Connect the Tech 2 to©the
2014Off-Board Programming
General Motors Corporation. Adapter.
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19. With the Tech 2, select Service Programming.

Important: DO NOT turn OFF the Off-Board Programming Adapter if the programming
procedure is interrupted or unsuccessful. Ensure that the control module and the Off-Board
Programming Adapter connections are secure and ensure that the Techline operating
software is up to date. Attempt to reprogram the control module. If the control module
cannot be programmed, replace the control module.

20. With the Tech 2, select Program.

21. After the download is complete, exit Service Programming.
22. Turn OFF the Off-Board Programming Adapter.

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Powertrain Control Module Programming (On-Board)

Before Programming a Control Module
Important: Do NOT program a control module unless you are directed by a service procedure or
you are directed by a General Motors Corporation service bulletin. Programming a control module
at any other time will not permanently correct a customers concern.

Ensure that the following conditions are met before programming a control module:

• Vehicle system voltage

- There is no charging system concern. All charging system concerns must be repaired before
programming a control module.
- Ensure that the battery voltage is greater than 12 volts but less than 16 volts. If the
battery voltage is low, the battery must be charged before programming the control
module.
- Ensure that a battery charger is NOT connected to the vehicles battery. Incorrect system
voltage, or voltage fluctuations from a battery charger may cause programming failure or
control module damage.
- Turn OFF or disable any system that may put a load on the vehicles battery.
• The twilight sentinel
• The interior lights
• The daytime running lights (DRL). Applying the parking brake, on most vehicles, disables the
DRL system. Refer to the Owners manual.
• The HVAC systems
• The engine cooling fans
• Ensure that the ignition switch is in the proper position. The scan tool prompts you to turn
ON the ignition, with the engine OFF. Do NOT change the position of the ignition switch
during the programming procedure, unless instructed to do so.
• Ensure that all tool connections are secure.
- The RS-232
- The connection at the DLC
- The voltage supply circuits
• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.

Remote Programming
1. Turn OFF the ignition.
2. Install the Tech 2 to the vehicle data link connector (DLC).
3. Turn ON the ignition, with the engine OFF.
4. Turn OFF all vehicle accessories.
5. With the Tech 2, select Service Programming.
6. With the Tech 2, select Request Info.
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7. Identify vehicle information as requested by the Tech 2.

8. Select the type of module you are programming.
9. Select the type of programming to be performed.
10. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual
VIN, write down the actual VIN and correct the VIN at the Techline terminal.
11. When complete, Exit Service Programming.
12. Turn OFF the Tech 2 and disconnect the Tech 2 from the vehicle.
13. Turn OFF the ignition.
14. Connect the Tech 2 to the Techline terminal.
15. Select Service Programming.
16. Select Tech 2 as the tool you are using.
17. Select the type of programming to be performed.
18. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary.
19. Select the type of module you are programming.
20. Identify what type of programming that you are performing:
• Normal--This type of programming is for updating an existing calibration or programming
a new controller.
• Vehicle Configuration Index (VCI)--This selection is used if the vehicle VIN is unavailable
or not recognized by the Techline terminal. You will need to contact the Techline
Customer Support center to use this option.
• Reconfigure--This is to reconfigure a vehicle, such as tire size and axle ratio changes.
21. Select the appropriate calibration file.
22. Ensure that all connections are secure.
23. Select Reprog in order to initiate the download of the new calibration to the Tech 2.
24. After the download is complete, turn OFF the Tech 2.
25. Disconnect the Tech 2 from the Techline terminal.
26. Install the Tech 2 to the vehicle data link connector (DLC).
27. Turn ON the Tech 2.
28. Turn ON the ignition, with the engine OFF.
29. Select Service Programming.

Important: DO NOT turn OFF the ignition if the programming procedure is interrupted or
unsuccessful. Ensure that all the PCM and the DLC connections are secure and the Techline
operating software is up to date. Attempt to reprogram the control module. If the control
module cannot be programmed, replace the control module. Refer to Powertrain Control
Module Replacement .

30. Select Program.

31. After the download is complete, EXIT Service Programming.
32. Turn OFF the ignition for 30 seconds.
33. Turn OFF the Tech 2.
34. The following procedures must be completed after replacing and programming the PCM:
• Reset the fluid life indexes. Refer to GM Oil Life System Resetting in Maintenance and
Lubrication.
• Perform the crankshaft system variation learn procedure. Refer to Crankshaft Position
System Variation Learn .
• Perform the Throttle Position Sensor Learn procedure. Refer to Throttle Position Sensor
Replacement .
• Perform the Idle Air Control (IAC) Valve Learn procedure. Refer to Idle Air Control Valve
Replacement
• Reset the Inspection/Maintenance (I/M) System Status. Refer to Inspection/Maintenance
(I/M) Complete System Set Procedure .

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• Perform the Vehicle Theft Deterrent Password Learn procedure. Refer to Programming
Theft Deterrent System Components in Theft Deterrent.

Programming Verification
1. With a scan tool, clear the DTCs.
2. Attempt to start the engine.
3. Repeat the Service Programming procedure if the engine does not start or operates poorly.
Perform the following procedures before programming the PCM:
• Ensure that the control module and the DLC connections are OK.
• Ensure that the Techline operating software is up to date.
• Ensure that the calibration part number is correct for the vehicle.
4. Attempt to program the control module. If the control module still cannot be programmed
properly, replace the control module. Refer to Powertrain Control Module Replacement . You
must program the replacement control module.

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Powertrain Control Module Replacement

Removal Procedure
Notice: Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in
order to prevent internal PCM damage.

Important: It is necessary to record the remaining engine oil life. If the replacement module
is not programed with the remaining engine oil life, the engine oil life will default to 100%. If
the replacement module is not programmed with the remaining engine oil life, the engine oil
will need to be changed at 5000 km (3,000 mi) from the last engine oil change.

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining
engine oil life.

2. Turn OFF the ignition.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or
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equipment come in contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle or its components.

3. Disconnect the negative battery cable.

4. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector.
5. Loosen the intake air duct clamp at the throttle body.
6. Loosen the air filter element/PCM housing cover screws.
7. Remove the air filter element/PCM housing cover, the MAF/IAT sensor, and the intake air
duct.
8. Disconnect both PCM connectors.
9. Remove the PCM.

Installation Procedure
Important: You must inspect the following areas before installing the PCM and insure that:
• There is no debris in the air filter element/PCM housing assembly, or in the MAF/IAT sensor
inlet screen that may distort the air flow.
• There are no signs of damage to the air filter element/PCM housing assembly, or to the intake
air duct. If a problem is found, replace the component as necessary.

Important: If the PCM is being programmed using the Off-Board method, perform the
programming before continuing with the steps listed below. Refer to the Off-Board procedure in
Powertrain Control Module Programming .

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1. Install the PCM.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the PCM connectors.

Tighten
Tighten the PCM connectors screws to 8 N·m (71 lb in).

3. Install the intake air duct, the MAF/IAT sensor, and the air filter element/PCM housing cover
to the throttle body.

Important: You must properly install the intake air duct to the throttle body. An improperly
installed, distorted, or damaged air filter or intake air duct may cause a DTC to set.

4. Align and engage the tabs on the air filter element/PCM housing cover with the slots in the
air filter element/PCM housing.
5. Tighten the air element/PCM housing cover screws

Tighten
Tighten the air element/PCM housing cover screws to 4 N·m (35 lb in).

6. Tighten the intake air duct clamp at the throttle body.

Tighten
Tighten the clamp to 3 N·m (27 lb in).

7. Reconnect the MAF/IAT sensor connector.

8. Connect the negative battery cable.

Important: The replacement PCM must be programmed.

9. Program the PCM. Refer to Powertrain Control Module Programming .

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Secondary Air Injection Pump Replacement - Bank 1

Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the retaining screws from the front portion of the right front wheel well/splash
shield.
3. Lower the splash shield far enough to gain access to the AIR pump assembly.
4. Loosen and lower the AIR exhaust hose pinch clamp.
5. Disconnect the AIR exhaust hose from the AIR pump.
6. Carefully remove the AIR inlet hose/filter assembly from the AIR pump.
7. Disconnect the AIR pump electrical connector.
8. Loosen the lower AIR to cradle bracket nuts.
9. Remove the upper AIR pump to cradle bolt.
10. Lift up and pull out to remove the AIR pump from the cradle bracket.

Installation Procedure
1. Install the lower AIR pump bolts/nuts into the cradle bracket and push down.

2. Install the upper AIR pump to cradle bolt.

Tighten
Tighten the upper AIR pump to cradle bolt to 9 N·m (80 lb in).

Tighten
Tighten the lower AIR pump to cradle bolt/nuts to 9 N·m (80 lb in).

Important: Listen for a CLICK in order to ensure proper connection of the AIR inlet
hose/filter to the AIR pump.

3. Ensure that the rubber O-ring is on the bottom of the AIR pump.
4. Install the AIR inlet hose/filter assembly to the AIR pump.
5. Install the AIR pump exhaust hose to the AIR pump, and secure the hose with a hose clamp.
6. Reconnect the AIR pump electrical connector.
7. Raise the wheel well/splash shield into position.
8. Re-install the wheel well/splash shield retaining screws.
9. Lower the vehicle.

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Secondary Air Injection Pump Replacement - Bank 2

Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the retaining screws from the front portion of the left front wheel well/splash shield.
3. Lower the splash shield far enough to gain access to the AIR pump assembly.
4. Loosen and lower the AIR exhaust hose pinch clamp.
5. Disconnect the AIR exhaust hose from the AIR pump.
6. Carefully remove the AIR inlet hose/filter assembly from the AIR pump.
7. Disconnect the AIR pump electrical connector.
8. Loosen the lower AIR to cradle bracket nuts.
9. Remove the upper AIR pump to cradle bolt.
10. Lift up and pull out the pump in order to remove the AIR pump from the cradle bracket.

Installation Procedure
1. Install the lower AIR pump bolts/nuts into the cradle bracket and push down.

2. Install the upper AIR pump to cradle bolt.

Tighten
Tighten the upper AIR pump to cradle bolt to 9 N·m (80 lb in).

Important: Listen for a CLICK in order to ensure proper connection of the AIR inlet hose and
filter to the AIR pump.

3. Ensure that the rubber O-ring is on the bottom of the AIR pump.
4. Install the AIR inlet hose and filter assembly to the AIR pump.
5. Install the AIR pump exhaust hose to the AIR pump, and secure the hose with a hose clamp.
6. Reconnect the AIR pump electrical connector.
7. Raise the wheel well/splash shield into position.
8. Re-install the wheel well/splash shield retaining screws.
9. Lower the vehicle.

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Secondary Air Injection Pump Replacement

3. Lower the splash shield far enough to gain access to the secondary air injection (AIR) pump
(2) assembly.
4. Loosen and lower the AIR outlet hose pinch clamp.
5. Remove the AIR inlet hose from the AIR pump (2).
6. Disconnect the AIR pump electrical connector.
7. Remove the upper AIR pump to cradle bolt.
8. Lift up and pull out the pump in order to remove the AIR pump (2) from the cradle bracket.

Installation Procedure

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1. Install the lower AIR pump bolts/nuts into the cradle bracket and push down.

2. Install the upper AIR pump to cradle bolt.

Tighten
Tighten the upper and lower AIR pump to cradle bolts to 9 N·m (80 lb in.)

3. Connect the AIR pump electrical connector.

4. Install the AIR outlet hose and pinch clamp to the AIR pump (2).
5. Install the AIR inlet hose to the AIR pump (2).
6. Lower the vehicle.

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Secondary Air Injection Vacuum Control Solenoid Valve

Replacement
Removal Procedure
1. Remove the fuel injector sight shield. Refer to XXX in Engine Mechanical.

2. Disconnect the AIR vacuum control valve electrical connector.

3. Disconnect the vacuum lines.
4. Remove the nut securing the AIR vacuum control valve to the bank 1 AIR shut-off valve
bracket.
5. Remove the AIR vacuum control valve.

Installation Procedure

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1. Install the AIR vacuum control valve to the bank 1 AIR shut-off valve bracket.

Tighten
Tighten the nut to 9 N·m (80 lb in).

2. Reconnect the vacuum lines.

3. Reconnect the AIR vacuum control valve electrical connector.
4. Install the fuel injection sight shield. Refer to XXX in Engine Mechanical

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Spark Plug Inspection

Spark Plug Usage
• Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability
conditions. Refer to Evaporative Emission Control System Description for the correct spark
plug.
• Ensure that the spark plug has the correct heat range. An incorrect heat range causes the
following conditions:
- Spark plug fouling--colder plug
- Pre-ignition causing spark plug and/or engine damage--hotter plug

Spark Plug Inspection

•

l Inspect the terminal post (1) for damage.

- Inspect for a bent or a broken terminal post (1).
- Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1)
should NOT move.
•

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l Inspect the insulator (2) for flashover, for carbon tracking, and for soot. These conditions
are caused by the electrical charge traveling across the insulator (2) between the terminal
post (1) and the ground. Inspect for the following conditions:
- Inspect the spark plug boot for damage.
- Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or
water. A spark plug boot that is saturated causes arcing to ground.
•

l Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the
crack instead of the electrodes (3, 4).
•

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l Inspect for evidence of improper arcing.

- Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer
to Evaporative Emission Control System Description . . An excessively wide electrode gap can
prevent correct spark plug operation.
- Inspect for the correct spark plug torque. Refer to Evaporative Emission Control System
Description . Insufficient torque can prevent correct spark plug operation. An over torqued
spark plug, causes the insulator (2) to crack.
- Inspect for signs of tracking that occurred near the insulator tip instead of the center
electrode (4).
- Inspect for a broken or worn side electrode (3).
- Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
• A rattling sound indicates internal damage.
• A loose center electrode (4) reduces the spark intensity.
- Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminate the
gap.
- Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped.
- Inspect for excessive fouling.
• l Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged
threads can cause the spark plug to not seat correctly during installation.

Spark Plug Visual Inspection

• Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are
normal combustion by-products from fuels with additives.
• Carbon Fouled--Dry, fluffy black carbon, or soot caused by the following conditions:
- Rich fuel mixtures
• Leaking fuel injectors

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• Excessive fuel pressure

• Restricted air filter element
• Incorrect combustion
- Reduced ignition system voltage output
• Weak coils
• Worn ignition wires
• Incorrect spark plug gap
- Excessive idling or slow speeds during light loads can keep spark plug temperatures so low
that normal combustion deposits may not burn off.
• Deposit Fouling--Oil, coolant, or additives that include substances such as silicone, or very
white coating, reduce the spark intensity. Most powdery deposits will not affect the spark
intensity unless the substances form into a glazing over the electrode.

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Spark Plug Replacement

Tools Required
J 43094 Spark Plug Boot Puller

Removal Procedure
1. Turn OFF the ignition switch.
2. Remove the ignition coil assembly. Refer to Ignition Coil Replacement - Bank 2 or Ignition
Coil Replacement - Bank 1 .
3. Use the J 43094 in order to remove the spark plug boots from the spark plugs.

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.

4. Remove the spark plugs from the engine.

Installation Procedure
Notice: Use only the spark plugs specified for use in the vehicle. Do not install spark plugs
that are either hotter or colder than those specified for the vehicle. Installing spark plugs of
another type can severely damage the engine.

1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to
the gap specifications. Refer to Ignition System Specifications . Correct as necessary.

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2. Install the spark plugs to the engine.

Tighten
Tighten the spark plugs between 17-23 N·m (13-16 lb ft).

3. Install the spark plug boots to the ignition coil assembly.

4. Refer to Ignition Coil Replacement - Bank 2 or Ignition Coil Replacement - Bank 1 .

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Throttle Body Assembly Replacement

Removal Procedure
Notice: Do not damage the MAF sensor screen. A damaged screen could restrict airflow and lead
to a driveability concern.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .

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2. Remove the MAF sensor electrical connector (1) from the MAF sensor (2).
3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .

4. Remove the PCV valve fresh air tube.

5. Remove the cruise control cable (2) from the accelerator controls cable bracket (1).
6. Remove the accelerator cable (3) from the accelerator controls cable bracket (1).
7. Remove the cruise control cable (2) from the throttle body lever.

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8. Remove the accelerator control cable (3) from the throttle body lever (2).

9. Remove the idle air control (IAC) valve electrical connector (1) from the IAC valve (4).
10. Remove the throttle position (TP) sensor electrical connector (2) from the TP sensor (3).

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11. Remove the fuel feed and return lines from the retainer (5) on the accelerator controls cable
bracket. Refer to Metal Collar Quick Connect Fitting Service .

12. Remove the transaxle shift cable clip (1) from the accelerator controls cable bracket.

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13. Remove the throttle body (2) from the water crossover (1).

14. Remove the accelerator controls cable bracket (3) from the throttle body (1).

Installation Procedure
Notice: Do not use a cleaner which contains methyl ethyl ketone. This extremely strong solvent
may damage components and is not necessary for this type of cleaning.

Use a carburetor cleaner in order to remove deposits.

Refer to the instructions provided with the cleaner.

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Notice: The outlet of the air cleaner assembly and the MAF sensor inlet duct must line up when
completely installed. Misalignment may cause incorrect airflow readings resulting in MIL
illumination or a driveability concern. An improperly installed inlet duct assembly or air cleaner
assembly may cause misalignment.

Important: DO NOT reuse the old throttle body gasket.

1. Install the throttle body (2) from the water crossover (1).

Tighten
Tighten the bolts to 12 N·m (106 lb in).

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2. Position the new throttle body gasket on to the throttle body.

3. Install accelerator control bracket bolts to the throttle body.

Tighten
Tighten the bolts to 12 N·m (106 lb in).

4. Install the IAC valve electrical connector (1) to the IAC valve (4).
5. Install the TP sensor electrical connector (2) to the TP sensor (3).

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6. Install the accelerator control cable (3) at the throttle body lever (2).

7. Install the cruise control cable (2) at the throttle body lever.
8. Install the accelerator cable (3) to the accelerator controls cable bracket (1).
9. Install the cruise control cable to the accelerator controls cable bracket (1).

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10. Install the transaxle shift cable clip (1) to the accelerator controls cable bracket.

11. Install the fuel feed and return lines from the retainer (5) on to the accelerator controls cable
bracket.

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12. Install the MAF sensor electrical connector (1) to the MAF sensor (2).
13. Install the air cleaner intake duct clamp to the air cleaner intake air duct.

Tighten
Tighten the air cleaner intake duct clamps to 3 N·m (27 lb in).

14. Install the PCV valve fresh air tube.

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15. Install the fuel injector sight shield.

Tighten
Tighten the nuts to 2.3 N·m (20 lb in ).

16. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
17. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .

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Throttle Position Sensor Replacement

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.

2. Remove the nuts (2) from the fuel injector sight shield (1).

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3. Remove the idle air control (IAC) electrical connector (1) from the throttle position (TP)
sensor (4).
4. Remove the TP sensor electrical connector (2) from the TP sensor (3).

5. Remove the throttle body assembly (2). Refer to Throttle Body Assembly Replacement .

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6. Remove the TP sensor mounting bolts (3) from the TP sensor (2).
7. Remove the TP sensor (2) from the throttle body (1).
8. Discard the O-ring.

Installation Procedure

1. Install the new O-ring on to the TP sensor.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the TP sensor (2) on to the throttle body (1).

Tighten
Tighten the TP sensor screws to 2.3 N·m (20 lb in).

3. Install the throttle body assembly (2). Refer to Throttle Body Assembly Replacement .

4. Install the TP sensor electrical connector (2) to the TP sensor (3).

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5. Install the IAC electrical connector (1) to the TP sensor (4).

6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.

7. Install the fuel injector sight shield (1) to the engine.

8. Install the fuel injector sight shield nuts (2) to the fuel injector sight shield (1).

Tighten
Tighten the TP sensor screws to 3 N·m (27 lb in).

9. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats .

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Fastener Tightening Specifications (LX5)

Specification
Application Metric English
Condenser Mounting Bolt 13 N·m 115 lb in
Cooling Fan Mounting Bolt 6 N·m 53 lb in
Drive Belt Idler Pulley Bolt 50 N·m 37 lb ft
EGR Inlet Pipe Bolt 24 N·m 18 lb ft
EGR Inlet Pipe Nut 60 N·m 44 lb ft
EGR Outlet Pipe Bolt (Intake Manifold Side) 10 N·m 89 lb in
EGR Outlet Pipe Bolt (Water Crossover Side) 24 N·m 18 lb ft
Electric Cooling Fan Blade Retaining Nut 6 N·m 53 lb in
Electric Cooling Fan Motor Mounting Screw 6 N·m 53 lb in
Engine Coolant Heater Bolt 10 N·m 89 lb in
Secondary AIR Relay Bracket Nut 6 N·m 53 lb in
Surge Tank Bolt and Nut 6 N·m 53 lb in
Surge Tank Inlet Pipe Retaining Bolt 9 N·m 80 lb in
Thermostat Housing Bolt 9 N·m 80 lb in
Transaxle Oil Cooler Line Retaining Bolt 6 N·m 53 lb in
Upper Radiator Mounting Bracket Bolt 10 N·m 89 lb in
Water Housing Crossover Bolt 25 N·m 18 lb ft
Water Pump Long Bolt 14 N·m 124 lb in
Water Pump Pulley Bolt 12 N·m 106 lb in
Water Pump Short Bolt 14 N·m 124 lb in

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Fastener Tightening Specifications (L47)

Specification
Application Metric English
Condenser Mounting Bolt 13 N·m 115 lb in
Cooling Fan Mounting Bolt 6 N·m 53 lb in
EGR Inlet Pipe Bolt 25 N·m 18 lb ft
EGR Inlet Pipe Nut 60 N·m 44 lb ft
Electric Cooling Fan Blade Retaining Nut 6 N·m 53 lb in
Electric Cooling Fan Motor Mounting Screw 6 N·m 53 lb in
Engine Coolant Heater Bolt 10 N·m 89 lb in
Fuel Rail Bracket Retaining Nut 4 N·m 35 lb in
Oil Level Indicator Tube Nut 10 N·m 89 lb in
Rear Lift Bracket Bolt 24 N·m 18 lb ft
Secondary AIR Relay Bracket Nut 6 N·m 53 lb in
Surge Tank Bolt and Nut 6 N·m 53 lb in
Surge Tank Inlet Fitting 47 N·m 35 lb ft
Thermostat Housing Bolt 10 N·m 89 lb in
Transaxle Oil Cooler Line (at Radiator) 31 N·m 23 lb ft
Transaxle Oil Cooler Line Retaining Bolt 6 N·m 53 lb in
Upper Radiator Mounting Bracket Bolt 10 N·m 89 lb in
Water Housing Crossover Bolt 25 N·m 18 lb ft
Water Pump 100 N·m 74 lb ft
Water Pump Belt Tensioner Bolt 10 N·m 89 lb in
Water Pump Cover bolt 10 N·m 89 lb in

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Coolant Level Switch

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Cooling Fans and Relays

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Cooling System Connector End Views

Table 1: Coolant Level Switch
Table 2: Cooling Fan - Left
Table 3: Cooling Fan - Right

Coolant Level Switch

• 12052641
Connector Part Information
• 2-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A YEL/BLK 68 Low Coolant Level Indicator Control
B BLK 250 Ground

Cooling Fan - Left

• 12085030
Connector Part Information
• 2-Way F Metri-Pack 630 Series (BLK)
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Pin Wire Color Circuit No. Function

A BLK 250 Ground
B LT BLU 409 Cooling Fan Motor Supply Voltage

Cooling Fan - Right

• 12085030
Connector Part Information
• 2-Way F Metri-Pack 630 Series (BLK)
Pin Wire Color Circuit No. Function
A WHT 504 Cooling Fan Motor Ground
B GRY 532 Cooling Fan Motor Supply Voltage

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Coolant Heater Cord Replacement (L47)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the coolant heater cord (1) from the right coolant heater (3).
3. Lower the vehicle.
4. Cut the coolant heater cord strap (2) from the engine wiring harness.

5. Disconnect the coolant

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6. Cut the coolant heater cord straps (2) from the engine wiring harness.
7. Remove the coolant heater cord (1) from the loom at the fuel rail support bracket.
8. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 4.0L.

9. Remove the coolant heater cord clips (3) from the fuel injector sight shield studs.
10. Remove the coolant heater cord (2) from the vehicle.

Installation Procedure

1. Install the coolant heater cord (2) to the vehicle.

2. Place the coolant heater cord clips (3) over the fuel injector sight shield studs.
3. Tie a new coolant heater cord strap (1) to the engine wiring harness at the front of the

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engine.

4. Connect the coolant heater cord (1) to the left coolant heater (3).
5. Tie new coolant heater cord straps (2) to the engine wiring harness at the rear of the engine.
6. Secure the excess coolant heater cord (1) to the loom at the fuel rail support bracket.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

8. Connect the coolant heater cord (1) to the right coolant heater (3).
9. Lower the vehicle.
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical - 4.0L.

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Coolant Heater Cord Replacement (LX5)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the coolant heater cord (2) from the right coolant heater (4).
3. Disconnect the coolant heater cord clip (3) from the vehicle speed sensor stud.
4. Lower the vehicle.
5. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 3.5L.
6. Cut the coolant heater cord straps (1) from the engine wiring harness.

© 2014 General Motors Corporation. All rights reserved.

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7. Disconnect the coolant heater cord (2) from the left coolant heater (3).
8. Remove the coolant heater cord (2) from the retainer clips (1).
9. Remove the coolant heater cord (2) from the loom at the rear engine lift bracket.
10. Remove the coolant heater cord (2) from the vehicle.

Installation Procedure

1. Install the coolant heater cord (2) to the vehicle.

2. Connect the coolant heater cord (2) to the left coolant heater (3).
3. Route the coolant heater cord (2) through the retainer clips (1).
4. Secure the excess coolant heater cord (2) to the loom at the rear engine lift bracket.

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5. Tie new coolant heater cord straps (1) to the engine wiring harness at the front of the
engine.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Connect the coolant heater cord (2) to the right coolant heater (4).
8. Connect the coolant heater cord clip (3) to the vehicle speed sensor stud.
9. Lower the vehicle.
10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical - 3.5L.

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Cooling System Draining and Filling (L47)

Draining Procedure
Caution: As long as there is pressure in the cooling system, the temperature can be considerably
higher than the boiling temperature of the solution in the radiator without causing the solution to
boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the
solution to boil instantaneously -- possibly with explosive force -- spewing the solution over the
engine, fenders and the person removing the cap.

Caution: An electric fan under the hood can start up even when the engine is not running and can
injure you. Keep hands, clothing and tools away from any underhood electric fan.

1. Remove the surge tank pressure cap.

1.1. Clean the cap.
1.2. Pressure test the cap.
1.3. If necessary, replace the cap.
1.4. Clean the surge tank filler neck. Inspect the filler neck.
2. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

3. Open the radiator drain at the bottom of the radiator.

4. Completely drain the cooling system.
5. If the coolant is dirty, or if there are deposits in the radiator, flush the cooling system before
refilling. Refer to Flushing .
6. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
6.1. Clean the outside of the surge tank.
6.2. Pour out any fluid.
6.3. Thoroughly clean the inside of the surge tank using soap and water.
© 2014 General Motors Corporation. All rights reserved.

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6.4. Thoroughly flush the surge tank with clean water and drain.
7. Install the surge tank. Refer to Radiator Surge Tank Replacement .
8. Close the radiator drain.
9. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

Filling Procedure
Notice: Do not add cold water to the cooling system with the engine at or above operating
temperature. Adding cold water causes rapid cooling, resulting in possible engine damage.

NOTICE: When adding coolant, it is important that you use GM Goodwrench DEX-COOL® or
HAVOLINE® DEX-COOL® coolant. If Coolant other than DEX-COOL® or HAVOLINE® DEX-COOL®
is added to the system the engine coolant will require change sooner; at 50 000 km (30,000 mi) or
24 months.

Notice: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze can freeze at -
22°C (-8°F).

Notice: This engine uses DEX-COOL® and GM coolant supplement (sealant) P/N 3634621
specifically designed for use in aluminum engines. Failure to use the engine coolant supplement
(sealant) and the approved coolant antifreeze could result in major engine damage. When refilling
the cooling system, add three pellets of the engine coolant supplement sealant GM P/N 3634621 to
the lower radiator hose.

Important: This engine is not equipped with block drains, 2.5 L (2 Qt) of residual coolant remains
in the engine block.

1. Refill the cooling system. In order to ensure sufficient engine cooling, freezing and corrosion
protection, maintain the protection level at -37°C (-34°F) or lower.
2. Start the engine.
3. Place the heater and A/C control in any A/C mode except Max and the temperature in the
highest setting.
4. Allow the engine to continue idling until the lower radiator to water pump hose is hot.
5. Turn OFF the engine.

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6. Allow the engine to cool to outside temperature. Ensure the coolant level in the surge tank is
at the proper level (1).

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Cooling System Draining and Filling (LX5)

Caution: An electric fan under the hood can start up even when the engine is not running and can
injure you. Keep hands, clothing and tools away from any underhood electric fan.

1. Remove the surge tank pressure cap.

3. Open the radiator drain at the bottom of the radiator.

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Filling Procedure
Notice: Do not add cold water to the cooling system with the engine at or above operating
temperature. Adding cold water causes rapid cooling, resulting in possible engine damage.

Notice: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze can freeze at -
22°C (-8°F).

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.

6. Allow the engine to cool to outside temperature. Ensure the coolant level in the surge tank is
at the proper level (1).

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Engine Coolant Crossover Pipe Replacement (L47)

Tools Required
J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 4.0L.

4. Disconnect the brake booster vacuum tube from the water housing crossover.
5. Disconnect the fuel regulator vacuum tube (1).
6. Disconnect the secondary AIR solenoid vacuum tube (2).
7. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls -
4.0 L.

© 2014 General Motors Corporation. All rights reserved.

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8. Disconnect the surge tank inlet hose from the fitting.

9. Disconnect the fuel rail bracket retaining nut at the rear lift bracket.

10. Remove the surge tank inlet fitting.

11. Remove the rear lift bracket bolt.
12. Remove the rear lift bracket.
13. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine
Controls - 4.0 L.

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14. Disconnect the EGR inlet pipe nut (1) from the front exhaust manifold pipe.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve inlet pipe must be replaced if disconnected from the water
crossover.

15. Remove the EGR inlet pipe bolt (2) and flange (3) from the water crossover.
16. Remove the EGR inlet pipe and discard.
17. Remove the EVAP emission canister purge valve. Refer to Evaporative Emission Canister
Purge Solenoid Valve Replacement in Engine Controls - 4.0L.

18. Disconnect the electrical connector from the MAP sensor.

19. Remove the MAP sensor.

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20. Position the J 38185 (2) to the clamp in order to remove the inlet radiator hose (1) from the
water housing crossover.
21. Remove the outlet radiator hose from the thermostat housing.
22. Remove the water pump. Refer to Water Pump Replacement .

23. Remove the two bolts (3) attaching the water pump belt tensioner (1) to the water
crossover.
24. Remove the water pump belt tensioner (1).

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25. Disconnect the cable harness clip at the water housing crossover and position aside.
26. Disconnect the heater hose from the water housing crossover.
27. Remove the water housing crossover from the engine.
28. Clean and inspect the water crossover. Refer to Water Crossover Cleaning and Inspection in
Engine Mechanical - 4.0 L Unit Repair.

Installation Procedure

1. With all 8 crossover retaining bolts inserted, slide the upper and lower water housing
crossover gaskets onto the bolts.

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Important: Care should be taken when installing the water housing bolts, so that the
gaskets are in the correct position.

2. Place the water housing crossover in position and hand start the bolts to hold the crossover
in place.

3. Tighten the water housing crossover bolts.

Tighten
Tighten the water housing crossover bolts to 25 N·m (18 lb ft).

4. Connect the heater hose to the water housing crossover.

5. Connect the cable harness clip to the water housing crossover.

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6. Install the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.

Tighten
Tighten the water pump belt tensioner bolts (3) to 10 N·m (89 lb in).

7. Install the water pump. Refer to Water Pump Replacement .

8. Connect the outlet radiator hose to the thermostat housing.

9. Position the J 38185 (2) to the clamp in order to connect the inlet radiator hose (1) to the
water housing crossover.

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10. Install the MAP sensor.

11. Connect the electrical connector to the MAP sensor.
12. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine
Controls - 4.0 L.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve inlet pipe must be replaced if disconnected from the water
crossover.

13. Hand start the NEW EGR inlet pipe nut (1) to the front exhaust manifold pipe to prevent
crossthreading.

Tighten

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Tighten the EGR inlet pipe nut to 60 N·m (44 lb ft).

14. Connect the EGR inlet pipe flange (3) to the water crossover.
15. Install the EGR inlet pipe-to-water crossover flange bolt (2).

Tighten
Tighten the EGR inlet pipe bolt to 25 N·m (18 lb ft).

16. Install the EVAP emission canister purge valve. Refer to Evaporative Emission Canister Purge
Solenoid Valve Replacement in Engine Controls - 4.0 L.

17. Position the rear lift bracket to the water crossover.

18. Install the rear lift bracket bolt.

Tighten
Tighten the rear lift bracket bolt to 24 N·m (18 lb ft).

19. Install the surge tank inlet fitting.

Tighten
Tighten the surge tank inlet fitting to 47 N·m (35 lb ft).

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20. Connect the surge tank inlet hose to the fitting.

21. Connect the fuel rail bracket retaining nut to the rear lift bracket.

Tighten
Tighten the fuel rail bracket retaining nut to 4 N·m (35 lb in).

22. Connect the secondary AIR solenoid vacuum tube (2) to the housing crossover.
23. Connect the fuel regulator vacuum tube (1).
24. Connect the brake booster vacuum tube.
25. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls -
4.0 L.
26. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine

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Mechanical - 4.0 L.
27. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
28. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Engine Coolant Crossover Pipe Replacement (LX5)

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine
Controls - 3.5 L.
3. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls -
3.5 L.
4. Disconnect the right exhaust manifold and position aside. Refer to Exhaust Manifold
Replacement - Right Side in Engine Exhaust.

5. Disconnect the inlet radiator hose (2) from the water housing crossover.

© 2014 General Motors Corporation. All rights reserved.

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6. Disconnect the heater inlet hose from the water crossover.

7. Disconnect the EGR inlet pipe nut (3) from the exhaust crossover.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve inlet pipe must be replaced if disconnected from the water
crossover.

8. Remove the EGR inlet pipe bolt (2) from the water crossover.
9. Remove the EGR inlet pipe (1) and discard.

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Important: The EGR valve outlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve outlet pipe must be replaced if disconnected from the water
crossover.

10. Remove the EGR valve outlet pipe bolts from the intake manifold and the water crossover.
11. Remove the EGR outlet pipe and discard.
12. Remove the EGR heat shield and EGR valve. Refer to Exhaust Gas Recirculation Valve
Replacement in Engine Controls - 3.5 L.

13. Remove the water housing crossover bolts (1-6).

14. Remove the water housing crossover from the engine.

15. Discard the water crossover gaskets.
16. If necessary, disassemble the water housing crossover. Refer to Water Crossover
Disassemble in Engine Mechanical-3.5L Unit Repair.
17. Clean and inspect the water housing crossover. Refer to Water Crossover Cleaning and

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Inspection in Engine Mechanical-3.5L Unit Repair.

Installation Procedure
1. If necessary, assemble the water housing crossover. Refer to Water Crossover Assemble in
Engine Mechanical-3.5L Unit Repair.

2. Position the new gaskets (1) to the water housing crossover.

Important: Care should be taken when installing the water housing crossover bolts, so that
the gaskets are in the correct position.

3. Place the water housing crossover in position.

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4. Hand start the water housing crossover bolts.

Tighten
Tighten water housing crossover bolts in sequence (1-6) to 25 N·m (18 lb ft).

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Important: The EGR valve inlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve inlet pipe must be replaced if disconnected from the water
crossover.

5. Hand start the NEW EGR inlet pipe-to-crossover pipe nut (3) to prevent crossthreading.

Tighten
Tighten the EGR inlet pipe nut to 60 N·m (44 lb ft).

6. Connect the EGR inlet pipe flange to the water crossover.

7. Install the EGR inlet pipe-to-water crossover flange bolt (2).

Tighten
Tighten the EGR inlet pipe bolt to 24 N·m (18 lb ft).

Important: The EGR valve outlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve outlet pipe must be replaced if disconnected from the water
crossover.

8. Install the NEW EGR outlet pipe with NEW O-ring seal.
9. Install the EGR outlet pipe-to-intake manifold bolts.

Tighten
Tighten the EGR outlet pipe-to-intake manifold bolts to 10 N·m (89 lb in).

10. Install the EGR outlet pipe-to-water crossover bolts

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Tighten
Tighten the EGR outlet pipe-to-water crossover bolts to 24 N·m (18 lb ft).

11. Install the EGR heat shield and EGR valve. Refer to Exhaust Gas Recirculation Valve
Replacement in Engine Controls - 3.5 L.

12. Connect the heater inlet hose to the water crossover.

13. Connect the inlet radiator hose (2) to the water housing crossover.
14. Connect the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side in
Engine Exhaust.
15. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls -
3.5 L.
16. Install the air cleaner inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine
Controls - 3.5 L.
17. Fill the cooling system. Refer to Cooling System Draining and Filling .

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18. Inspect for leaks.

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Engine Coolant Fan Replacement (L47)

Tools Required
• J 37097-A Hose Clamp Remover/Installer
• J 41623-B Cooler Quick Connect Tool

Removal Procedure
Caution: An electric fan under the hood can start up even when the engine is not running
and can injure you. Keep hands, clothing and tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or
damaged fan blade or housing should always be replaced.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
2. Remove the upper tie bar. Refer to Front End Upper Tie Bar Replacement in Body Front End.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .

4. Position the J 37097-A (3) to the clamp in order to remove the radiator hose (2) from the
radiator (1), and place aside over the engine.

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the upper transaxle oil cooler line retaining bolt and retainer from the fan shroud.
6. Slide the plastic cap off the quick connect joint.
7. Disconnect the upper transaxle oil cooler line from the radiator using the J 41623-B .

8. Disconnect the wiring harness electrical connectors (1) from the cooling fan motors.
9. Remove the clips (2) attaching the harness to the fan shroud.
10. Disconnect the 2 retainers from the A/C discharge hose.

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11. Remove the 2 fan shroud mounting bolts.

Important: Care should be taken when removing the cooling fan assembly not to damage
the lower attachment points of both the cooling fan assembly and radiator.

12. Lift the cooling fan assembly off the lower mounting features of the radiator and position
towards the right side of the vehicle in order to remove.

Important: The fan blade retaining nut is left hand thread, damage may occur to motor
threads if attempting to remove as a right hand thread nut.

13. Remove the fan retaining nut (5) from the motor (2).
14. Remove the fan (4) from the motor shaft.

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15. Remove the motor retaining screws (3).

16. Remove the motor (2) from the shroud (1).

Installation Procedure

1. Install the motor (2) to the shroud (1).

2. Install the motor retaining screws (3).

Tighten
Tighten the electric cooling fan motor mounting screws to 6 N·m (53 lb in).

3. Install the fan (4) to the motor shaft.

4. Install the fan retaining nut (5) to the motor (2).

Tighten
Tighten the electric cooling fan blade retaining nut to 6 N·m (53 lb in).

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Important: Care should be taken when installing the cooling fan assembly not to damage
the lower attachment points of both the cooling fan assembly and radiator.

5. Install the cooling fan assembly into position, aligning the lower feet of the shroud to the
mounting features on the radiator.

Important: The bolts retaining the cooling fan to the radiator end tanks are a special length
and should be the ONLY bolts used upon reinstallation. The use of longer bolts will damage
the radiator end tanks.

6. Install the cooling fan mounting bolts

Tighten
Tighten the cooling fan mounting bolts to 6 N·m (53 lb in).

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7. Connect the wiring harness electrical connectors (1) to the cooling fan motors.
8. Attach the wiring harness retaining clips (2) to the fan shroud.
9. Connect the 2 retainers to the A/C discharge hose.

10. Push the upper transaxle oil cooler line into the radiator quick connect fitting, until a "click" is
heard.
11. Tug gently on the cooler line to ensure proper retention.
12. Slide the plastic cap (1) over the quick connect joint.

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13. Install the upper transaxle oil cooler line retaining bolt to the fan shroud.

Tighten
Tighten the transaxle oil cooler line retaining bolt to 6 N·m (53 lb in).

14. Position the J 37097-A (3) to the clamp in order to connect the radiator hose (2) to the
radiator (1).
15. Install the upper tie bar. Refer to Front End Upper Tie Bar Replacement in Body Front End.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
17. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Engine Coolant Fan Replacement (LX5)

Tools Required
J 41623-B Cooler Quick Connect Tool

Removal Procedure
Caution: An electric fan under the hood can start up even when the engine is not running
and can injure you. Keep hands, clothing and tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or
damaged fan blade or housing should always be replaced.

3. Disconnect the wiring harness electrical connectors from the cooling fan motors.
4. Remove the clips attaching the wiring harness to the fan shroud.
5. Remove the lower air deflector. Refer to Front Air Deflector Replacement in Body Front End.

© 2014 General Motors Corporation. All rights reserved.

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6. Remove the transaxle oil cooler line retaining bolt and clip from the fan shroud.
7. Lower the vehicle.
8. Slide the plastic cap off the upper quick connect joint.
9. Disconnect the upper transaxle oil cooler line from the radiator using the J 41623-B

10. Remove the two fan shroud mounting bolts.

Important: Care should be taken when removing the cooling fan assembly not to damage
the lower attachment points of both the cooling fan assembly and radiator.

11. Lift the cooling fan assembly off the lower mounting features of the radiator and remove from
the vehicle.

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Important: The fan blade retaining nut is left hand thread, damage may occur to motor
threads if attempting to remove as a right hand thread nut.

12. Remove the fan retaining nut (5) from the motor (2).
13. Remove the fan (4) from the motor shaft.
14. Remove the motor retaining screws (3).
15. Remove the motor (2) from the shroud (1).

Installation Procedure

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1. Install the motor (2) to the shroud (1).

2. Install the motor retaining screws (3).

Tighten
Tighten the electric cooling fan motor mounting screws to 6 N·m (53 lb in).

3. Install the fan (4) to the motor shaft.

4. Install the fan retaining nut (5) to the motor (2).

Tighten
Tighten the electric cooling fan blade retaining nut to 6 N·m (53 lb in).

Important: Care should be taken when installing the cooling fan assembly not to damage
lower attachment points of both the cooling fan assembly and radiator.

5. Install the cooling fan assembly into position, aligning the lower feet of the shroud to the
lower mounting features on the radiator.

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6. Install the cooling fan mounting bolts

Tighten
Tighten the cooling fan mounting bolts to 6 N·m (53 lb in).

7. Push the upper transaxle oil cooler line into the radiator quick connect fitting, until a "click" is
heard.
8. Tug gently on the cooler line to ensure proper retention.
9. Slide the plastic cap (1) over the quick connect joint.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

11. Install the transaxle oil cooler line retaining clip and bolt to the fan shroud.

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Tighten
Tighten the transaxle oil cooler line retaining bolt to 6 N·m (53 lb in).

12. Install the lower air deflector. Refer to Front Air Deflector Replacement in Body Front End.

13. Connect the wiring harness electrical connectors to the cooling fan motors.
14. Attach the wiring harness retaining clips to the fan shroud.
15. Install the upper tie bar. Refer to Front End Upper Tie Bar Replacement in Body Front End.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.

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Engine Coolant Heater Replacement - Left Side (L47)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

3. Disconnect the electrical connector at the engine coolant heater (1).

4. Remove the engine coolant heater bolt.
5. Remove the left engine coolant heater (1).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Align the threaded hole in the engine block with the hole labeled "L" (2) on the left engine
coolant heater.

2. Install the left engine coolant heater (1).

3. Install the engine coolant heater bolt.

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Tighten
Tighten the engine coolant heater bolt to 10 N·m (89 lb in).

4. Connect the electrical connector to the engine coolant heater (1).

5. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
6. Lower the vehicle.

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Engine Coolant Heater Replacement - Left Side (LX5)

Removal Procedure
1. Remove the upper tie bar. Refer to Front End Upper Tie Bar Replacement in Body Front End.

2. Disconnect the coolant heater cord (2) from the left coolant heater (3).

3. Remove the engine coolant heater bolt.

4. Remove the left engine coolant heater.

© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure

1. Align the threaded hole in the engine block with the hole labeled "L" (2) on the left engine
coolant heater.

2. Install the left engine coolant heater.

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installing fasteners in order to avoid damage to parts and systems.

3. Install the engine coolant heater bolt.

Tighten
Tighten the engine coolant heater bolt to 10 N·m (89 lb in).

4. Connect the coolant heater cord (2) to the left coolant heater (3).
5. Install the upper tie bar. Refer to Front End Upper Tie Bar Replacement in Body Front End.

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Engine Coolant Heater Replacement - Right Side (L47)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the electrical connector at the engine coolant heater.

3. Remove the engine coolant heater bolt.
4. Remove the right engine coolant heater.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Align the threaded hole in the engine block with the hole labeled "R" (1) on the right engine
coolant heater.

2. Install the right engine coolant heater.

3. Install the engine coolant heater bolt.

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Tighten
Tighten the engine coolant heater bolt to 10 N·m (89 lb in).

4. Connect the electrical connector to the engine coolant heater.

5. Lower the vehicle.

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Engine Coolant Heater Replacement - Right Side (LX5)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Disconnect the coolant heater cord (2) from the right coolant heater (4).

3. Remove the engine coolant heater bolt.

4. Remove the right engine coolant heater.
© 2014 General Motors Corporation. All rights reserved.

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Installation Procedure

1. Align the threaded hole in the engine block with the hole labeled "R" (1) on the right engine
coolant heater.

2. Install the right engine coolant heater.

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installing fasteners in order to avoid damage to parts and systems.

3. Install the engine coolant heater bolt.

Tighten
Tighten the engine coolant heater bolt to 10 N·m (89 lb in).

4. Connect the coolant heater cord (2) to the right coolant heater (4).
5. Lower the vehicle.

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Engine Coolant Thermostat Replacement (L47)

Tools Required
J 38185 Spring Hose Clamp Pliers

Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L in order to gain access to the thermostat housing.
3. Position theJ 38185 to the clamp in order to remove the outlet radiator hose from the
thermostat housing.

4. Remove the thermostat housing bolts.

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the thermostat and the thermostat housing gasket from the water pump housing.
6. Remove the thermostat housing from the water pump housing.

Installation Procedure

1. Install the new thermostat and gasket into the water pump housing.
2. Position the thermostat housing to the water pump housing.

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3. Install the thermostat housing bolts.

Tighten
Tighten the thermostat housing bolts to 10 N·m (89 lb in).

4. Position theJ 38185 to the clamp in order to connect the outlet radiator hose to the
thermostat housing.
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Engine Coolant Thermostat Replacement (LX5)

Tools Required
J 38185 Hose Clamp Pliers

Both the thermostat housing and thermostat are serviced as an assembly.

Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling .

2. Position theJ 38185 to the clamps in order to remove the outlet radiator hose and outlet
heater hose from the thermostat housing.

© 2014 General Motors Corporation. All rights reserved.

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3. Remove the thermostat housing bolts.

4. Remove the thermostat housing/thermostat from the cylinder head.

Installation Procedure

1. Ensure the new thermostat housing seal (1) is properly seated into the groove of the
thermostat housing.

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2. Position the new thermostat housing/thermostat to the cylinder head.

3. Install the thermostat housing bolts.

Tighten
Tighten the thermostat housing bolts to 9 N·m (80 lb in).

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4. Position the J 38185 to the clamps in order to connect the outlet radiator hose and outlet
heater hose to the thermostat housing.
5. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Flushing
1. Park the vehicle on a level surface.
2. Remove and clean (flush) the coolant surge tank. Refer to Radiator Surge Tank
Replacement .
3. Flush the engine cooling system. Follow the flushing equipment manufacturer's instructions.
4. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement .
5. Fill the cooling system. Refer to Cooling System Draining and Filling .

© 2014 General Motors Corporation. All rights reserved.

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Radiator Inlet Hose Replacement (L47)

Tools Required
J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the coolant. Refer to Cooling System Draining and Filling .

2. Using the J 38185 loosen and move the inlet radiator hose clamp (1)
3. Remove the inlet radiator hose from the radiator.

© 2014 General Motors Corporation. All rights reserved.

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4. Using the J 38185 loosen and move the inlet radiator hose clamp at the engine.
5. Remove the inlet radiator hose from the engine.
6. Disconnect the hose clip (1) at the upper radiator support bar and remove the hose.

Installation Procedure

1. Install the inlet radiator hose to the engine.

2. Using the J 38185 install the inlet radiator hose clamp at the engine.
3. Position the hose and fasten to the clamp (1) at the upper radiator support.

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4. Install the inlet radiator hose to the radiator.

5. Using the J 38185 install the inlet radiator hose clamp (1) at the radiator.
6. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Radiator Inlet Hose Replacement (LX5)

Tools Required
J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .

2. Position the J 38185 to the clamp in order to remove the inlet radiator hose (2) from the
water housing crossover.

© 2014 General Motors Corporation. All rights reserved.

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3. Position the J 38185 to the clamp in order to remove the inlet radiator hose from the
radiator.

Installation Procedure

1. Position the J 38185 to the clamp in order to connect the inlet radiator hose to the radiator.

2. Position the J 38185 to the clamp in order to connect the inlet radiator hose (2) to the water
housing crossover.
3. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Radiator Outlet Hose Replacement (L47)

Tools Required
• J 37097-A Hose Clamp Remover/Installer
• J 38185 Hose Clamp Pliers

Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
2. Drain the cooling system. Refer to Cooling System Draining and Filling .

3. Using the J 37097-A loosen and move the outlet radiator hose clamp (1) at the radiator.
4. Remove the outlet radiator hose from the radiator.

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5. Using the J 38185 loosen and move the outlet radiator hose clamp at the engine.
6. Remove the outlet radiator hose (1) from the engine.

Installation Procedure

1. Install the outlet radiator hose (1) to the engine.

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2. Install the outlet radiator hose to the radiator.

3. Using the J 37097-A install the outlet radiator hose clamp (1).
4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
5. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Radiator Outlet Hose Replacement (LX5)

Tools Required
J 38185 Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .

2. Position the J 38185 to the clamp in order to remove the outlet radiator hose (1) from the
thermostat housing.

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3. Position the J 38185 to the clamp in order to remove the outlet radiator hose from the
radiator.

Installation Procedure

1. Position the J 38185 to the clamp in order to connect the outlet radiator hose to the radiator.

2. Position the J 38185 to the clamp in order to connect the outlet radiator hose (1) to the
thermostat housing.
3. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Radiator Replacement (L47)

Tools Required
J 37097-A Hose Clamp Remover/Installer

Removal Procedure
1. Remove the cooling fans. Refer to Engine Cooling Fan Replacement .

2. Position the J 37097-A to the clamp in order to remove the outlet radiator hose from the
radiator.
3. Disconnect the lower transaxle oil cooler line from the radiator.

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4. Remove the upper radiator seal.

5. Remove the headlamps. Refer to Headlamp Replacement in Lighting Systems.

6. Remove the 2 condenser mounting bolts.

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Important: Care should be taken when removing the condenser not to damage the lower
attachment points of both the radiator and condenser.

7. Lift the condenser upward slightly in order to release the lower feet from the lower mounting
features located at the front of the radiator.
8. Lift the radiator up and out of the vehicle.

Installation Procedure

1. Position the radiator behind the condenser.

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Important: Care should be taken when installing the condenser not to damage the lower
attachment points of both the radiator and condenser.

2. Position the condenser, aligning the lower feet to the lower mounting features located at the
front of the radiator.

Important: The bolts retaining the condenser to the radiator end tanks are a special length
and should be the ONLY bolts used upon reinstallation. The use of longer bolts will damage
the radiator end tanks.

3. Install the condenser mounting bolts.

Tighten
Tighten the condenser mounting bolts to 13 N·m (115 lb in).

4. Install the headlamps. Refer to Headlamp Replacement in Lighting Systems.

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5. Install the upper radiator seal.

Important: Ensure the lower transaxle oil cooler line is positioned upwards while tightening.

6. Connect the lower transaxle oil cooler line into the radiator.

Tighten
Tighten the transaxle oil cooler line to 31 N·m (23 lb ft).

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7. Position the J 37097-A to the clamp in order to connect the outlet radiator hose to the
radiator.
8. Install the cooling fans. Refer to Engine Cooling Fan Replacement .

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Radiator Replacement (LX5)

Tools Required
J 41623-B Cooler Quick Connect Tool

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the cooling fans. Refer to Engine Cooling Fan Replacement .

3. Disconnect the upper and lower radiator hoses from the radiator and position aside.
4. Slide the plastic cap off the lower quick connect joint.
5. Disconnect the lower Transaxle oil cooler line from the radiator using the J 41623-B .

© 2014 General Motors Corporation. All rights reserved.

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6. Remove the upper radiator seal.

7. Remove the front headlamps. Refer to Headlamp Replacement in Lighting Systems.

8. Remove the 2 condenser mounting bolts.

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Important: Care should be taken when removing the condenser not to damage the lower
attachment points of both the radiator and condenser.

9. Lift the condenser upward slightly in order to release the lower feet from the lower mounting
features located at the front of the radiator.
10. Lift the radiator up and out of the vehicle.

Installation Procedure

1. Position the radiator behind the condenser.

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Important: Care should be taken when installing the condenser not to damage the lower
attachment points of both the radiator and condenser.

2. Position the condenser, aligning the lower feet to the lower mounting features located at the
front of the radiator.

3. Install the condenser mounting bolts.

Tighten
Tighten the condenser mounting bolts to 13 N·m (115 lb in).

4. Install the headlamps. Refer to Headlamp Replacement in Lighting Systems.

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5. Install the upper radiator seal.

6. Push the lower transaxle oil cooler line into the radiator quick connect fitting, until a "click" is
heard.
7. Tug gently on the cooler line to ensure proper retention.
8. Slide the plastic cap (1) over the quick connect joint.

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9. Install the upper and lower radiator hoses to the radiator.

10. Install the cooling fans. Refer to Engine Cooling Fan Replacement .
11. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Radiator Surge Tank Replacement

Tools Required
J 37097-A Hose Clamp Remover/Installer

Removal Procedure
1. Partially drain the engine coolant. Refer to Cooling System Draining and Filling

2. Disconnect the surge tank inlet hose from the surge tank.

© 2014 General Motors Corporation. All rights reserved.

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3. Remove the secondary AIR relay bracket mounting nuts (2).

4. Remove the secondary AIR relay bracket (1).

5. Remove the surge tank mounting screw (3) and nuts (2).
6. Disconnect the coolant level sensor.

7. Position the J 37097-A in order to release the clamp and the surge tank outlet hose from the
surge tank.
8. Remove the surge tank.

Installation Procedure

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1. Install the surge tank outlet hose to the surge tank.

2. Position the surge tank (1) over the two studs at the wheelhouse.

3. Install the surge tank fasteners and push nut (3).

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Tighten
Tighten the surge tank nut (2) and bolt (4) to 6 N·m (53 lb in).

4. Connect the coolant level sensor electrical connection.

5. Install the secondary AIR relay bracket (1) over the studs.
6. Install the two secondary AIR relay bracket nuts (2).

Tighten
Tighten the secondary AIR relay bracket nuts (2) to 6 N·m (53 lb in).

7. Connect the surge tank inlet hose to the surge tank.

8. Fill the cooling system. Refer to Cooling System Draining and Filling

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Surge Tank Pipe Replacement - Inlet (L47)

Removal Procedure
1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-4.0L.
2. Partially drain the Cooling system. Refer to Cooling System Draining and Filling .

3. Disconnect the surge tank inlet hose from the surge tank.

4. Remove the PCV fresh air tube (1).

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5. Disconnect the surge tank inlet hose from the engine.

6. Remove the 2 push nuts attaching the pipe to the engine.

7. Remove the surge tank inlet hose/pipe assembly from the vehicle.

Installation Procedure

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1. Install the surge tank inlet hose/pipe assembly to the vehicle.

2. Install the 2 push nuts attaching the pipe to the engine.

3. Connect the surge tank inlet hose to the engine.

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4. Install the PCV fresh air tube (1).

5. Connect the surge tank inlet hose to the surge tank.

6. Fill the cooling system. Refer to Cooling System Draining and Filling .
7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-4.0L.

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Surge Tank Pipe Replacement - Inlet (LX5)

Removal Procedure
1. Partially drain the cooling system. Refer to Cooling System Draining and Filling .

2. Disconnect the surge tank inlet hose from the surge tank.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 3.5 L.

4. Disconnect the surge tank inlet hose from the engine.

5. Remove the bolt attaching
© 2014the pipeMotors
General assembly to theAll
Corporation. engine.
rights reserved.

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6. Remove the surge tank inlet pipe assembly.

Installation Procedure

1. Install the surge tank inlet pipe assembly to the engine.

2. Install the bolt attaching the pipe assembly to the engine.

Tighten
Tighten the surge tank inlet pipe bolt to 9 N·m (80 lb in).

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3. Connect the surge tank inlet hose to the surge tank.

4. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical - 3.5 L.
5. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Surge Tank Pipe Replacement - Outlet (L47)

Tools Required
• J 37097-A Hose Clamp Remover/Installer
• J 38185 Hose Clamp Pliers

Removal Procedure
1. Partially drain the engine coolant. Refer to Cooling System Draining and Filling

2. Position the J 37097-A (3) to the clamp in order to remove the surge tank outlet hose (2)
from the surge tank (1).

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3. Position the J 38185 (3) to the clamp in order to remove the surge tank outlet hose (1) from
the heater pipe (2).

4. Remove the 2 push nuts (2) attaching the surge tank outlet hose (1) to the cowl panel.
5. Remove the surge tank outlet hose (1) from vehicle.

Installation Procedure

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1. Position the surge tank outlet hose (1) over the studs at the cowl panel.
2. Install the 2 push nuts (2) attaching the surge tank outlet hose (1) to the cowl panel.

3. Position the J 38185 (3) to the clamp in order to connect the surge tank outlet hose (1) to
the heater pipe (2).

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4. Position the J 37097-A (3) to the clamp in order to connect the surge tank outlet hose (2) to
the surge tank (1).
5. Fill the cooling system. Refer to Cooling System Draining and Filling

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Surge Tank Pipe Replacement - Outlet (LX5)

Tools Required
J 38185 Hose Clamp Pliers

Removal Procedure
1. Partially drain the engine coolant. Refer to Cooling System Draining and Filling .

2. Position the J 38185 to the clamp in order to remove the surge tank outlet hose (2) from the
surge tank (1).
3. Position the J 38185 to the clamp in order to remove the surge tank outlet hose (2) from the
heater pipe (3).
4. Remove the surge tank outlet hose (2) from vehicle.

Installation Procedure

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1. Position the J 38185 to the clamp in order to connect the surge tank outlet hose (2) to the
heater pipe (3).
2. Position the J 38185 to the clamp in order to connect the surge tank outlet hose (2) to the
surge tank (1).
3. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Water Pump Replacement (L47)

Tools Required
J 38816-A Water Pump Remover & Installer

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
3. Remove the secondary AIR injection control valve. Refer to Secondary Air Injection Control
Valve Replacement - Bank 2 in Engine Controls - 4.0 L.
4. Remove the oil level indicator tube nut.

5. Remove the water pump belt cover.

© 2014 General Motors Corporation. All rights reserved.

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6. Remove the water pump drive belt (4).

7. Disconnect the radiator outlet hose from the thermostat housing.

8. Remove the water pump cover bolts.

9. Remove the water pump cover.
10. Disconnect the heater return hose.

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11. Position the J 38816-A to the water pump locking ears.

12. Fasten the support plate to the water housing crossover, to ensure proper engagement of the
tool to the water pump locking ears.
13. Using the J 38816-A , turn the pump clockwise in order to remove the pump from the
housing.
14. Remove the support plate from the water housing crossover.

15. Remove the water pump from the vehicle.

16. Remove the seal from the water crossover.
17. Clean the sealing surfaces of the water housing crossover and the pump cover.
18. Clean and inspect the water pump. Refer to Water Pump Cleaning and Inspection in Engine
Mechanical - 4.0 L Unit Repair.

Installation Procedure

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1. Insert the seal into the recessed portion of the water crossover.

Important: The notched locking ear (1) must be in the 7 o'clock position.

2. Index the water pumps locking ears with the tangs in the water crossover.

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3. Position the J 38816-A to the water pump locking ears.

4. Fasten the support plate to the water housing crossover, to ensure proper engagement of the
tool to the water pump locking ears.

5. Turn the J 38816-A counterclockwise.

Tighten
Tighten the water pump to 100 N·m (74 lb ft).

6. Remove the support plate from the water housing crossover.

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7. Connect the water pump cover to the heater return hose.

8. Install the water pump cover to the water housing crossover.
9. Install the water pump cover bolts.

Tighten
Tighten the water pump cover bolts to 10 N·m (89 lb in).

10. Connect the radiator outlet hose to the thermostat housing.

11. Install the water pump drive belt (4).

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12. Install the water pump belt cover.

13. Install the oil level indicator tube nut.

Tighten
Tighten the oil level indicator tube nut to 10 N·m (89 lb in).

14. Install the secondary AIR injection control valve. Refer to Secondary Air Injection Control
Valve Replacement - Bank 2 in Engine Controls - 4.0 L.
15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0 L.
16. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Water Pump Replacement (LX5)

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Loosen the water pump pulley bolts.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 L.

4. Remove the drive belt idler pulley bolt.

5. Remove the drive belt idler pulley.

6. Remove the water pump pulley

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7. Remove the water pump pulley.

8. Remove the long water pump bolts (1).

9. Remove the short water pump bolts (1).

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10. Remove the water pump from the engine.

11. Remove the water pump gasket.
12. Clean and inspect the water pump. Refer to Water Pump Cleaning and Inspection in Engine
Mechanical - 3.5 L Unit Repair.

Installation Procedure

1. Install the new water pump gasket.

2. Place the water pump in position on the front cover.

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3. Install the short water pump bolts.

Tighten
Tighten the short water pump bolts in the sequence shown to 14 N·m (124 lb in).

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4. Install the long water pump bolts (1).

Tighten
Tighten the long water pump bolts to 14 N·m (124 lb in).

5. Install the water pump pulley.

6. Install the water pump pulley bolts and hand tighten.

7. Install the drive belt idler pulley.

8. Install the drive belt idler pulley bolt.

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Tighten
Tighten the drive belt idler pulley bolt to 50 N·m (37 lb ft).

9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 L.
10. Tighten the water pump pulley bolts.

Tighten
Tighten the water pump pulley bolts to 12 N·m (106 lb in).

11. Fill the cooling system. Refer to Cooling System Draining and Filling .

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Fastener Tightening Specifications

Specification
Application Metric English
A/C Compressor Mounting Fasteners (LX5)
l Bolts 50 N·m 37 lb ft
l Front Nut 50 N·m 37 lb ft
l Rear Nut 25 N·m 18 lb ft
Battery Cables to Battery Bolt 17 N·m 13 lb ft
Battery Cable to Rear Fuse Block Nut 15 N·m 11 lb ft
Battery Negative Cable to Floor Pan Bolt 36 N·m 27 lb ft
Battery Positive Cable to Remote Positive Terminal Nut (LX5) 15 N·m 11 lb ft
Battery Positive Cable to Remote Positive Terminal Nut (L47) 12 N·m 106 lb in
Battery Retainer Bolt 17 N·m 13 lb ft
Drive Belt Idler Pulley Bolt (LX5) 50 N·m 37 lb ft
Engine Ground Cable Bolt (L47) 50 N·m 37 lb ft
Generator Mounting Bolts 50 N·m 37 lb ft
Generator Output BAT Terminal Nut 12.5 N·m 111 lb in
Starter Motor Mounting Bolts (LX5) 50 N·m 37 lb ft
Starter Motor Mounting Bolts (L47) 30 N·m 22 lb ft
Starter Solenoid BAT Terminal Nut 10 N·m 89 lb in
Starter Solenoid "S" Terminal Nut (LX5) 3.4 N·m 30 lb in
Starter Solenoid "S" Terminal Nut (L47) 4 N·m 35 lb in

© 2014 General Motors Corporation. All rights reserved.

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Battery Usage
Application Specification
Catalog Number 1819
Cold Cranking Amperage (CCA) 770 A
Reserve Capacity 115 Minutes
Replacement Model Number 100-6YR

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Engine Electrical Connector End Views

Generator

• 12047950
Connector Part Information
• 4-Way M Metri-Pack Mixed Series (BLK)
Pin Wire Color Circuit No. Function
A -- -- Not Used
B RED 225 Generator Turn On Signal
C GRY 23 Generator Field Duty Cycle Signal
D ORN 3340 Battery Positive Voltage

© 2014 General Motors Corporation. All rights reserved.

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Generator Usage
Application Specification
Generator Model AD237
Rated Output 125 A
Load Test Output 87 A

© 2014 General Motors Corporation. All rights reserved.

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Starter Usage
Application Model
Starter Model (L47) PG-260L
Starter Model (LX5) PG-260M

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Generator Controls and Battery

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Starter Soleniod Controls

© 2014 General Motors Corporation. All rights reserved.

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Battery Negative Cable Disconnection and Connection

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

2. Disconnect the negative battery cable from the battery.

Installation Procedure

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1. Connect the negative battery cable to the battery.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

2. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Battery Negative Cable Replacement

Removal Procedure
Important:
• Always use replacement cables that are of the same type, diameter and length of the cables
that you are replacing.
• Always route the replacement cable the same way as the original cable.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

2. Disconnect the body harness from the battery negative cable.

3. Disconnect the battery negative cable from the floor pan.
4. Remove the battery negative cable from the vehicle.

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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Important: When installing the battery negative cable, be sure that the cable eyelet is
installed with the flat side down. Keep the crimped side facing upward.

1. Connect the body end of the battery negative cable to the floor pan.

Tighten
Tighten the battery negative cable to floor pan bolt to 36 N·m (27 lb ft).

2. Connect the body harness connector to the body harness.

3. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Battery Positive Cable Replacement

1. Remove the interior trim moldings. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim to expose the positive battery cable.
2. Position the passenger seat rearward to gain access to the underside of the instrument panel.
3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

4. Disconnect the battery positive cable (1) from the battery.

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5. Remove the nut (1) securing the battery positive cable to the rear fuse block.
6. Remove the right closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gages and Console.

7. Remove the battery cable retainers (2) from the rocker panel area.

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8. Remove the remote positive terminal nut (1) and disconnect the battery positive cable from
the underhood fuse block (2).
9. Remove the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.

10. Disconnect the battery cable retainer from the body side rail.
11. Remove the blower motor to gain access to the battery cable grommet. Refer to Blower
Motor Replacement in Heating Ventilation and Air Conditioning.

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12. Unseat the battery cable grommet (2) from the cowl panel (3).
13. Carefully remove the battery cable (1) from the vehicle by pulling the cable through the cowl
panel (3) and out of the vehicle.

Installation Procedure

Important: Protect the battery cable with tape prior to inserting through the cowl to prevent
cutting of the insulation while installing the cable.

1. Slide the battery cable (1) through the opening in the cowl panel (3).

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2. Seat the cable grommet (2) by pressing the grommet into the cowl toward the engine
compartment.
3. Install the blower motor. Refer to Blower Motor Replacement in Heating Ventilation and Air
Conditioning.

4. Install the battery cable retainer to the body side rail.

5. Install the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.

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6. Connect the battery positive cable to the underhood fuse block (2).
• LX5

Tighten
Tighten the battery positive cable to remote positive terminal nut to 15 N·m (11 lb ft).

• L47

Tighten
Tighten the battery positive cable to remote positive terminal nut to 12 N·m (106 lb in).

7. Route the battery cable (1) along the rocker panel and install the cable retainers (2).
8. Install the right closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gages and Console.

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9. Connect the battery positive cable to the rear fuse block.

Tighten
Tighten the battery positive cable to rear fuse block nut (1) to 15 N·m (11 lb ft).

10. Connect the battery positive cable (1) to the battery.

Tighten
Tighten the battery cable bolt to 17 N·m (13 lb ft).

11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
12. Install the interior trim moldings. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.

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Battery Replacement
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

2. Disconnect the battery positive cable (1) from the battery.

3. Remove the battery vent tube (1) from the battery.

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4. Remove the battery retainer bolt and battery retainer.

5. Remove the battery.

Installation Procedure

1. Install the battery.

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2. Install the battery retainer and bolt.

Tighten
Tighten the battery retainer bolt to 17 N·m (13 lb ft).

Important: Ensure the vent tube (1) is properly routed through the floor pan grommet.

3. Install the battery vent tube (1) to the battery.

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4. Connect the battery positive cable (1) to the battery.

Tighten
Tighten the battery cable bolt to 17 N·m (13 lb ft).

5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Engine Ground Strap Replacement (L47)

1. Remove the bolt (1) securing the engine ground cable (2) to the right side body frame rail.
2. Remove the bolt securing the engine ground cable to the generator.
3. Remove the engine ground cable from the vehicle.

Installation Procedure
1. Position the engine ground cable to the engine.

2. Install the bolt securing the engine ground cable to the generator.

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Tighten
Tighten the generator mounting bolt to 50 N·m (37 lb ft).

3. Install the bolt (1) securing the engine ground cable (2) to the right side body frame rail.

Tighten
Tighten the engine ground cable bolt to 50 N·m (37 lb ft).

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Generator Cable Replacement (L47)

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical-
4.0L.

3. Remove the nut (1) securing the battery positive cable to the remote positive terminal.

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4. Disconnect the starter solenoid BAT terminal wire from the starter.

5. Reposition the protective boot from the generator output BAT terminal for access.
6. Remove the generator output BAT terminal nut and disconnect the positive lead from the
generator.

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7. Disconnect the cable harness clips from the front of the camshaft cover.
8. Remove the generator cable from the vehicle.

Installation Procedure
1. Position the generator cable to the engine.

2. Connect the battery positive lead and install the generator output BAT terminal nut.

Tighten
Tighten the generator output BAT terminal nut to 12.5 N·m (111 lb in).

3. Press the protective boot on to the generator output BAT terminal.

4. Connect the cable harness clips to the front of the camshaft cover.

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5. Connect the starter solenoid BAT terminal wire.

Tighten
Tighten the starter solenoid BAT terminal nut to 10 N·m (89 lb in).

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6. Install the nut (1) securing the battery positive cable to the remote positive terminal.

Tighten
Tighten the battery positive cable to remote positive terminal nut to 12 N·m (106 lb in).

7. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical-4.0L.
8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Generator Replacement (L47)

Removal Procedure
The Delphi AD237 (KG7) generator is serviced as a complete unit only.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-4.0L.
3. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.

4. Disconnect the wiring harness connector from the generator.

5. Reposition the protective boot from the generator output BAT terminal for access.
6. Remove the generator output BAT terminal nut and disconnect the positive lead from the
generator.

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7. Loosen the lower generator bolt (3).

8. Remove the generator bolts (1, 2) from the generator.
9. Remove the generator from the vehicle.

Installation Procedure

1. Position the generator to the A/C compressor and engine.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the generator mounting bolts (1, 2).

Tighten
Tighten the generator mounting bolts to 50 N·m (37 lb ft).

3. Connect the wiring harness connector to the generator.

4. Connect the battery positive lead and install the generator output BAT terminal nut.

Tighten
Tighten the generator output BAT terminal nut to 12.5 N·m (111 lb in).

5. Press the protective boot on to the generator output BAT terminal.

6. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
7. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-4.0L.
8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Generator Replacement (LX5)

Removal Procedure
The Delphi AD237 (KG7) generator is serviced as a complete unit only.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 L.
3. Remove the engine cooling fan assembly. Refer to Engine Cooling Fan Replacement in Engine
Cooling.

4. Disconnect the wiring harness connector from the generator.

5. Reposition the protective boot from the generator output BAT terminal for access.
6. Remove the generator output BAT terminal nut and disconnect the battery positive lead from
the generator.

© 2014 General Motors Corporation. All rights reserved.

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7. Remove the drive belt idler pulley bolt and the drive belt idler pulley.
8. Remove the 2 upper generator mounting bolts.
9. Position the generator upward in order to gain access to the two upper A/C compressor
mounting bolts.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

11. Remove the upper A/C compressor mounting bolts (1).

12. Loosen the rear A/C compressor nut (2).
13. Remove the front A/C compressor nut (3).
14. Carefully position the A/C compressor away from the engine block, in order to allow
clearance to remove the generator.
15. lower the vehicle.
16. Remove the generator from the vehicle.

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Installation Procedure
1. Position the generator to the engine.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

3. Install the A/C compressor to the front (4) and rear (5) studs on the engine block.

4. Install and hand tighten the A/C compressor mounting bolts (1) and nuts (2, 3).

Tighten
• Tighten the front nut (3) to 50 N·m (37 lb ft).
• Tighten the bolts (1) to 50 N·m (37 lb ft).
• Tighten the rear nut (2) to 25 N·m (18 lb ft).
5. Lower the vehicle.

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6. Install and hand tighten the 2 upper generator mounting bolts.

7. Install the drive belt idler pulley and drive belt idler pulley bolt.
8. Tighten the bolts in the order described. The following is a mandatory torque sequence:

Tighten
Tighten the idler pulley bolt to 50 N·m (37 lb ft).

Tighten
Tighten the generator mounting bolts to 50 N·m (37 lb ft).

9. Connect the wiring harness connector to the generator.

10. Connect the battery positive lead and install the generator output BAT terminal nut.

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Tighten
Tighten the generator output BAT terminal nut to 12.5 N·m (111 lb in).

11. Press the protective boot on to the generator output BAT terminal.
12. Install the engine cooling fan assembly. Refer to Engine Cooling Fan Replacement in Engine
Cooling.
13. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 L.
14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Starter Replacement (L47)

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical-
4.0 L.

3. Disconnect the BAT cable from the starter solenoid.

4. Disconnect the wire from the "S" terminal on the starter solenoid.

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5. Remove the 2 starter motor mounting bolts.

6. Remove the starter motor.

Installation Procedure

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may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

1. Connect the starter solenoid "S" terminal wire.

Tighten
Tighten the starter solenoid "S" terminal nut to 4 N·m (35 lb in).

2. Connect the starter solenoid BAT terminal wire.

Tighten
Tighten the starter solenoid BAT terminal nut to 10 N·m (89 lb in).

3. Install the starter motor.

4. Install the starter motor mounting bolts.

Tighten
Tighten the starter motor mounting bolts to 30 N·m (22 lb ft).

5. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical-4.0 L.
6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Starter Replacement (LX5)

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the lower air deflector. Refer to Front Air Deflector Replacement in Body Front End.
4. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in
Automatic Transaxle-4T65-E.

5. Disconnect the BAT cable from the starter solenoid.

6. Disconnect the wire from the "S" terminal on the starter solenoid.

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7. Remove the 2 starter motor mounting bolts.

8. Remove the starter motor.

Installation Procedure

1. Install the starter motor.

2. Install the starter motor mounting bolts.

Tighten
Tighten the starter motor mounting bolts to 50 N·m (37 lb ft).

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3. Connect the starter solenoid BAT terminal wire.

Tighten
Tighten the starter solenoid BAT terminal nut to 10 N·m (89 lb in).

4. Connect the starter solenoid "S" terminal wire.

Tighten
Tighten the starter solenoid "S" terminal nut to 3.4 N·m (30 lb in).

5. Install the torque converter cover. Refer to Torque Converter Cover Replacement in
Automatic Transaxle-4T65-E.
6. Install the lower air deflector. Refer to Front Air Deflector Replacement in Body Front End.
7. Lower the vehicle.
8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection .

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Fastener Tightening Specifications (L47)

Specification
Application Metric English
Catalytic Converter Nut 25 N·m 18 lb ft
Center Exhaust Hanger Bolt 30 N·m 22 lb ft
Coil Cassette Ground Wire Nut 17 N·m 13 lb ft
EGR Inlet Pipe Nut 60 N·m 44 lb ft
Engine Frame Bolt 191 N·m 141 lb ft
Engine Mount Nut 80 N·m 59 lb ft
Exhaust Manifold Bolt 25 N·m 18 lb ft
Exhaust Manifold Nut 25 N·m 18 lb ft
Exhaust Manifold Rear Pipe to Exhaust Manifold Flange Seal Retainer Bolt 25 N·m 18 lb ft
Exhaust Manifold Rear Pipe to Right Exhaust Manifold Bolt 40 N·m 30 lb ft
Front Exhaust Manifold Pipe Bolt 25 N·m 18 lb ft
Front Exhaust Manifold Pipe Support Bolt 25 N·m 18 lb ft
Intermediate Shaft Pinch Bolt 45 N·m 33 lb ft
Muffler Clamp Nut 40 N·m 30 lb ft
Power Steering Gear Heat Shield Bolt 9 N·m 80 lb in
Rear Exhaust Hanger Bolt 50 N·m 37 lb ft
Rear Exhaust Hanger Nut 30 N·m 22 lb ft
Secondary AIR Tube Nut 12 N·m 106 lb in
Transaxle Mount Nut 80 N·m 59 lb ft
Vehicle Speed Sensor Heat Shield Nut 50 N·m 37 lb ft

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Fastener Tightening Specifications (LX5)

Specification
Application Metric English
Accelerator Control Cable Bracket Bolt 13 N·m 115 lb in
Accelerator Control Cable Bracket Nut 10 N·m 89 lb in
Catalytic Converter Nut 25 N·m 18 lb ft
Center Exhaust Hanger Bolt 30 N·m 22 lb ft
EGR Inlet Pipe Nut 60 N·m 44 lb ft
Exhaust Manifold Bolt 25 N·m 18 lb ft
Exhaust Manifold Crossover Bolt 25 N·m 18 lb ft
Exhaust Manifold Heat Shield Bolt 9 N·m 80 lb in
Exhaust Manifold Pipe Nut 50 N·m 37 lb ft
Exhaust Manifold Stud 9 N·m 80 lb in
Muffler Clamp Nut 40 N·m 30 lb ft
Rear Exhaust Hanger Bolt 50 N·m 37 lb ft
Rear Exhaust Hanger Nut 30 N·m 22 lb ft

© 2014 General Motors Corporation. All rights reserved.

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Catalytic Converter Heat Shield Replacement (L36)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the exhaust system. Refer to Exhaust System Replacement .

Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal
injury.

2. Drill through the center of the heat shield rivets.

3. Remove the heat shield (2) from the floor panel in the following order:
3.1. Pull downward on the heat shield (2) in order to disengage from the retaining stud (1).
3.2. Slide the heat shield (2) to the left, out from under the oxygen sensor wiring harness
heat shield.

Installation Procedure

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1. Position the heat shield (2) to the floor panel in the following order:
1.1. Slide the heat shield (2) to the right, under the oxygen sensor wiring harness heat
shield.
1.2. Push the heat shield (2) upward, over the retaining stud (1).
1.3. Align the holes in the heat shield (2) with the holes in the floor panel.
2. Using a rivet gun, fasten both the oxygen sensor wiring harness heat shield and the catalytic
converter heat shield (2) to the floor panel with a single rivet (3).
3. Install the remaining rivets.
4. Install the exhaust system. Refer to Exhaust System Replacement .

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Exhaust Manifold Front Pipe Replacement (L47)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
2. Remove the transaxle assembly. Refer to Transmission Replacement in Automatic Transaxle -
4T80-E.

3. Remove the two bolts attaching the left exhaust manifold to the front exhaust manifold pipe.

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4. Remove the bolt (1) securing the front exhaust manifold pipe (2) to the crankcase.
5. Remove the nut securing the coil cassette ground wire to the cylinder head.
6. Remove the bolt (3) securing the front exhaust manifold pipe (2) to the cylinder head.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water
crossover. The EGR valve inlet pipe must be replaced if disconnected from the water
crossover.

7. Disconnect the EGR inlet pipe nut from the front exhaust manifold pipe (2).
8. Remove the front exhaust manifold pipe (2).
9. Remove the front exhaust manifold pipe seal from the left exhaust manifold. Do not reuse
the seal.
10. Remove the exhaust manifold flange retainer.

Installation Procedure

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Notice: When inspecting or replacing exhaust system components, make sure there is
adequate clearance from all points on the underbody to prevent overheating of the floor pan
and possible damage to the passenger compartment insulation and trim materials.

1. Place the retainer and a NEW front exhaust manifold pipe seal over the left exhaust manifold.
2. Insert the front exhaust manifold pipe (2) around the left exhaust manifold.

3. Install the bolts (1, 3) securing the front exhaust manifold pipe (2) to the engine.

Tighten
Tighten the front exhaust manifold pipe support bolts to 25 N·m (18 lb ft).

4. Install the nut securing the coil cassette ground wire to the cylinder head.

Tighten
Tighten the coil cassette ground wire nut to 17 N·m (13 lb ft).

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5. Install the two bolts securing the front exhaust manifold pipe to the left exhaust manifold.

Tighten
Tighten the front exhaust manifold pipe bolts to 25 N·m (18 lb ft).

6. Hand start the EGR inlet pipe nut to the front exhaust manifold pipe to prevent
crossthreading.

Tighten
Tighten the EGR inlet pipe nut to 60 N·m (44 lb ft).

7. Install the transaxle assembly. Refer to Transmission Replacement in Automatic Transaxle -

4T80-E.
8. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .

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Exhaust Manifold Heat Shield Replacement (LX5)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

1. Remove the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.
2. Remove the exhaust manifold heat shield from the left exhaust manifold.

Installation Procedure

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1. Position the exhaust manifold heat shield to the left exhaust manifold.

2. Install the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.

Tighten
Tighten the exhaust manifold heat shield bolts to 9 N·m (80 lb in).

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Exhaust Manifold Pipe Replacement (LX5)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the four nuts securing the catalytic converter to the exhaust manifold pipe.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the
normal mounting position.

3. Position the exhaust system rearward, enough to allow the studs located in the front of the
catalytic converter to clear the exhaust manifold pipe.
4. Remove the catalytic converter gasket. Do not reuse the gasket.

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5. Remove the two nuts attaching the exhaust manifold pipe to the right exhaust manifold.
6. Remove the exhaust manifold pipe and the gasket. Do not reuse the gasket.

Installation Procedure

1. Place a NEW exhaust manifold pipe gasket over the right exhaust manifold studs.

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2. Position the exhaust manifold pipe to the right exhaust manifold.

3. Install the two nuts attaching the exhaust manifold pipe to the right exhaust manifold.

Tighten
Tighten the exhaust manifold pipe nuts to 50 N·m (37 lb ft).

4. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the
normal mounting position.

5. Position the catalytic converter to the exhaust manifold pipe.

6. Install the four nuts in order to secure the catalytic converter to the exhaust manifold pipe.

Tighten
Tighten the catalytic converter nuts to 25 N·m (18 lb ft).

7. Lower the vehicle.

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Exhaust Manifold Rear Pipe Replacement (L47)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the four nuts securing the catalytic converter to the exhaust manifold rear pipe.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the
normal mounting position.

3. Position the exhaust system rearward, enough to allow the studs located in the front of the
catalytic converter to clear the exhaust manifold rear pipe.
4. Remove the catalytic converter gasket. Do not reuse the gasket.

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the two bolts (2) attaching the exhaust manifold rear pipe to the right exhaust
manifold.
6. Remove the two bolts (3) securing the exhaust manifold rear pipe to the exhaust manifold
front pipe.
7. Remove the exhaust manifold rear pipe and the gasket (1). Do not reuse the gasket.
8. Remove the exhaust manifold pipe seal (4) from the exhaust manifold front pipe. Do not
reuse the seal.
9. Remove the exhaust manifold flange seal retainer (5).

Installation Procedure

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1. Install the following components to the exhaust manifold rear pipe:

1.1. Position a NEW exhaust manifold pipe seal (4) and the exhaust manifold flange seal
retainer (5) to the exhaust manifold rear pipe flange.
1.2. Insert the two retaining bolts (3) through the exhaust manifold rear pipe flange and
into the exhaust manifold flange seal retainer (5).
1.3. Finger tighten the two retaining bolts (3) in order to retain the pipe seal (4) and
retainer (5).
1.4. Position a NEW gasket (1) to the exhaust manifold rear pipe flange.
1.5. Insert the two retaining bolts (2) through the exhaust manifold rear pipe flange and
into the gasket (1).
2. Insert the exhaust manifold rear pipe around the exhaust manifold front pipe and up to the
right exhaust manifold.

3. Install the two bolts (2) attaching the exhaust manifold rear pipe to the right exhaust
manifold.

Tighten
1. Tighten the 2 right exhaust manifold rear pipe to right exhaust manifold bolts to
40 N·m (30 lb ft).
2. Tighten the 2 left exhaust manifold rear pipe to exhaust manifold flange seal retainer
bolts to 25 N·m (18 lb ft).

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4. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the
normal mounting position.

5. Position the catalytic converter to the exhaust manifold rear pipe.

6. Install the four nuts in order to secure the catalytic converter to the exhaust manifold rear
pipe.

Tighten
Tighten the catalytic converter nuts to 25 N·m (18 lb ft).

7. Lower the vehicle.

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Exhaust Manifold Replacement - Left Side (L47)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the two nuts (2) attaching the secondary AIR tube (3) to the exhaust manifold (1).
2. Remove the secondary AIR tube (3) and the gasket from the exhaust manifold (1). Do not
reuse the gasket.
3. Remove the front engine mount bracket. Refer to Engine Front Mount Bracket Replacement
in Engine Mechanical - 4.0 L.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the oxygen sensor if replacement is necessary. Refer to Heated Oxygen Sensor
Replacement - Bank 2 Sensor 1 in Engine Controls - 4.0 L.

© 2014 General Motors Corporation. All rights reserved.

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6. Remove the two bolts attaching the left exhaust manifold to the front exhaust manifold pipe.

7. Remove the left exhaust manifold retaining bolts.

8. Remove the left exhaust manifold and the gasket from the engine. Do not reuse the gasket.
9. Remove the front exhaust manifold pipe seal from the left exhaust manifold. Do not reuse
the seal.
10. Remove the exhaust manifold flange seal retainer.
11. Clean and inspect the left exhaust manifold. Refer to Exhaust Manifold Cleaning and
Inspection - Left Side in Engine Mechanical-4.0L Unit Repair.

Installation Procedure

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1. Place the retainer and a NEW front exhaust manifold pipe seal over the left exhaust manifold.
2. Position a NEW exhaust manifold gasket between the left exhaust manifold and the left
cylinder head.
3. Insert the left exhaust manifold into the front exhaust manifold pipe and up to the left
cylinder head.

4. Install the left exhaust manifold bolts.

Tighten
Tighten the exhaust manifold bolts to 25 N·m (18 lb ft).

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5. Install the two bolts attaching the left exhaust manifold to the front exhaust manifold pipe.

Tighten
Tighten the front exhaust manifold pipe bolts to 25 N·m (18 lb ft).

6. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 in
Engine Controls - 4.0 L.
7. Install the front engine mount bracket. Refer to Engine Front Mount Bracket Replacement in
Engine Mechanical -4.0 L.
8. Lower the vehicle.

9. Install the new gasket to the secondary AIR tube.

10. Install the two nuts (2) attaching the secondary AIR tube (3) to the exhaust manifold (1).

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Tighten
Tighten the secondary AIR tube nuts to 12 N·m (106 lb in).

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Exhaust Manifold Replacement - Left Side (LX5)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the engine cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.
2. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement in
Engine Mechanical - 3.5 L.

3. Remove the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.
4. Remove the exhaust manifold heat shield from the left exhaust manifold.

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5. Remove the two bolts attaching the left exhaust manifold to the right exhaust manifold
crossover.

6. Remove the left exhaust manifold retaining bolts.

7. Remove the left exhaust manifold and the gasket from the engine. Do not reuse the gasket.
8. Remove the exhaust manifold crossover seal from the left exhaust manifold. Do not reuse the
seal.
9. Remove the exhaust manifold flange seal retainer.
10. Clean and inspect the left exhaust manifold. Refer to Exhaust Manifold Cleaning and
Inspection - Left Side in Engine Mechanical-3.5L Unit Repair.

Installation Procedure

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1. Place the retainer and a NEW exhaust manifold crossover seal over the left exhaust manifold.
2. Position a NEW exhaust manifold gasket between the left exhaust manifold and the left
cylinder head.
3. Insert the left exhaust manifold into the crossover pipe from the right exhaust manifold and
up to the left cylinder head.

4. Install the left exhaust manifold bolts.

Tighten
Tighten the exhaust manifold bolts to 25 N·m (18 lb ft).

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5. Install the two bolts attaching the left exhaust manifold to the right exhaust manifold
crossover.

Tighten
Tighten the exhaust manifold crossover bolts to 25 N·m (18 lb ft).

6. Position the exhaust manifold heat shield to the left exhaust manifold.
7. Install the bolts attaching exhaust manifold heat shield to the left exhaust manifold.

Tighten
Tighten the exhaust manifold heat shield bolts to 9 N·m (80 lb in).

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8. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement in
Engine Mechanical - 3.5 L.
9. Install the engine cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.

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Exhaust Manifold Replacement - Right Side (L47)

Tools Required
J 42640 Steering Column Lock Pin

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Disconnect the heated oxygen sensor at the sensor pigtail.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the
LOCK position before disconnecting the steering column or intermediate shaft from the
steering gear. Failure to do so will cause the coil assembly in the steering column to become
uncentered which will cause damage to the coil assembly.

2. Lock the steering column by installing the J 42640 into the underside of the steering column.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
6. Remove the secondary AIR tube (1) and the gasket from the exhaust manifold (3). Do not
reuse the gasket.

7. Disconnect the post heated oxygen sensor wiring harness retainer from the power steering
gear heat shield.
8. Remove the two bolts securing the heat shield.
9. Remove the heat shield from the power steering gear.

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10. Remove the rearward nut (3) securing the vehicle speed sensor heat shield (1).
11. Loosen the forward nut (2) in order to remove the heat shield (1).
12. Remove the heat shield (1) from the transaxle.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can
result in damage to the steering gear and/or damage to the intermediate shaft. This damage
may cause loss of steering control which could result in personal injury.

13. Remove the intermediate shaft pinch bolt.

14. Disconnect the intermediate shaft from the steering gear.

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15. Remove the nut securing the right engine mount to the right engine mount bracket.

16. Remove the nut securing the left transaxle mount to the left transaxle mount bracket.

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17. Support the rear of the engine frame with a tall screw jack.
18. Remove the four rearward engine frame-to-body bolts.
19. Lower the screw jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to
lower.
20. Remove the heated oxygen sensor if replacement is necessary. Refer to Heated Oxygen
Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.0 L.

21. Remove the right exhaust manifold retaining nuts.

22. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
23. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and
Inspection - Right Side in Engine Mechanical-4.0L Unit Repair.

Installation Procedure

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1. Place a NEW exhaust manifold gasket over the cylinder head studs.
2. Position the right exhaust manifold to the right cylinder head.

3. Install the right exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 25 N·m (18 lb ft).

4. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1
Sensor 1 in Engine Controls - 4.0 L.

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5. Raise the engine cradle into position.

6. Install the four rearward engine frame-to-body bolts.

Tighten
Tighten the engine frame bolts to 191 N·m (141 lb ft).

7. Remove the screw jack.

8. Install the nut securing the left transaxle mount to the left transaxle mount bracket.

Tighten
Tighten the transaxle mount nut to 80 N·m (59 lb ft).

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9. Install the nut securing the right engine mount to the right engine mount bracket.

Tighten
Tighten the engine mount nut to 80 N·m (59 lb ft).

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to
pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation,
the two mating shafts may disengage. Disengagement of the two mating shafts will cause
loss of steering control which could result in personal injury.

10. Connect the intermediate shaft to the steering gear.

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11. Install the intermediate shaft pinch bolt.

Tighten
Tighten the intermediate shaft pinch bolt to 45 N·m (33 lb ft).

12. Position the vehicle speed sensor heat shield (1) to the studs on transaxle.
13. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield to the
transaxle.

Tighten
Tighten the vehicle speed sensor heat shield nuts to 50 N·m (37 lb ft).

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14. Position the power steering gear heat shield to the power steering gear.
15. Install the two bolts securing the heat shield.

Tighten
Tighten the power steering gear heat shield bolts to 9 N·m (79 lb in).

16. Connect the post heated oxygen sensor wiring harness retainer to the heat shield.

17. Install the new gasket to the secondary AIR tube (1).
18. Install the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).

Tighten
Tighten the secondary AIR tube nuts to 12 N·m (106 lb in).

19. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
20. Lower the vehicle.

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21. Remove the J 42640 from the steering column.

22. Connect the heated oxygen sensor at the sensor pigtail.

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Exhaust Manifold Replacement - Right Side (LX5)

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Disconnect the cruise control cable (2) from the throttle body lever and bracket and position
aside.
2. Disconnect the accelerator cable from the throttle body lever and bracket and position aside.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine
Controls - 3.5 L.
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.5 L.

© 2014 General Motors Corporation. All rights reserved.

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5. Remove the fasteners attaching the accelerator control cable bracket to the throttle body.
6. Remove the accelerator control cable bracket.
7. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in
Hydraulic Brakes.
8. Remove the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal
Replacement in Automatic Transaxle - 4T65-E.
9. Set the park brake and chock the wheels.

10. Fully lift the retainer from the transaxle range selector cable mechanism.

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11. Disconnect the transaxle range selector cable terminal from the transaxle manual shift lever
pin.
12. Press the locking tabs inward in order to release the transaxle range selector cable from the
bracket.
13. Remove the transaxle range selector cable and position aside.

14. Remove the bolt (1) connecting the ground lead to the top of the transaxle.

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15. Disconnect the C101 (2) at the left strut tower.

16. Disconnect the left wheel speed sensor connector (3).

17. Remove the left wheel speed sensor lead (1) from the retaining brackets (2).

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18. Disconnect the C100 (2) at the top of the transaxle.

19. Disconnect the harness (3) from the harness clip (1) and position the harness (3) aside.

20. Remove the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.
21. Position the exhaust manifold heat shield aside in order to remove the right exhaust manifold
crossover bolts.
22. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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23. Remove the two bolts attaching the left exhaust manifold to the right exhaust manifold
crossover.
24. Remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .

25. Remove the right exhaust manifold studs.

26. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine
Controls - 3.5 L.

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27. Disconnect the EGR inlet pipe from the right exhaust manifold.
28. Remove the right exhaust manifold retaining bolts.
29. Lower the vehicle.
30. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
31. Remove the exhaust manifold crossover seal from the left exhaust manifold. Do not reuse the
seal.
32. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and
Inspection - Right Side in Engine Mechanical-3.5L Unit Repair.

Installation Procedure
1. Place a NEW exhaust manifold crossover seal over the left exhaust manifold.

2. Install the right exhaust manifold to the engine in the following order:

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2.1. Align the exhaust manifold to the cylinder head.

2.2. Place the crossover portion of the exhaust manifold around the left exhaust manifold.
2.3. Hold the right exhaust manifold to the right cylinder head using a retaining bolt.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Grasp the right exhaust manifold and remove the retaining bolt.
5. Place a NEW exhaust manifold gasket between the right exhaust manifold and the right
cylinder head.

6. Install the right exhaust manifold bolts.

Tighten
Tighten the exhaust manifold bolts to 25 N·m (18 lb ft).

7. Connect the EGR inlet pipe to the right exhaust manifold.

Tighten
Tighten the EGR inlet pipe nut to 60 N·m (44 lb ft).

8. Install the right exhaust manifold studs.

Tighten
Tighten the exhaust manifold studs to 9 N·m (80 lb in).

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9. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine
Controls - 3.5 L.
10. Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .

11. Install the two bolts attaching the left exhaust manifold to the right exhaust manifold
crossover.

Tighten
Tighten the exhaust manifold crossover bolts to 25 N·m (18 lb ft).

12. Lower the vehicle.

13. Position the exhaust manifold heat shield to the left exhaust manifold.
14. Install the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.

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Tighten
Tighten the exhaust manifold heat shield bolts to 9 N·m (80 lb in).

15. Connect the harness (3) to the harness clip (1).

16. Connect the C100 (2) to the transaxle.

17. Connect the left wheel speed sensor connector (3) to the left wheel speed sensor.
18. Attach the left wheel speed sensor lead (1) to the retaining brackets (2).

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19. Connect the C101 (2) at the left strut tower.

20. Install the bolt (1) connecting the ground lead to the top of the transaxle.

Tighten
Tighten the ground lead bolt to 17 N·m (13 lb ft).

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21. Insert the transaxle range selector cable into the bracket.
22. Connect the transaxle range selector cable terminal to the transaxle manual shift lever pin.

23. Install the retainer to the transaxle range selector cable mechanism.
24. Adjust the transaxle range selector cable. Refer to Range Selector Lever Cable Adjustment in
Automatic Transaxle - 4T65-E.
25. Install the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement
in Automatic Transaxle - 4T65-E.
26. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in
Hydraulic Brakes.

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27. Position the accelerator control cable bracket to the throttle body.
28. Install the fasteners attaching the accelerator control cable bracket to the throttle body.

Tighten
• Tighten the accelerator control cable bracket bolt to 13 N·m (115 lb in).
• Tighten the accelerator control cable bracket nuts to 10 N·m (89 lb in).
29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.5 L.
30. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine
Controls - 3.5 L.

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Important: The throttle should operate freely without binding between full closed and wide
open throttle.

31. Connect the accelerator cable to the throttle body lever and bracket.
32. Connect the cruise control cable (2) to the throttle body lever and bracket.

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Exhaust Muffler Replacement

Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the exhaust pipe and muffler.

3. Cut (1) the exhaust pipe as close as possible to the welded portion (2) of the muffler using a
suitable cut off tool.

© 2014 General Motors Corporation. All rights reserved.

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4. Remove the nut securing the rear exhaust hanger to the rear exhaust hanger bracket.
5. Remove the muffler from the vehicle.
6. Apply a suitable lubricant to the tail pipe hanger rod in order to ease the removal of the
hanger.
7. Pull outward on the rear exhaust hanger in order to remove it from the tail pipe hanger rod.

Installation Procedure

Notice: When inspecting or replacing exhaust system components, make sure there is
adequate clearance from all points on the underbody to prevent overheating of the floor pan

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and possible damage to the passenger compartment insulation and trim materials.

1. Join the muffler and the exhaust pipe together.

2. Install the muffler clamp. Do not tighten at this time.

3. Apply a soapy solution to the tail pipe hanger rod and the inner diameter of the rear exhaust
hanger in order to ease the installation of the hanger.
4. Press the rear exhaust hanger over the tail pipe hanger rod.
5. Position the rear exhaust hanger to the rear exhaust hanger bracket.

6. Install the nut securing the rear exhaust hanger to the rear exhaust hanger bracket.

Tighten
Tighten the rear exhaust hanger nut to 30 N·m (22 lb ft).

7. Align the muffler to the vehicle, ensuring the rear tail pipe opening is positioned horizontally.
8. Tighten the muffler clamp previously installed in step 2.

Tighten
Tighten the muffler clamp nuts to 40 N·m (30 lb ft).

9. Lower the vehicle.

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Exhaust System Insulator, Hanger, Bracket

Replacement
Removal Procedure
Service the exhaust hangers individually in order to retain the support of the exhaust system.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the bolt securing the center exhaust hanger to the rear suspension support bracket.

© 2014 General Motors Corporation. All rights reserved.

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3. Apply a suitable lubricant to the exhaust pipe hanger rod in order to ease the removal of the
hanger.
4. Pull outward on the center exhaust hanger in order to remove it from the exhaust pipe
hanger rod.

5. Remove the nut securing the rear exhaust hanger to the rear exhaust hanger bracket.

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6. Apply a suitable lubricant to the tail pipe hanger rod in order to ease the removal of the
hanger.
7. Pull outward on the rear exhaust hanger in order to remove it from the tail pipe hanger rod.

Installation Procedure

1. Apply a soapy solution to the tail pipe hanger rod and the inner diameter of the rear exhaust
hanger in order to ease the installation of the hanger.
2. Press the rear exhaust hanger over the tail pipe hanger rod.

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3. Position the rear exhaust hanger to the rear exhaust hanger bracket.

4. Install the nut securing the rear exhaust hanger to the rear exhaust hanger bracket.

Tighten
Tighten the rear exhaust hanger nut to 30 N·m (22 lb ft).

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5. Apply a soapy solution to the exhaust pipe hanger rod and the inner diameter of the center
exhaust hanger in order to ease the installation of the hanger.
6. Press the center exhaust hanger over the exhaust pipe hanger rod.

7. Install the bolt securing the center exhaust hanger to the rear suspension support bracket.

Tighten
Tighten the center exhaust hanger bolt to 30 N·m (22 lb ft).

8. Lower the vehicle.

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Exhaust System Replacement

Removal Procedure
Servicing of the catalytic converter, resonator or pipe requires the replacement of the exhaust
system as a complete one-piece unit.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring
Harness Heat Shield Replacement .
3. Disconnect the heated oxygen sensor at the pigtail.
4. Remove the heated oxygen sensor if replacement is necessary. Refer to Heated Oxygen
Sensor 2 Replacement in Engine Controls - 3.5 L. or Heated Oxygen Sensor Replacement -
Bank 1 Sensor 2 in Engine Controls - 4.0 L.

5. Remove the four nuts securing the catalytic converter to the exhaust manifold pipe.
6. Remove the catalytic converter gasket. Do not reuse the gasket.
7. Suitably support the exhaust system.

© 2014 General Motors Corporation. All rights reserved.

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8. Remove the two bolts securing the center exhaust hangers to the rear suspension support
brackets.

9. Remove the two bolts securing the rear exhaust hanger brackets to the rear compartment
rails.
10. With the aid of an assistant, Lower the exhaust system.

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11. Remove the two nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
12. Remove the rear exhaust hanger brackets from the rear exhaust hangers.

Installation Procedure

1. Install the rear exhaust hanger brackets to the rear exhaust hangers.

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2. Install the two nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.

Tighten
Tighten the rear exhaust hanger nuts to 30 N·m (22 lb ft).

3. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the
normal mounting position.

4. With the aid of an assistant, raise the exhaust system into position, aligning the catalytic
converter with the exhaust manifold pipe.
5. Finger tighten the four nuts to the catalytic converter studs.

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6. Install the two bolts securing the rear exhaust hanger brackets to the rear compartment
rails.

Tighten
Tighten the rear exhaust hanger bolts to 50 N·m (37 lb ft).

7. Install the two bolts securing the center exhaust hangers to the rear suspension support
brackets.

Tighten
Tighten the center exhaust hanger bolts to 30 N·m (22 lb ft).

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8. Tighten the four catalytic converter nuts previously installed in step 5.

Tighten
Tighten the catalytic converter nuts to 25 N·m (18 lb ft).

9. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 2 Replacement in Engine
Controls - 3.5 L. or Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 in Engine Controls
- 4.0 L.
10. Install the oxygen sensor wiring harness heat shield. Refer to Oxygen Sensor Wiring Harness
Heat Shield Replacement .
11. Lower the vehicle.

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Oxygen Sensor Wiring Harness Heat Shield

Replacement
Removal Procedure
Caution: In order to avoid being burned, do not service the exhaust system while it is still hot.
Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal
injury.

2. Drill through the center of the heat shield rivets.

3. Remove the heat shield (2) from the floor panel.
4. Remove the oxygen sensor retainer (1) from the heat shield (2).

Installation Procedure

© 2014 General Motors Corporation. All rights reserved.

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1. Install the oxygen sensor retainer (1) to the heat shield.

2. Position the heat shield (2) to the floor panel, aligning the holes.
3. Using a rivet gun, fasten both the oxygen sensor wiring harness heat shield (2) and the
catalytic converter heat shield to the floor panel with a single rivet (3).
4. Install the remaining rivets.
5. Lower the vehicle.

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Fastener Tightening Specifications

Specification
Application Metric English
Compact Disc (CD) Bracket Fasteners 9 N·m 80 lb in
Compact Disc (CD) to Bracket Fasteners 2 N·m 18 lb in
Door Speaker Retaining Screws 1.8 N·m 16 lb in
Front Speaker Assembly Retaining Screws 1.8 N·m 16 lb in
Radio Amplifier Bracket Fasteners 9 N·m 80 lb in
Radio Antenna Module Retaining Screws 9 N·m 80 lb in
Rear Speaker Assembly Retaining Screws 2 N·m 18 lb in

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428620

Front Speakers (U80)

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428604

Power and Grounds

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428609

Radio Antenna Module

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428618

Radio Output (U80)

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428622

Rear Speakers (U80)

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428607

Remote Playback Device (CD Changer)

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 428611

Speaker Output

© 2014 General Motors Corporation. All rights reserved.

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| Aurora (VIN G) Service Manual | Body and Accessories | Entertainment |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 468648

Steering Wheel Controls Schematics

© 2014 General Motors Corporation. All rights reserved.

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Entertainment Connector End Views

Table 1: Audio Amplifier C1 (U80)
Table 2: Audio Amplifier C2 (U80)
Table 3: Radio
Table 4: Radio (w/U80)
Table 5: Radio Antenna Module
Table 6: Remote Playback Device -- CD Changer
Table 7: Speaker -- LF Door
Table 8: Speaker -- LF Door Tweeter
Table 9: Speaker -- LR
Table 10: Speaker -- LR Door
Table 11: Speaker -- LR Subwoofer (w/u80)
Table 12: Speaker -- RF Door
Table 13: Speaker -- RR
Table 14: Speaker -- RR Door
Table 15: Speaker -- RR Subwoofer (w/U80)

Audio Amplifier C1 (U80)

• 12110244
Connector Part Information
• 24-Way F Micro-pack 100 Series (PNK)
Pin Wire Color Circuit No. Function
A1 PNK 608 14 Volt Reference
A2-A6 -- -- Not Used
A7 DK GRN 117 Right Front Speaker Output (-)
A8 LT GRN 200 Right Front Speaker Output (+)
A9 DK BLU 46 Right Rear Speaker Output (+)
A10 LT BLU 115 Right Rear Speaker Output (-)
A11 GRY 118 Left Front Speaker Output (-)
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A12 TAN 201 Left Front Speaker Output (+)

B1-B4 -- -- Not Used
B5 TAN 511 Left Front Low Level Audio Signal (+)
B6 LT GRN/BLK 512 Right Front Low Level Audio Signal (+)
B7 BRN/WHT 599 Left Rear Low Level Audio Signal (+)
B8 DK BLU 546 Right Rear Low Level Audio Signal (+)
B9 LT GRN 1948 Right Front Low Level Audio Signal (-)
B10 BLK 1946 Right Rear Low Level Audio Signal (-)
B11 BRN 1999 Left Rear Low Level Audio Signal (-)
B12 DK GRN 1947 Left Front Low Level Audio Signal (-)

Audio Amplifier C2 (U80)

• 12110626
Connector Part Information
• 8-Way F Metri-pack 280 Series (GRY)
Pin Wire Color Circuit No. Function
A BLK/WHT 551 Ground
B YEL 116 Left Rear Speaker Output (-)
C DK BLU/WHT 346 Left Subwoofer Speaker Output (+)
D DK GRN 1795 Right Subwoofer Output (+)
E LT BLU/BLK 315 Right Subwoofer Output (-)
F LT GRN/BLK 1794 Left Subwoofer Output (-)
G BRN 199 Left Rear Speaker Output (+)
H RED 1242 Battery Positive Voltage

Radio

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• 15317985
Connector Part Information
• 32-Way M Flex (DK GRY)
Pin* Wire Color Circuit No. Function
A1 FW 1807 Class 2 Serial Data (Primary)
A2 FW 1807 Class 2 Serial Data (Primary)
A3 FW 608 14 Volt Reference
A4 FW 1486 FM Composite Signal
A5-A6 -- -- Not Used
A7 FW 659 Cellular Telephone Voice Low Reference
A8 FW 658 Cellular Telephone Voice Signal
A9 FW 372 Remote Radio Audio Output (-)
A10 FW 367 Remote Radio Audio Output (-)
A11 FW 368 Remote Radio Right Audio Signal
A12 FW 199 Left Rear Speaker Output (+)
A13 FW 116 Left Rear Speaker Output (-)
A14 FW 117 Right Front Speaker Output (-)
A15 FW 200 Right Front Speaker Output (+)
A16 FW 551 Ground
B1 FW 2240 Battery Positive Voltage
B2 FW 2240 Battery Positive Voltage
B3 FW 1487 Antenna Enable Signal
B4 FW 1491 Backlight Lamps Control
B5 FW 450 Ground
B6-B10 -- -- Not Used
B11 FW 514 Ground
B12 FW 201 Left Front Speaker Output (+)
B13 FW 118 Left Front Speaker Output (-)
B14 FW 115 Right Rear Speaker Output (-)
B15 FW 46 Right Rear Speaker Output (+)

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B16 FW 551 Ground

* A Pins = Top

B Pins = Bottom

Radio (w/U80)

• 15317985
Connector Part Information
• 32-Way M Flex (DK GRY)
Pin* Wire Color Circuit No. Function
A1 FW 1807 Class 2 Serial Data (Primary)
A2 FW 1807 Class 2 Serial Data (Primary)
A3 FW 608 14 Volt Reference
A4 FW 1486 FM Composite Signal
A5-A6 -- -- Not Used
A7 FW 659 Cellular Telephone Voice Low Reference
A8 FW 658 Cellular Telephone Voice Signal
A9 FW 372 Remote Radio Audio Output (-)
A10 FW 367 Remote Radio Left Audio Signal
A11 FW 368 Remote Radio Right Audio Signal
A12 Flex 599 Left Rear Low Level Audio Signal (+)
A13 FW 1999 Left Rear Low Level Audio Signal (-)
A14 FW 1948 Right Front Low Level Audio Signal (-)
A15 Flex 512 Right Front Low Level Audio Signal (+)
A16 FW 551 Ground
B1 FW 2240 Battery Positive Voltage
B2 FW 2240 Battery Positive Voltage
B3 FW 1487 Antenna Enable Signal
B4 FW 1491 Backlight Lamps Control
B5 FW 450 Ground

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B6 FW 551 Ground
B7-B10 -- -- Not Used
B11 FW 514 Ground
B12 FW 511 Left Front Low Level Audio Signal (+)
B13 FW 1947 Left Front Low Level Audio Signal (-)
B14 FW 1946 Right Rear Low Level Audio Signal (-)
B15 FW 546 Right Rear Low Level Audio Signal (+)
B16 FW 551 Ground
* A Pins = Top

B Pins = Bottom

Radio Antenna Module

• AMP # 172166-1
Connector Part Information
• 3-Way M Metri-pack 150 Series (WHT)
Pin Wire Color Circuit No. Function
1 -- -- Not Used
2 WHT 1487 Antenna Enable Signal
3 WHT/ORN 1486 FM Composite Signal

Remote Playback Device -- CD Changer

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• 12047531
Connector Part Information
• 10-Way F Micro-pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
1 BRN/WHT 367 Remote Radio Left Audio Signal
2 DK GRN/WHT 368 Remote Radio Right Audio Signal
3 BLK/WHT 372 Remote Radio Audio Output (-)
4 BARE 1782 Drain Wire
5 ORN 2640 Battery Positive Voltage
6 -- -- Not Used
7 BLK/WHT 551 Ground
8 -- -- Not Used
9 PPL 1807 Class 2 Serial Data (Primary)
10 PPL 1807 Class 2 Serial Data (Primary)

Speaker -- LF Door

• 12052832
Connector Part Information
• 2-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function

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A GRY 118 Left Front Speaker Output (-)

B TAN 201 Left Front Speaker Output (+)

Speaker -- LF Door Tweeter

• 12047662
Connector Part Information
• 2-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A GRY 118 Left Front Speaker Output (-)
B TAN 201 Left Front Speaker Output (+)

Speaker -- LR

• 12052832
Connector Part Information
• 2-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A YEL 116 Left Rear Speaker Output (+)
B BRN 199 Left Rear Speaker Output (-)

Speaker -- LR Door

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• 12052832
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BRN 199 Left Rear Speaker Output (+)
B YEL 116 Left Rear Speaker Output (-)

Speaker -- LR Subwoofer (w/u80)

• 12052832
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A YEL 346 Left Subwoofer Speaker Output (+)
B BRN 1794 Left Subwoofer Speaker Output (-)

Speaker -- RF Door

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• 12052832
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A DK GRN 117 Right Front Speaker Output (-)
B LT GRN 200 Right Front Speaker Output (+)

Speaker -- RR

• 12052832
Connector Part Information
• 2-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 115 Right Rear Speaker Output (-)
B DK BLU 46 Right Rear Speaker Output (+)

Speaker -- RR Door

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• 12052832
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BRN 46 Right Rear Speaker Output (+)
B YEL 115 Right Rear Speaker Output (-)

Speaker -- RR Subwoofer (w/U80)

• 12052832
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 1795 Right Subwoofer Speaker Output (+)
B DK BLU 315 Right Subwoofer Speaker Output (-)

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Antenna Cable Replacement

Removal Procedure

1. Remove the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.
2. Remove the center pillar trim panel. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
3. Remove the right rear upper quarter trim panel. Refer to Rear Quarter Upper Trim Panel
Replacement in Interior Trim.
4. Remove the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Instrument Panel, Gages and Console.
5. Lower the headliner in order to gain access to the coaxial cable harness along the right side
of the vehicle. Refer to Headlining Trim Panel Replacement in Interior Trim.
6. Disconnect the coaxial cable connectors (2).

© 2014 General Motors Corporation. All rights reserved.

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7. Disconnect the ground cable (1) from the roof beam.

8. Disconnect the antenna connection (2) at the windshield.

9. Disconnect the coaxial cable from the antenna module located on the rear roof beam.

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10. Disconnect the power lead connection (2).

11. Remove the rosebud clips (3) from the roof beams.
12. Remove the coaxial cable harness from the vehicle.

Installation Procedure

1. Install the coaxial cable harness to the roof beams with the rosebud clips (3).
2. Connect the power lead connectors (2).

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3. Install the antenna connection (2) at the windshield.

4. Connect the ground connector (1) to the roof beam.

5. Connect the coaxial cable connectors (2).

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6. Install the coaxial cable connections to the antenna module.

7. Install the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Instrument Panel, Gages and Console.
8. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
9. Install the upper rear quarter trim panel. Refer to Rear Quarter Upper Trim Panel
Replacement in Interior Trim.
10. Install the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.

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Cassette Player Care and Cleaning

Tools Required
J 39916-A CD and Cassette Diagnostic Audio Kit

If you do not regularly clean the tape player, the tape player is subject to the following conditions:

• Reduced sound quality

• Ruined cassettes
• A damaged tape mechanism

Cassette tapes may not operate properly if they are not stored in their cases away from the
following conditions:

• Contaminants
• Direct sunlight
• Extreme heat

Cleaning Intervals
Clean the cassette tape player every 15 hours of operation for optimum performance. After you
clean the player, press and hold the EJECT button for five seconds to reset the CLEAN indicator.
The radio will display --- to show that the indicator has been reset.

As a minimum clean the cassette tape player after 50 hours of playing time. This will prevent
damage to the cassette tape player mechanism. The radio may display CLN, CLEAN or CLEAN TAPE
(depending on the family of radio being used), if equipped with the Clean Tape Indicator Feature.
This indicates that you have used the tape player for 50 hours without resetting the tape clean
timer. If this message appears on the display, clean the cassette tape player. The player will still
play tapes, however the player should be cleaned as soon as possible in order to prevent damage
to the tapes and/or the player.

Cassettes are subject to wear and the sound quality may degrade over time. If you notice a
reduction in sound quality, play a different cassette. A new cassette will indicate whether the tape
or the tape player is at fault.

If the sound quality does not improve when the second tape is played, clean the cassette player.
Perform this step regardless of when you last cleaned the cassette player.

If a noticeable improvement is not achieved after cleaning the player, remove the radio assembly
for repair.

Head and Capstan Cleaning

The following two components are cleaned on a tape player:
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• The head
• The capstan

Important: Do not contact the tape head with magnetized tools. If the head becomes magnetized,
every cassette played in the player will be degraded.

In order to properly clean a tape player, the preferred method would be to use the cleaning
cassette in J 39916-A

To prevent the cleaning cassette from being ejected, perform the following steps:

1. Turn the ignition switch to one of the following positions (depending on the vehicle line) :
• ON
• RUN
• ACC
• ACCESSORY
2. Turn the radio off.
3. Press and hold the TAPE button for five seconds. The tape symbol on the display will flash for
two seconds.
4. Insert the scrubbing action cleaning cassette.
5. Eject the cleaning cassette after the manufacturer's recommended cleaning time. When the
cleaning cassette has been ejected, the Cut Tape Detection Feature is active again.

The alternative method would be to use a non scrubbing action, wet type cleaning cassette. This
cassette uses a fabric belt to clean the tape head. This type of cleaning cassette will not eject on its
own. A non scrubbing action cassette may not clean as thoroughly as the scrubbing type cleaning
cassette. The use of this cassette is not recommended.

After you clean the player, press and hold the EJECT button for five seconds to reset the CLEAN
indicator. The radio will display --- to show that the indicator has been reset.

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Coaxial Cable Replacement

Removal Procedure

1. Remove the radio. Refer to Radio Replacement .

2. Remove the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.
3. Remove the center pillar trim panel. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
4. Remove the right rear upper quarter trim panel. Refer to Rear Quarter Upper Trim Panel
Replacement in Interior Trim.
5. Remove the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Interior Trim.
6. Lower the headliner in order to gain access to the coaxial cable harness along the right side
of the vehicle. Refer to Headlining Trim Panel Replacement in Interior Trim.
7. Disconnect the antenna coaxial cable from the radio cavity by sliding the cable connection
upwards out of the retainer.
8. Remove the remaining cable clips (1) from the instrument panel support.
9. Disconnect the coaxial cable connectors (2).

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10. Disconnect the ground cable (1) from the roof beam.
11. Disconnect the antenna connection (2) at the windshield.

12. Disconnect the coaxial cable from the antenna module located on the rear roof beam.

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13. Disconnect the power lead connection (2).

14. Remove the rosebud clips (3) from the roof beams.
15. Remove the coaxial cable harness from the vehicle.

Installation Procedure

1. Install the coaxial cable harness to the roof beams with the rosebud clips (3).
2. Connect the power lead connectors (2).

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3. Install the antenna connection (2) at the windshield.

4. Connect the ground connector (1) to the roof beam.

5. Connect the coaxial cable connectors (2).

6. Install the cable clips (1) to the instrument panel support.
7. Insert the cable connector into the retainer in the radio cavity.

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8. Install the coaxial cable connections to the antenna module.

9. Install the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Interior Trim.
10. Install the radio. Refer to Radio Replacement .
11. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
12. Install the upper rear quarter trim panel. Refer to Rear Quarter Upper Trim Panel
Replacement in Interior Trim.
13. Install the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.

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Front Upper Speaker Replacement

Removal Procedure
1. Remove the upper door trim panel. Refer to Front Side Door Trim Panel Replacement in
Doors.
2. Disconnect the upper door speaker electrical connector from the door harness.

3. Remove the upper door speaker/grille assembly by gently prying it from the upper door trim
panel.

Installation Procedure

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1. Install the upper door speaker/grille assembly into the upper door trim panel.
2. Ensure that the speaker grille is properly seated in the upper door trim panel.
3. Connect the upper door speaker electrical connector.
4. Install the upper door trim panel . Refer to Front Side Door Trim Panel Replacement in Doors.

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Radio Antenna Cable Extension Cable Replacement

Removal Procedure

1. Remove the radio. Refer to Radio Replacement .

2. Remove the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.
3. Remove the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Instrument Panel, Gages and Console.
4. Disconnect the antenna coaxial cable from the radio cavity by sliding the cable connection
upwards out of the retainer.
5. Remove the remaining cable clips (1) from the instrument panel support.
6. Disconnect the coaxial cable connector (2).
7. Remove the antenna extension cable from the vehicle.

Installation Procedure
1. Position the antenna extension to the vehicle.

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2. Connect the coaxial cable connectors (2).

3. Install the cable clips (1) to the instrument panel support.
4. Insert the cable connector into the retainer in the radio cavity.
5. Install the upper instrument panel trim pad. Refer to Instrument Panel Upper Trim Pad
Replacement in Instrument Panel, Gages and Console.
6. Install the radio. Refer to Radio Replacement .
7. Install the right side windshield garnish molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.

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Radio Antenna Module Replacement

Removal Procedure

1. Lower the rear of the headliner far enough to access the antenna module. Refer to Headlining
Trim Panel Replacement in Interior Trim.
2. Disconnect the electrical connectors from the radio antenna module.
3. Remove the fastener retaining the radio antenna module to the roof beam.
4. Remove the radio antenna module.

Installation Procedure

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1. Install the radio antenna module to the roof beam, ensuring that the alignment tab is
properly located.
2. Install radio module retaining fastener.

Tighten
Tighten the radio module retaining fasteners to 9 N·m (80 lb in).

3. Connect the electrical connectors to the radio antenna module.

4. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.

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Radio Front Side Door Lower Speaker Replacement

Removal Procedure

1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement in Doors.
2. Note the location of the electrical connector.
3. Disconnect the speaker electrical connector.
4. Remove the speaker fasteners (1).
5. Remove the speaker.

Installation Procedure

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1. Install the speaker into the door with the electrical connector located as noted during
removal.

2. Install the speaker fasteners (1).

Tighten
Tighten the speaker fasteners to 1.8 N·m (16 lb in).

3. Connect the electrical connector (2).

4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement in Doors.

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Radio Rear Side Door Speaker Replacement

Removal Procedure

1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement in Doors.
2. Disconnect the electrical connector from the rear door speaker.
3. Remove the rear door speaker fasteners.
4. Remove the rear door speaker.

Installation Procedure

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1. Position the rear door speaker to the rear door trim panel.
2. Install the fasteners in order to secure the rear door speaker to the rear door trim panel.

Tighten
Tighten the door speaker fasteners to 1.8 N·m (16 lb in).

3. Connect the electrical connector.

4. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement in Doors.

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Radio Rear Speaker Replacement

Removal Procedure

1. Lower the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.
2. Disconnect the speaker electrical connectors (1).
3. Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.

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4. Remove the rear speaker fasteners.

5. Remove the rear speakers from the vehicle.

Installation Procedure

1. Position the rear speaker into the opening in the rear shelf.
2. Install the fasteners in order to secure the rear speakers to the vehicle.

Tighten
Tighten the speaker fasteners to 2 N·m (18 lb in).

3. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.

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4. Install the speaker electrical connectors (1).

5. Install the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.

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Radio Replacement (w/o UM8)

Removal Procedure

1. Remove the instrument panel center trim panel. Refer to Instrument Panel Center Trim Panel
Replacement in Instrument Panel, Gages and Console.
2. Depress the spring clip retainers at the sides of the radio.
3. Pull the radio straight out to remove.

Installation Procedure

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1. Position the radio into the opening in the instrument panel.

2. Push inward to engage the spring clips.
3. Ensure the spring clips are fully engaged.
4. Install the instrument panel center trim panel. Refer to Instrument Panel Center Trim Panel
Replacement in Instrument Panel, Gages and Console.

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Radio Speaker Amplifier Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
2. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.

3. Disconnect the radio amplifier electrical connectors (2).

4. Remove the fasteners retaining the radio amplifier to the mounting bracket.
5. Lift the radio amplifier to remove.

Installation Procedure

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1. Install the alignment tabs (1), on the radio amplifier, over the mounting bracket.
2. Install the radio amplifier electrical connectors (2).

3. Install the fasteners to retain the radio amplifier to the mounting bracket.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Remote Compact Disc Player Replacement

Removal Procedure
1. Open the rear compartment.
2. Remove the right side rear compartment trim. Refer to Rear Compartment Trim Panel
Replacement in Body Rear End.

3. Remove the fasteners securing the CD mounting bracket to the rear compartment.
4. Disconnect the electrical connector from the remote CD player.

5. Remove the fasteners©securing theMotors

2014 General remote CD player
Corporation. All to mounting
rights reserved.bracket.

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6. Separate the remote CD player from the bracket.

Installation Procedure

1. Position the CD player into the mounting bracket.

2. Install the fasteners in order to secure the CD player to the bracket.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

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3. Position the CD player and bracket into the rear compartment.

4. Connect the electrical connectors.
5. Install the fasteners in order to secure the rear compartment CD player and bracket to the
vehicle.

Tighten
Tighten the rear compartment CD player bracket fasteners to 9 N·m (80 lb in).

6. Install the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.
7. Close the rear compartment deck lid.

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Steering Wheel Control Switches Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring, you
must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct
procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the steering wheel inflatable restraint module. Refer to Inflatable Restraint Steering
Wheel Module Replacement in SIR.
3. Remove the steering wheel control switch by gently pulling it away from the steering wheel.
4. Disconnect the steering wheel control switch electrical connector.
5. Remove the steering wheel control switch from the steering wheel.

Installation Procedure

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1. Connect the electrical connector to the steering wheel control switch.

2. Align the steering control switch engagement tabs to the steering wheel.
3. Push in on the steering wheel control switch in order to secure the steering wheel control
switch to the steering wheel.
4. Install the steering wheel inflatable restraint module. Refer to Inflatable Restraint Steering
Wheel Module Replacement in SIR.
5. Enable the SIR. Refer to Enabling the SIR System in SIR.

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Emblem/Nameplate Replacement (Aurora)

Nameplate Procedure

1. Wash the affected panel with a soap and water mixture.

2. Dry the affected panel using a clean cloth.
3. Remove all traces of adhesive from the rear deck lid (1) and from the back of the
emblem/nameplate (2) using 3M General Purpose Adhesive Cleaner 08984 or equivalent.
4. Wipe the panel with a clean cloth and an alcohol and water mixture.

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5. If the body is below 21°C (70°F), warm the affected panel with a heat lamp or a heat gun
while proceeding with the following step.

Important: Care should be exercised not to touch the tape with your hands or allow the
adhesive tape to come in contact with any dirt or foreign matter.

6. Peel the backing from the adhesive tape.

7. Using the following dimensions align the nameplate (2) to the rear compartment lid:
• 25.7 mm (+/- 2 mm) 1.01 in (+/- 0.08 in) (A) from the horizontal edge (3).
• 109.5 mm (+/-2.0 mm) 4.31 in (+/- 0.08 in) (B) from the centerline of the rear
compartment lid 1.
8. Press the nameplate (2) firmly in place in order to ensure proper adhesion to the rear
compartment lid.

Hood Emblem Procedure

1. Wash the affected panel with a soap and water mixture.

2. Dry the affected panel using a clean cloth.
3. Remove all traces of adhesive from the hood and from the back of the emblem (1) using 3M
General Purpose Adhesive Cleaner 08984 or equivalent.
4. Wipe the hood with a clean cloth and an alcohol and water mixture.

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5. If the body is below 21°C (70°F), warm the affected panel with a heat lamp or a heat gun
while proceeding with the following steps.

Important: Care should be exercised not to touch the tape with your hands or allow the
adhesive tape to come in contact with any dirt or foreign matter.

6. Peel the backing from the adhesive tape.

7. Using the following dimensions align the emblem to the hood:
• 70.0 mm (+/- 2 mm) 2.76 in (+/- 0.08 in) A from the front edge of the hood (1).
• 43.5 mm (+/-2.0 mm) 1.71 in (+/- 0.08 in) B from the centerline of the hood 1.
8. Press the emblem firmly in place in order to ensure proper adhesion to the hood.

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Emblem/Nameplate Replacement (Rear Decklid

Designation)

1. Wash the affected panel with a soap and water mixture.

2. Dry the affected panel using a clean cloth.
3. Remove all traces of adhesive from the rear deck lid (3) and from the back of the emblem
(2) using 3M General Purpose Adhesive Cleaner 08984 or equivalent.
4. Wipe the panel with a clean cloth and an alcohol and water mixture.

5. If the body is below 21°C (70°F), warm the affected panel with a heat lamp or a heat gun
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while proceeding with the following step.

Important: Care should be exercised not to touch the tape with your hands or allow the
adhesive tape to come in contact with any dirt or foreign matter.

6. Peel the backing from the adhesive tape.

7. Using the following dimensions align the emblem (1) with the rear deck lid:
• 13.4 mm (+/- 2 mm) 0.53 in (+/- 0.08 in) (A) from the top edge of the license plate
pocket (2).
• 41.25 mm (+/-2.0 mm) 1.62 in (+/- 0.08 in) (B) from the centerline of the rear deck
lid (3).
8. Press the emblem (1) firmly in place in order to ensure proper adhesion to the rear deck lid.

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Front Side Door Molding Replacement

Removal Procedure

1. Starting at the rear of the door, split the foam tape using a braided wire or a flat-bladed tool
inserted between the molding and the sheet metal. If using a flat-bladed tool, protect the
surrounding surfaces. Use care not to damage the paint.
2. Remove the door molding (3) from the door.
3. Clean the old adhesive from the door and the molding (if reusing) with 3M General Purpose
Adhesive Cleaner 08984 or equivalent.

Installation Procedure

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Important: The body must be dry and the door must be closed prior to molding installation.

1. If the molding is being reused, apply new adhesive tape (2) to the molding.
2. Align the molding using the locator pins (1).
3. Remove the backing from the tape (2).
4. Align and press the molding (3) to the door. Assure proper wetout of the adhesive by
applying heavy hand pressure against the molding, rubbing along the entire length of the
molding. Wear clean gloves or use a clean towel while performing this step.

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Molding Repair

1. Wash the affected area with Liquid Wash and Wax GM P/N 1052870 or an equivalent.
2. Wipe the area dry.
3. Wipe the panel and the adhesive side of the molding with a clean lint-free cloth.
4. If the acrylic foam tape residue is still present on the body side panel, use the 3M 07502 with
a drill motor which operates between 4000 and 4500 RPM in order to remove the tape
residue.
5. Use varnish makers and painters (VM&P) naphtha or a (50/50 mixture) by volume of
isopropyl alcohol and water in order to clean the area.
6. If needed, apply a length of masking tape as a molding guide.
7. The body and molding temperature should be at room temperature no lower than 16°C (60°
F) when installed.

Notice: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape
and the mating surface with Adhesive Cleaner. Wipe the tape and mating surface with a
clean, soft cloth. If the tape is damaged, refer to Emblem/Nameplate Replacement.

8. Apply the adhesive foam tape to the back of the molding and press the molding in place. If
you use GM P/N 1052621 or an equivalent, apply constant pressure to the molding for
30 seconds or until a firm adhesion bond is made.

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Rear Side Door Molding Replacement

Removal Procedure

Installation Procedure

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Rocker Panel Molding Replacement

Removal Procedure
1. Open both doors.

2. Starting at the front of the molding (2), pull the rocker molding away from the vehicle in
order to release the molding from the vehicle (3).

Installation Procedure

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1. Align the molding retainers to the holes in the rocker panel and snap the molding (2) into
place.
2. Ensure the clips are fully engaged in the lower side frame.
3. Close the doors and check the molding for proper fit.

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Fastener Tightening Specifications

Specification
Application Metric English
Brake Bracket to Strut 17 N·m 13 lb ft
Control Arm Bolts 158 N·m 117 lb ft
Control Arm Front Nut 158 N·m 117 lb ft
Drive Axle Nut 160 N·m 118 lb ft
Front Wheel Speed Sensor Bracket to Strut 17 N·m 13 lb ft
Hub and Bearing to Knuckle 95 N·m 70 lb ft
Service Ball Joint to Knuckle nut
l First Pass 10 N·m 89 lb in
l Second Pass + 180 degrees
Stabilizer Shaft Bracket Bolt 47 N·m 35 lb ft
Stabilizer Shaft Link Nut 17 N·m 13 lb ft
Strut Mount to Body Nut 47 N·m 35 lb ft
Strut to Knuckle Nut 185 N·m 136 lb ft
Strut to Strut Mount Nut 75 N·m 55 lb ft
Tie Rod Nut
l First Pass 30 N·m 22 lb ft
l Second Pass + 180 degrees

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Front Wheel Bearing and Hub Replacement

Tools Required
J 28733-B Front Hub Spindle Remover

Removal Procedure
1. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Clean the drive axle threads of all dirt. Lubricate the threads.

4. Insert a drift punch or a screwdriver into the caliper and the rotor in order to prevent the
rotor from turning.
5. Remove the drive axle nut.
6. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.

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7. Disconnect the ABS front wheel speed sensor connector. Unclip the connector from the dust
shield.

8. Remove the wheel bearing and hub retaining bolts.

Important: Replace the hub and bearing only as an assembly.

9. Use the J 28733-B in order to separate the hub and bearing from the drive axle.
10. Clean the rust and the foreign material from the following components in order to allow
proper seating of the bearing into the knuckle:
• The knuckle mounting face
• The bore
• The chamber

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Installation Procedure
1. Remove the protective plastic cover before installation. Do not handle the knuckle or hub
assembly by the ABS sensor wire.
2. Carefully install the dust shield. Do not damage the bearing outboard lip seal, or the wheel
bearing and hub retaining bolts.
3. Apply a thin layer of grease to the steering knuckle bore.
4. Install the wheel bearing and hub and dust shield to the steering knuckle.

5. Install the wheel bearing and hub retaining bolts.

Tighten
Tighten the wheel bearing and hub retaining bolts to 95 N·m (70 lb ft).

6. Install the new drive axle nut, draw hub and bearing onto the axle.

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7. Connect the ABS front wheel speed sensor connector. Clip the connector to its proper
location.
8. Install the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.

9. Insert a drift punch or a screwdriver into the caliper and rotor in order to prevent the rotor
from turning.

Tighten
Tighten the drive axle nut to 160 N·m (118 lb ft).

10. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
11. Lower the vehicle.

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Lower Control Arm Ball Joint Replacement

Removal Procedure
The ball joint is serviced only with the lower control arm and cannot be serviced separately. Refer
to Lower Control Arm Replacement .

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Lower Control Arm Replacement

Tools Required
J 43828 Ball Joint Separator

Removal Procedure
Notice: Use only the recommended tools for separating the ball joint from the knuckle.
Failure to use the recommended tools may cause damage to the ball joint and seal.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.

3. Disconnect the stabilizer link to control arm bolt.

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4. Remove the cotter pin (1). Loosen the nut (2) from the ball stud.

Notice: Care must be exercised to prevent Tri-Pot joints from being over-extended. When
either end of the shaft is disconnected, over-extension of the joint could result in separation
of internal components and possible joint failure. Drive axle joint seal protectors should be
used any time service is performed on or near the drive axles. Failure to observe this can
result in interior joint or seal damage and possible joint failures.

5. Use the J 43828 in order to remove the ball joint from the steering knuckle.

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6. Remove the control arm mounting bolts.

7. Remove the control arm from the frame.

Installation Procedure

1. Install the control arm to the frame.

Important: Do not tighten the control arm nuts at this time. Before tightening the control
arm mounting nuts, support the weight of the vehicle by the control arms in order to obtain
the vehicle design trim heights.

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2. Install the bolts, washers and nuts.

3. Connect the stabilizer link to the control arm.
4. Connect the ball joint to the knuckle.

5. Install the cotter pin.

Tighten
• Tighten the stabilizer shaft link assembly nut to 17 N·m (13 lb ft).
• Tighten the ball joint nut to 10 N·m (89 lb in). Then, tighten the two flats to a
minimum of 55 N·m (41 lb ft) in order to align the cotter pin slot.
6. Lower the vehicle and support the lower control arm with a jackstand to set the control arm
bushings into the normal position.
7. Tighten the control arm bolts in the following sequence:

Tighten
1. Tighten the rear mounting bolt to 158 N·m (117 lb ft).
2. Tighten the front mounting nut to 158 N·m (117 lb ft).
8. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
9. Lower the vehicle.
10. Check suspension alignment.

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Stabilizer Shaft Insulator Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the stabilizer shaft bracket bolts.
3. Remove the stabilizer shaft bracket.
4. Using a pry bar, lift upwards on the stabilizer shaft and remove the stabilizer shaft insulator.

Installation Procedure

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1. Using a pry bar, lift up on the stabilizer shaft and install the stabilizer shaft insulator.
2. Install the stabilizer shaft bracket.

3. Install the stabilizer shaft bracket bolts.

Tighten
Tighten the stabilizer shaft bracket bolts to 50 N·m (37 lb ft).

4. Lower the vehicle.

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Stabilizer Shaft Link Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
3. Remove the stabilizer shaft link bolt.

4. Remove the stabilizer shaft insulators and spacers.

Installation Procedure

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1. Loosely install the stabilizer link components.

Tighten
Tighten the stabilizer link nuts to 17 N·m (13 lb ft).

2. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
3. Lower the vehicle.

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Stabilizer Shaft Replacement

Tools Required
J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement .
4. Remove the stabilizer shaft insulators. Refer to Stabilizer Shaft Insulator Replacement .

5. Remove the left outer tie rod retaining nut.

6. Using J 24319-B seperate the outer tie rod from the steering knuckle.
7. Remove the exhaust pipe. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.

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8. Turn the left strut completely to the left. Guide the stabilizer shaft out the left side of the
vehicle between the body and the strut.
9. Remove the stabilizer shaft (3) out from under the vehicle.

Installation Procedure

1. Install the stabilizer shaft (3) to the vehicle.

2. Install the exhaust pipe. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.

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3. Loosely install the following components:

3.1. The left and right stabilizer shaft insulators
3.2. The brackets
3.3. The bolts
4. Install the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement .

5. Install the left tie rod end (1) to the steering knuckle.

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may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

6. Install the left outer tie rod retaining nut.

Tighten
• Tighten the stabilizer shaft insulator bracket bolts to 47 N·m (35 lb ft).
• Tighten the outer tie rod to steering knuckle retaining nut to 30 N·m (22 lb ft) pluss an
aditional 180 degrees.
7. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
8. Lower the vehicle.

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Steering Knuckle Replacement

Tools Required
• J 43828 Ball Joint Separator
• J 24319-B Steering Linkage and Tie Rod Puller

3. Insert drift of screwdriver into the caliper and rotor in order to prevent rotor from turning.
4. Remove the drive axle nut.
5. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
6. Remove the wheel bearing and hub from the vehicle. Refer to Stabilizer Shaft Insulator
Replacement .

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7. Remove the outer tie rod retaining nut.

8. Using J 24319-B separate the outer tie rod from the steering knuckle.

9. Remove the front strut to steering knuckle retaining nuts (1) and bolts (3).

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10. Remove the lower ball joint cotter pin (1) and nut (2).

11. UseJ 43828 to separate the ball joint from the steering knuckle.
12. Remove the steering knuckle from the vehicle.

Installation Procedure

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1. Install the lower ball joint into the steering knuckle.

2. Install lower ball joint nut.

Tighten
Tighten the lower ball joint nut (2) to 10 N·m (88 lb in) plus an additional 180-300 degrees
(3-5 flats). For cotter pin alignment, tighten the nut up to, but do not exceed 60 degrees
additional rotation. Do not back off nut for cotter pin (1) alignment.

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3. Install the outer tie rod to the steering knuckle.

Tighten
Tighten the outer tie rod to steering knuckle retaining nut to 75 N·m (55 lb ft).

4. Install the hub and bearing to the steering knuckle/drive axle. Refer to Front Wheel Bearing
and Hub Replacement .

5. Install the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

6. Install the drive axle (2) nut by inserting drift of screwdriver (1) into the caliper and rotor in
order to prevent rotor from turning.

Tighten
Tighten the drive axle nut to 145 N·m (107 lb ft).

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7. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.

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Strut Assembly Replacement

Removal Procedure
Notice: Care should be taken to avoid chipping or cracking the spring coating when handling the
front suspension coil spring. Failure to observe this notice may result in spring breakage.

1. Remove the strut mount fasteners.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.

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4. Disconnect the ABS front wheel speed sensor connector.

5. Remove the speed sensor bracket from the strut.

Notice: The knuckle must be retained after the strut-to-knuckle bolts have been removed.
Failure to observe this may cause ball joint and/or wheel drive shaft damage.

6. Remove the brake line bracket from the strut on the left side.

7. Remove the strut to knuckle bolts (3) and the nuts (1) in order to separate the strut from the
steering knuckle (2).
8. Remove the strut from the vehicle.

Installation Procedure
1. Install the strut into place.

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2. Install the 3 strut mount fasteners.

Tighten
Tighten the strut mount to body nuts to 47 N·m (35 lb ft).

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3. Install the strut to knuckle bolts (3) and the nuts (1) in order to install the strut to the
steering knuckle (2).
4. Connect the brake line to the strut on the left side.
5. Connect the speed sensor to the bracket strut.

6. Connect the ABS front wheel speed sensor connector.

Tighten
• Tighten the strut to knuckle bolts to 185 N·m (136 lb ft).
• Tighten the brake line and the speed sensor bracket bolts to 17 N·m (13 lb ft).
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.

Important: Perform a front wheel alignment after installing the strut.

8. Lower the vehicle.

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Strut, Strut Component, and Spring Replacement

Tools Required
• J 3289-20 Holding Fixture
• J 34013-B Strut Compressor
• J 34013-38 Alignment Rod
• J 34013-20 Damper Rod Clamp

Removal Procedure

Notice: Use care when handling the coil springs in order to avoid chipping or scratching the
coating. Damage to the coating will result in premature failure of the coil springs.

1. Remove the strut assembly from the vehicle in order to perform this procedure. Refer to
Strut Assembly Replacement .
2. Install the strut (1) into the J 34013-B .
3. Turn the compressor forcing screw (3) until the spring compresses slightly.

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4. Use a socket (3) in order to prevent the strut shaft from turning. Remove the strut shaft
retaining nut.

5. Install the J 34013-38 in order to help guide the strut shaft out of the assembly.
6. Loosen the compressor screw while guiding the strut shaft out of the assembly. Continue
loosening the compressor screw until the strut and the spring may be removed.

Installation Procedure

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1. Install the strut in the J 34013-B with the J 34013-20 clamped on the strut shaft (1) in the
strut compressor.

Important:
• Ensure that the flat on the upper spring seat faces out from the centerline of the
vehicle. When you mount the spring seat in the strut compressor, ensure that the
spring seat faces in the same direction as the steering knuckle mounting flange.
• If the bearing had been removed from the upper spring seat, install the bearing into the
upper spring seat in the same orientation as it had been. Also, install the bearing in the
spring seat before attaching to the strut mount.

2. Install the spring over the strut in the correct position.

3. Move the assembly upright in the strut compressor.
4. Install the upper locking pin (2).

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5. Install the rod J 34013-38 into the strut guide strut shaft.
6. Start turning the compressor screw clockwise on the J 34013-B , while guiding the J 34013-
38 to the center strut shaft in the assembly.

7. Continue to turn the compressor forcing screw (3) on the strut compressor until the strut
shaft threads are visible through the top of the strut assembly (1).
8. Install the strut washer and retaining nut.

9. Remove the clamp J 34013-20 from the strut shaft.

Tighten
Tighten the strut mount retaining nut to 75 N·m (55 lb ft) while holding the strut shaft with
the socket.

10. Remove the strut from the strut compressor.

11. Install the strut assembly to the vehicle. Refer to Strut Assembly Replacement .

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Suspension Strut Disposal

Caution: Use the proper eye protection when drilling to prevent metal chips from causing physical
injury.

1. Clamp the strut in a vise horizontally with the rod (1) completely extended.
2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in) drill bit. Gas
or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in
order to contain the escaping oil.
3. Remove the strut from the vise.
4. Hold the strut over a drain pan vertically with the hole down.
5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut.

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Wheel Stud Replacement

Tools Required
J 35917 Ball Joint Remover

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

4. Using J 35917 press the stud from the wheel bearing and hub.
5. Remove the stud at the innermost notch in the knuckle, on the caliper side of the knuckle.

Installation Procedure

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1. Install a new stud. Use washers and wheel nuts to draw the stud into the hub and seat the
wheel stud.
2. Install the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Lower the vehicle.

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Fastener Tightening Specifications

Specification
Application Metric English
Horn Attaching Fastener 15 N·m 11 lb ft

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Horn Component Views

Dual Horns

(1) Horn Assembly

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Horn Connector End Views

Horn

• 12052644
Connector Part Information
• 2-Way F Metri-Pack 150 Series Sealed (GRY)
Pin Wire Color Circuit No. Function
A BLK 250 Ground
B DK GRN 29 Horn Control

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Horn Relay Replacement

Removal Procedure

1. Open the hood.

2. Remove the cover from the underhood fuse block.
3. Remove the horn relay (1) from the underhood fuse block.

Installation Procedure

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1. Install the horn relay (1) to the underhood fuse block.

2. Install the cover to the underhood fuse block.
3. Close the hood.

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Horn Replacement
Removal Procedure
1. Remove the Air Deflector. Refer to Front Air Deflector Replacement in Body Front End.

2. Disconnect the electrical connectors from the horns.

3. Remove the fastener retaining the horns to the left front frame rail.
4. Remove the horns.

Installation Procedure

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1. Install the horns to the left front frame rail.

2. Install the horn retaining fastener.

Tighten
Tighten the fastener to 15 N·m (11 lb ft).

3. Connect the electrical connectors to the horns.

4. Install the Air Deflector. Refer to Front Air Deflector Replacement in Body Front End.

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Horn Schematics

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Fastener Tightening Specifications

Specification
Application Metric English
Blower Motor Control Processor Screws 2 N·m 18 lb in
Mode Actuator Screws 1.4 N·m 12 lb in
Recirculation Actuator Screws 1.4 N·m 12 lb in
Temperature Actuator Screws 1.4 N·m 12 lb in

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Sensor Resistance Table

Temperature Outside Air Resistance Inside Air Resistance
Minimum Maximum Minimum Maximum
°C °F Resistance Resistance Resistance Resistance
k Ohms k Ohms k Ohms k Ohms
-10 14 5.27 5.98 15.42 16.89
-5 23 4.03 4.52 11.76 12.80
0 32 3.11 3.44 9.03 9.75
5 41 2.43 2.66 7.00 7.53
10 50 1.91 2.07 5.47 5.85
15 59 1.51 1.62 4.31 4.58
20 68 1.21 1.28 3.41 3.61
25 77 0.97 1.02 2.72 2.86
30 86 0.78 0.82 2.17 2.29
35 95 0.63 0.67 1.74 1.85
40 104 0.51 0.55 1.41 1.50

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HVAC Connector End Views

Table 1: A/C Compressor Clutch
Table 2: A/C Orifice Relay
Table 3: A/C Refrigerant Low Temperature Sensor
Table 4: A/C Refrigerant Pressure Sensor (w/LX5)
Table 5: A/C Refrigerant Pressure Sensor (w/L47)
Table 6: Air Temperature Actuator - Left
Table 7: Air Temperature Actuator - Right
Table 8: Air Temperature Sensor - Inside
Table 9: Air Temperature Sensor - Lower Right
Table 10: Air Temperature Sensor - Ambient
Table 11: Air Temperature Sensor - Upper Left
Table 12: Air Temperature Sensor - Upper Right
Table 13: Air Temperature Switch Assembly - Right
Table 14: Blower Motor Control Processor
Table 15: Blower Motor
Table 16: HVAC Control Module (w/CJ2)
Table 17: Mode Actuator
Table 18: Recirculation Actuator
Table 19: Sunload Sensor Assembly

A/C Compressor Clutch

• 12186685
Connector Part Information
• 2-Way (BLK)
Pin Wire Color Circuit No. Function
A DK GRN 59 A/C Compressor Clutch Supply Voltage
B BLK 1150 Ground

A/C Orifice Relay

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• 15324570
Connector Part Information
• 2-Way M GT 150 Series (BLK)
Pin Wire Color Circuit No. Function
A PNK/BLK 2262 A/C Orifice Relay Control Circuit
B BLK 250 Ground

A/C Refrigerant Low Temperature Sensor

• 12092512
Connector Part Information
• 2-Way (BLK)
Pin Wire Color Circuit No. Function
A BLK/WHT 2261 Low Reference
B GRY 731 A/C Refrigerant Low Temperature Sensor Signal

A/C Refrigerant Pressure Sensor (w/LX5)

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• 12110192
Connector Part Information
• 3-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 808 Low Reference
B GRY 474 5 Volt Reference
C RED/BLK 380 A/C Refrigerant Pressure Sensor Signal

A/C Refrigerant Pressure Sensor (w/L47)

• 12110192
Connector Part Information
• 3-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 808 Low Reference
B GRY 2700 5 Volt Reference
C RED/BLK 380 A/C Refrigerant Pressure Sensor Signal

Air Temperature Actuator - Left

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• 12064993
Connector Part Information
• 6-Way F Micro-Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
5 BRN 141 Ignition 3 Voltage
6 DK BLU 1199 Air Temperature Door Control
7 YEL 1791 Low Reference
8 -- -- Not Used
9 LT BLU 733 Air Temperature Door Position Signal
10 GRY 705 5 Volt Reference

Air Temperature Actuator - Right

• 12064993
Connector Part Information
• 6-Way F Micro-Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
5 BRN 141 Ignition 3 Voltage
6 WHT/BLK 1236 Air Temperature Door Control - Right
7 YEL 1791 Low Reference
8 -- -- Not Used

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9 DK BLU 1646 Air Temperature Door Position Signal - Right

10 GRY 705 5 Volt Reference

Air Temperature Sensor - Inside

• 15304747
Connector Part Information
• 2-Way M Metri-Pack 150 Series (RED)
Pin Wire Color Circuit No. Function
A DK GRN 734 Inside Air Temperature Sensor Signal
B YEL 61 Low Reference

Air Temperature Sensor - Lower Right

• 12047662
Connector Part Information
• 2-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 520 Lower Right Air Temperature Sensor Signal
B YEL 61 Low Reference

Air Temperature Sensor - Ambient

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• 12162195
Connector Part
Information • 2-way M Metri-Pack 150.2 Series Pull to Seat
(BLK)
Pin Wire Color Circuit No. Function
A LT GRN/BLK 735 Ambient Air Temperature Sensor Signal
B YEL 61 Low Reference

Air Temperature Sensor - Upper Left

• 12047662
Connector Part Information
• 2-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 516 Upper Left Air Temperature Sensor Signal
B YEL 61 Low Reference

Air Temperature Sensor - Upper Right

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• 12047662
Connector Part Information
• 2-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A TAN 517 Air Temperature Sensor Signal Upper Right
B YEL 61 Low Reference

Air Temperature Switch Assembly - Right

• 12064760
Connector Part Information
• 4-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A PNK 2145 Warmer/Cooler Passenger Switch Supply Voltage
B PPL 2146 Passenger HVAC Switch Signal
C YEL 1491 Backlight Lamps Control
D BLK/WHT 451 Ground

Blower Motor Control Processor

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• 12129566
Connector Part Information
• 4-Way F Metri-Pack 280 Series (GRY)
Pin Wire Color Circuit No. Function
A BLK 450 Ground
B ORN 1340 Battery Positive Voltage
C GRY 754 Blower Motor Speed Control
D -- -- Not Used

Blower Motor

• 12092311
Connector Part Information
• 3-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK -- Speed Control
B PPL -- Blower Motor Positive Voltage
C BRN -- Blower Motor Flange Ground

HVAC Control Module (w/CJ2)

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• 15317984
Connector Part Information
• 12-Way M (NAT)
Pin* Wire Color Circuit No. Function
A1 FW 451 Ground
A2 FW 41 Ignition 3 Voltage
A3-A4 -- -- Not Used
A5 FW 450 Ground
A6 -- -- Not Used
B1 FW 1491 Backlight Lamps Control
B2-B4 -- -- Not Used
B5 FW 1881 HVAC Control Module Clock Signal
B6 FW 1880 HVAC Control Module Data Signal
* A Pins= Top

B Pins= Bottom

Mode Actuator

Connector Part Information • 12064993

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• 6-Way F Micro-Pack 100 Series (BLK)

Pin Wire Color Circuit No. Function
5 BRN 141 Ignition 3 Voltage
6 YEL 1318 Mode Door Control
7 YEL 1791 Low Reference
8 -- -- Not Used
9 YEL/BLK 1814 Lower Mode Door Position Signal
10 GRY 705 5 Volt Reference

Recirculation Actuator

• 12064993
Connector Part Information
• 6-Way F Micro-Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
5 BRN 141 Ignition 3 Voltage
6 DK GRN 1614 Recirculation Door Control
7 YEL 1791 Low Reference
8 -- -- Not Used
9 PPL 1838 Recirculation Door Position Signal
10 GRY 705 5 Volt Reference

Sunload Sensor Assembly

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• 12064760
Connector Part Information
• 4-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU/BLK 590 Driver Solar Sensor Signal
B GRY 1548 Passenger Solar Sensor Signal
C YEL 61 Low Reference
D WHT 278 Ambient Light Sensor Signal

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A/C Orifice Solenoid

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Air Delivery

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Air Temperature Sensors

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Blower Control

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Compressor Control W/L47 (V8)

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Compressor Control W/LX5 (V6)

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Heater AC Control

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Steering Wheel Controls

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Air Inlet Valve Actuator Replacement

Removal Procedure
1. Remove the IP storage compartment. Refer to Instrument Panel Storage Compartment
Replacement in Instrument Panel, Gauges and Console.
2. Remove the right closeout panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gauges and Console.
3. Remove the Dash Integration Module (DIM) from the bracket.

4. Remove the rear two DIM module bracket screws.

5. Reposition the DIM module bracket to gain access to the recirculation actuator.
6. Remove the electrical connector from the recirculation actuator.
7. Remove the recirculation actuator retaining screws.

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8. Remove the recirculation actuator.

Installation Procedure

1. Install the recirculation actuator.

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may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the recirculation actuator retaining screws.

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

3. Install the electrical connector to the recirculation actuator.

4. Position the DIM module bracket to its original position.

5. Install the rear two DIM module bracket retaining screws.

Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

6. Install the DIM module into the bracket.

7. Install the right closeout panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gauges and Console.
8. Install the IP storage compartment. Refer to Instrument Panel Storage Compartment
Replacement in Instrument Panel, Gauges and Console.
9. Recalibrate the actuators. Refer to Actuator Recalibration in Body Controls System.

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Air Temperature Switch Assembly Replacement - Right

Side
Removal Procedure

1. Remove the right temperature switch plate by lifting up on the forward edge with a flat blade
tool.
2. Lift the switch plate up in order to remove from the door panel.
3. Disconnect the electrical connector.
4. Remove the right air temperature switch assembly from the switch plate .

Installation Procedure
1. Install the right air temperature switch assembly into the switch plate.
2. Connect the electrical connector.

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3. Install the right temperature switch plate with the rearward end inserted first.
4. Carefully push on the switch plate to seat into the door panel.

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Ambient Air Temperature Sensor Replacement

Removal Procedure

1. Disconnect the electrical connector from the sensor.

2. Remove the retainer and the ambient air temperature sensor.

Installation Procedure

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1. Install the ambient air temperature sensor with the retainer.

2. Connect the electrical connector to the sensor.

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Blower Motor Control Processor Replacement

Removal Procedure
1. Remove the right closeout panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side In Instrument Panel, Gauges and Console.
2. Remove the instrument panel compartment. Refer to Instrument Panel Storage Compartment
Replacement in Instrument Panel, Gauges and Console.
3. Remove the Dash Integration Module (DIM) from the bracket and position aside.
4. Remove the rear DIM bracket screws and lower the bracket enough to access the blower
motor control processor.

5. Disconnect the electrical connector (1).

6. Remove the blower motor control processor retaining screws.
7. Remove the blower motor control processor.

Installation Procedure
1. Install the blower motor control processor.

2. Install the retaining screw.

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Tighten
Tighten the screw to 2 N·m (18 lb in).

3. Connect the electrical connector (1).

4. Install the DIM bracket screws.

Tighten
Tighten the screw to 1.4 N·m (12 lb in).

5. Install the DIM into the bracket.

6. Install the instrument panel storage compartment. Refer to Instrument Panel Storage
Compartment Replacement in Instrument Panel, Gauges and Console.
7. Install the right closeout panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gauges and Console.

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Duct Air Temperature Sensor Replacement - Lower Left

Side
Removal Procedure

1. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Right Side or Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel,
Gauges and Console.
2. Disconnect the electrical connector from the sensor.

Installation Procedure
1. Connect the electrical connector to the sensor.

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2. Install the sensor into the sound insulator.

3. Install the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.

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Duct Air Temperature Sensor Replacement - Lower

Right Side
Removal Procedure

1. Remove the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gauges and Console.
2. Disconnect the electrical connector from the sensor.

Installation Procedure
1. Connect the electrical connector to the sensor.

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2. Install the sensor into the sound insulator.

3. Install the sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Right
Side in Instrument Panel, Gauges and Console.

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Duct Air Temperature Sensor Replacement - Upper Left

Side
Removal Procedure
1. Remove the left IP endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gauges and Console.

2. Remove the sensor by twisting 1/4 turn.

3. Disconnect the electrical connector from the sensor.

Installation Procedure
1. Connect the electrical connector to the sensor.

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2. Install the sensor into the duct and twist to lock in place.
3. Install the left IP endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gauges and Console.

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Duct Air Temperature Sensor Replacement - Upper

Right Side
Removal Procedure
1. Remove the right IP endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gauges and Console.

2. Remove the sensor by twisting 1/4 turn.

3. Disconnect the electrical connector from the sensor.

Installation Procedure
1. Connect the electrical connector to the sensor.

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2. Install the sensor into the duct and twist to lock in place.
3. Install the right IP endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gauges and Console.

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HVAC Control Module Replacement

Removal Procedure
1. Remove the center instrument panel (I/P) trim panel. Refer to Instrument Panel Center Trim
Panel Replacement .

2. Pinch the tabs on the control module and pull rearward on the control module to remove
from the I/P.

Installation Procedure

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1. Install the control module into the instrument panel ensuring the tabs are seated into the IP.
2. Install the center I/P trim panel. Refer to Instrument Panel Center Trim Panel Replacement .

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Inside Air Temperature Sensor Aspirator Replacement

3. Remove the aspirator mounting bolt.

4. Use a flat blade tool to lift the aspirator out of the HVAC case.

Installation Procedure

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1. Install the aspirator into the case.

2. Install the bolt.

Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

3. Connect the aspirator hose to the muffler.

4. Install the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.

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Inside Air Temperature Sensor Replacement

Removal Procedure
1. Remove the cluster trim plate. Refer to Instrument Panel Cluster Trim Plate Bezel
Replacement in Instrument Panel, Gauges and Console.
2. Remove the knee bolster . Refer to Knee Bolster Replacement in Instrument Panel, Gauges
and Console.

3. Disconnect the electrical connector.

4. Pull the inside air temperature sensor

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aspirator hose.

Installation Procedure

1. Install the inside air temperature sensor to the aspirator hose.

2. Connect the electrical connector.

3. Install the sensor into the instrument panel.

4. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges and
Console.
5. Install the cluster trim plate. Refer to Instrument Panel Cluster Trim Plate Bezel Replacement
in Instrument Panel, Gauges and Console.

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Mode Valve Actuator Replacement

Removal Procedure
1. Remove the left air temperature actuator. Refer to Air Temperature Actuator Replacement -
Left Side .

2. Remove the mode actuator retaining screws (1).

3. Remove the mode actuator.

Installation Procedure

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1. Align the mode valve levers with the cam slots.

2. Install the mode actuator.

3. Install the mode actuator retaining screws (1).

Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

4. Install the left air temperature actuator. Refer to Air Temperature Actuator Replacement -
Left Side .
5. Recalibrate the actuators. Refer to Actuator Recalibration in Body Controls System.

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Sun Load Sensor Assembly Replacement

Removal Procedure

1. Remove the defroster grille. Refer to Defroster Grille Replacement .

2. Disconnect the electrical connector from the sunload sensor assembly (2).
3. Remove the sunload sensor assembly.

Installation Procedure
1. Install the sunload sensor assembly.

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2. Connect the electrical connector to the sunload sensor assembly (2).

3. Install the defroster grille (1). Refer to Defroster Grille Replacement .

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Temperature Valve Actuator Replacement - Left Side

Removal Procedure

1. Remove the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauges and Console.
2. Remove the knee bolster . Refer to Knee Bolster Replacement in Instrument Panel, Gauges
and Console.
3. Remove the Instrument Panel Module (IPM). Refer to Instrument Panel Module Replacement
in Body Control System.
4. Remove the electrical connector from the left air temperature actuator.
5. Remove the left air temperature actuator retaining screws (1).

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6. Remove the left air temperature actuator.

Installation Procedure

1. Install the left air temperature actuator.

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2. Install the left air temperature actuator retaining screws (1).

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

3. Install the electrical connector to the left air temperature actuator.

4. Install the IPM. Refer to Instrument Panel Module Replacement in Body Control System.
5. Install the knee bolster . Refer to Knee Bolster Replacement in Instrument Panel, Gauges and
Console.
6. Install the left closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.
7. Recalibrate the actuators. Refer to Actuator Recalibration in Body Controls System.

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Temperature Valve Actuator Replacement - Right Side

Removal Procedure

1. Remove the IP storage compartment. Refer to Instrument Panel Storage Compartment

Replacement in Instrument Panel, Gauges and Console.
2. Remove the electrical connector from the right air temperature actuator.
3. Remove the right air temperature actuator retaining screws (1).

4. Remove the right air ©

temperature
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Installation Procedure

1. Install the right air temperature actuator.

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2. Install the right air temperature retaining screws (1).

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

3. Install the electrical connector to the right air temperature actuator.

4. Install the IPstorage compartment. Refer to Instrument Panel Storage Compartment
Replacement in Instrument Panel, Gauges and Console.
5. Recalibrate the actuators. Refer to Actuator Recalibration in Body Controls System.

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Fastener Tightening Specifications

Specification
Application Metric English
A/C Low Side Temperature Sensor 9 N·m 80 lb in
A/C Refrigerant Pressure Sensor 5 N·m 44 lb in
Air Distribution Duct Screws 1.4 N·m 12 lb in
Blower Control Module Screws 6 N·m 53 lb in
Blower Motor Screws 1.4 N·m 12 lb in
Condenser to Radiator Mounting Bolts 6 N·m 53 lb in
Compressor Hose Nut at Accumulator 20 N·m 15 lb ft
Compressor Hose Nut at Condenser 20 N·m 15 lb ft
Compressor Mounting Bolts 25 N·m 18 lb ft
Defroster Duct to Module Screws 1.4 N·m 12 lb in
Defroster Duct to Front of Dash Nut 9 N·m 80 lb in
Evaporator Core Cover 1.4 N·m 12 lb in
Evaporator Hose Assembly Nut at Accumulator 20 N·m 15 lb ft
Evaporator Hose Assembly Nut at Condenser 20 N·m 15 lb ft
Evaporator Hose Assembly Nut at Evaporator 20 N·m 15 lb ft
Heater Core Cover 1.4 N·m 12 lb in
Heater Core Retaining Screw 1.4 N·m 12 lb in
HVAC Module Mounting Bolts 9 N·m 80 lb in
Heater Core Cover 1.4 N·m 12 lb in
Heater Core Retaining Screws 1.4 N·m 12 lb in
Orifice Solenoid O-Ring Fitting 27 N·m 20 lb ft
Service Fitting 12 N·m 9 lb ft

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Refrigerant System Capacities

Refrigerant System Capacities
Specification
Application Metric English
PAG Oil GM P/N 12356151
l Accumulator Replacement 60 ml* 2.0 oz*
l Compressor Replacement 80 ml* 2.7 oz*
l Condenser Replacement 30 ml* 1.0 oz*
l Evaporator Replacement 90 ml* 3.0 oz*
l Total System PAG Oil Capacity 286 ml 9.7 oz
R-134a GM P/N 12345922 or the equivalent
l Refrigerant Charge 0.997 kg 2.2 lb
l * If more than the specified amount of PAG oil was drained from a component, add the
equal amount drained.

© 2014 General Motors Corporation. All rights reserved.

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Air Conditioning (A/C) Refrigerant Low Temperature

Sensor Replacement
Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Disconnect the electrical connector from the low side temperature sensor.

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3. Unscrew the A/C low side temperature sensor (1) from the refrigerant line and remove the
sensor from the vehicle.

Installation Procedure
1. Ensure the low side A/C temperature (1) sensor has a O-ring installed and the O-ring is not
damaged.

Lubricate the low side A/C temperature (1) with a light coating of refrigerant oil.

2. Install the A/C low side temperature (1) sensor to the refrigerant line.

Tighten
Tighten the sensor to 9 N·m (80 lb in).

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3. Connect the electrical connector to the sensor.

4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
5. Leak test the fittings of the component using the J 39400-A .

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Air Conditioning (A/C) Refrigerant Pressure Sensor

Replacement
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

3. Disconnect the electrical connector from the A/C refrigerant pressure sensor (1).
4. Remove the A/C refrigerant pressure sensor.

Installation Procedure
1. Lubricate the O-ring with 525 refrigerant oil.

2. Install the A/C refrigerant pressure sensor (1).

Tighten
Tighten the bolt to 5 N·m (44 lb in).

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3. Connect the electrical connector to the A/C refrigerant pressure sensor.

4. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Lower the vehicle.

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Air Conditioning Accumulator Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Disconnect the orifice valve wiring harness and position out of the way.

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3. Remove the accumulator cover (1).

4. Remove the A/C compressor suction hose (1) from the accumulator.

5. Remove the evaporator hose from the accumulator.

6. Remove the accumulator from the housing.

Installation Procedure
1. Add the proper amount of refrigerant oil to the accumulator. Refer to Refrigerant System
Capacities .
2. Install the accumulator into the housing.

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3. Install the evaporator hose and nut to the accumulator.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

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4. Install the A/C compressor suction hose (1) and nut to the accumulator.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

5. Install the accumulator cover (1).

6. Install the evaporator hose into the retainer.

7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
8. Leak test the fittings of the component using the J 39400-A .

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Air Conditioning Compressor Replacement (L47)

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-4.0L.
3. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
5. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
6. Remove the washer bottle. Refer to Windshield Washer Solvent Container Replacement in
Wipers/Washer Systems.
7. Disconnect the brake line retaining clips from frame in order to allow the brake lines to move
during removal of the A/C compressor.

Important: Seal the A/C compressor suction and discharge ports after the hoses are
removed in order to keep the A/C compressor oil from draining out of the compressor during
removal.

All A/C lines, hoses and components should be sealed after removal in order to avoid
excessive moisture contamination to the A/C system during servicing.

8. Disconnect the suction hose fitting from the compressor.

© 2014 General Motors Corporation. All rights reserved.

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9. Disconnect the discharge hose fitting from the compressor.

10. Disconnect the compressor electrical connector.

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11. Remove the rear compressor mounting fasteners (3, 4).

12. Remove the lower generator mounting bolt.
13. Remove the front compressor mounting fasteners (1, 2).

14. Remove the A/C compressor mounting stud (1).

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15. Rotate the compressor, in order to allow the A/C compressor to exit through the wheelhouse
opening.
16. Remove the compressor from the vehicle.

Installation Procedure
Important: When replacing the compressor it is necessary to drain and measure the old
compressor oil (be sure to rotate the shaft to ensure a complete draining). Drain the oil from
the new compressor and add the amount taken from the old compressor. Refer to Refrigerant
System Capacities .

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1. Install the A/C compressor through the wheelhouse opening.

2. Position the A/C compressor (2) on the mounting surface.

3. Install the A/C compressor mounting stud (1) through the appropriate compressor mounting
ear.

Tighten
Tighten the A/C compressor mounting stud to 25 N·m (18 lb ft).

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4. Install the A/C compressor mounting fasteners (1, 2, 3, 4) and hand tighten.

Tighten
• Tighten the A/C compressor mounting nut (1) to 50 N·m (37 lb ft).
• Tighten the A/C compressor mounting bolts (2, 3) to 50 N·m (37 lb ft).
• Tighten the A/C compressor mounting bolt (4) to 25 N·m (18 lb ft).
5. Install the generator mounting bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

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6. Connect the compressor electrical connector.

Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

7. Connect the discharge hose fitting to compressor.

Tighten
Tighten the discharge hose nut to 20 N·m (15 lb ft).

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8. Connect the suction hose nut to the compressor

Tighten
Tighten the suction hose fitting to the compressor to 20 N·m (15 lb ft).

9. Connect the brake line retaining clips onto the frame.

10. Install the belt. Refer to Drive Belt Replacement in Engine Mechanical-4.0L.
11. Install the washer bottle. Refer to Windshield Washer Solvent Container Replacement in
Wipers/Washer Systems.
12. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
13. Reinstall the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
14. Lower the vehicle.
15. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
16. Leak test the fittings of the component using the J 39400-A .

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Air Conditioning Compressor Replacement (LX5)

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-3.5L.
3. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
5. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
6. Remove the right wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
7. Support the front of the cradle with a floor jack.
8. Remove the right front cradle bolt and lower the cradle.
9. Remove the idler pulley and bolt. Refer to Drive Belt Idler Pulley Replacement in Engine
Mechanical-3.5L.

Important: Seal the A/C compressor suction and discharge ports after the hoses are
removed in order to keep the A/C compressor oil from draining out of the compressor during
removal.

All A/C lines, hoses and components should be sealed after removal in order to avoid
excessive moisture contamination to the A/C system during servicing.

© 2014 General Motors Corporation. All rights reserved.

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10. Disconnect the suction hose fitting from the compressor.

11. Disconnect the discharge hose fitting from the compressor.

12. Remove the upper generator mounting bolts and position the generator out of the way in
order to access the compressor mounting bolts.

13. Disconnect the compressor electrical connector.

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14. Remove the upper compressor mounting bolts (1).

15. Position the generator and install the idler pulley bolt to hold the generator in place.
16. Loosen the rear nut (2) and remove the front nut (3).
17. Remove the compressor from the engine block.
18. Rotate the compressor, in order to allow the A/C compressor to exit through the wheelhouse
opening.
19. Remove the compressor from the vehicle.

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1. Install the A/C compressor through the wheelhouse opening and position on the front (4) and
rear (5) studs.
2. Remove the generator idler pulley bolt and position generator out of the way.

3. Install and hand tighten the bolts (1) and nuts (2, 3).

Tighten
• Tighten the A/C compressor front nut (3) to 50 N·m (37 lb ft).
• Tighten the A/C compressor mounting bolts (1) to 50 N·m (37 lb ft).
• Tighten the A/C compressor rear nut (2) to 25 N·m (18 lb ft).

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4. Connect the compressor electrical connector.

5. Install the generator mounting bolts.

Tighten
Tighten the generator bolts to 50 N·m (37 lb ft).

Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

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6. Connect the discharge hose fitting to compressor.

Tighten
Tighten the discharge hose nut to 20 N·m (15 lb ft).

7. Connect the suction hose fitting to the compressor

Tighten
Tighten the suction hose nut to the compressor to 20 N·m (15 lb ft).

8. Install the idler pulley and bolt. Refer to Drive Belt Idler Pulley Replacement in Engine
Mechanical-3.5L.
9. Raise the right front cradle and install the bolt.

Tighten
Tighten the bolt to 191 N·m (141 lb ft).

10. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-3.5L.
11. Install the right side AIR pump. Refer to Secondary Air Injection Pump Replacement in
Engine Controls-3.5L.
12. Install the wheelhouse extension. Refer to Wheelhouse Extension Replacement in Body Front
End.
13. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
14. Reinstall the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
15. Lower the vehicle.
16. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
17. Leak test the fittings of the component using the J 39400-A .

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Air Conditioning Condenser Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the upper tie bar support brace bolts at the upper tie bar.
3. Loosen the support brace bolts from the headlamp and bumper fascia mounting panel and
position out of the way.

4. Remove the upper radiator seal.

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5. Remove the upper radiator mounting brackets.

6. Disconnect the compressor discharge hose (1) from the condenser.

7. Remove the front headlamps. Refer to Headlamp Replacement in Lighting Systems.

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8. Disconnect the evaporator hose from the condenser.

9. Remove the fasteners (1) from the left and right sides of the headlamp and bumper fascia
mounting panel.
10. Lift the headlamp and bumper fascia mounting panel and pull forward in car to obtain access
for the condenser removal.

Important: The bolt retaining the condenser to the radiator end tank is a special length and
should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the
radiator end tank.

11. Remove the two condenser to radiator mounting bolts.

12. Separate the condenser from the radiator by lifting out of the lower mounting tabs.

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13. Remove the two A/C condenser seals.

14. Lift the condenser up and remove from the vehicle.

Installation Procedure
1. Add the proper amount of refrigerant oil to the condenser. Refer to Refrigerant System
Capacities .
2. Place the condenser into the vehicle.
3. Install the condenser into the lower radiator mounting tabs.

4. Install the condenser mounting bolts.

Tighten
Tighten the connections to 6 N·m (53 lb in).

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5. Install the new A/C condenser seals.

6. Reposition the headlamp and bumper fascia mounting panel and install the fasteners (1).

Tighten
Tighten the bolt and nut to 9 N·m (7 lb ft).

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7. Install the evaporator hose and nut to the condenser.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

8. Install the compressor discharge hose and nut (1) to the condenser.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

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9. Install the upper radiator mounting brackets and bolts.

Tighten
Tighten the bolts to 9 N·m (7 lb ft).

10. Install the upper radiator seal.

11. Install the front fascia to tie bar support brackets and bolts.

Tighten
Tighten the bolts to 9 N·m (7 lb ft).

12. Install the front headlamps. Refer to Headlamp Replacement in Lighting Systems.

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13. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component using J 39400-A .

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Air Conditioning Evaporator Core Replacement

Removal Procedure
1. Remove the HVAC Module. Refer to HVAC Module Assembly Replacement .
2. Remove the mode actuator. Refer to Mode Actuator Replacement in HVAC Systems -
Automatic.
3. Remove the recirculation actuator. Refer to Recirculation Actuator Replacement in HVAC
Systems - Automatic.
4. Remove the right temperature actuator. Refer to Air Temperature Actuator Replacement -
Right Side in HVAC Systems - Automatic.
5. Remove the left temperature actuator. Refer to Air Temperature Actuator Replacement - Left
Side in HVAC Systems - Automatic.
6. Remove the fasteners that retain the mode actuator bracket.
7. Remove the mode actuator bracket.
8. Remove the upper module case fasteners.

9. Peel back the foam from the heater inlet.

© 2014 General Motors Corporation. All rights reserved.

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10. Remove the upper case.

11. Remove the evaporator core.

Installation Procedure
1. Add the proper amount of refrigerant oil to the evaporator. Refer to Refrigerant System
Capacities .

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2. Install the evaporator core into the module housing.

3. Install the upper module case.

4. Install the module case fasteners.

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Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

5. Reapply the foam at the heater inlet.

6. Install the mode actuator and bracket. Refer to Mode Actuator Replacement in HVAC Systems
- Automatic.
7. Install the left temperature actuator. Refer to Air Temperature Actuator Replacement - Left
Side in HVAC Systems - Automatic.
8. Install the right temperature actuator. Refer to Air Temperature Actuator Replacement -
Right Side in HVAC Systems - Automatic.
9. Install the recirculation actuator. Refer to Recirculation Actuator Replacement in HVAC
Systems - Automatic.
10. Install the HVAC module. Refer to HVAC Module Assembly Replacement .

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Air Conditioning Evaporator Hose Assembly

Replacement
Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Loosen the evaporator hose nut.

3. Disconnect the A/C evaporator hose (2) from the orifice valve.
4. Remove the evaporator hose nut.

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5. Disconnect the A/C evaporator hose from the accumulator.

6. Remove the evaporator hose nut from the evaporator.

7. Remove the A/C evaporator hose from the evaporator.

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8. Disconnect the electrical connector from the sensor.

9. Disconnect the surge tank hose from the surge tank.
10. Cap off the surge tank and line to prevent coolant leakage.
11. Pry up to remove the A/C line clip from the rail.
12. Remove the A/C evaporator hose from the vehicle.

Installation Procedure
1. Position the A/C evaporator hose in the vehicle.
2. Install the A/C evaporator hose clip to the rail.

Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

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3. Install the A/C evaporator hose to the evaporator.

4. Install the evaporator line fastener.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

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5. Connect the electrical connector to the temperature sensor.

6. Install the evaporator hose to the accumulator.

Tighten
Tighten the connection to 20 N·m (15 lb ft).

7. Install the A/C evaporator hose (2) to the orifice solenoid.

Tighten

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Tighten the connection to 20 N·m (15 lb ft).

8. Remove the caps the surge tank and hose.

9. Connect the surge tank hose to the surge tank.
10. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
11. Leak test the fittings of the component using the J 39400-A .

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Air Distributor Duct Replacement

Removal Procedure
1. Remove the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauges and Console.
2. Remove the right side sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges and Console.
3. Remove the console assembly. Refer to Front Floor Console Replacement in Instrument
Panel, Gauges and Console.

4. Remove the air distributor duct screws (1, 2). Due to the difficulty in the removal of the right
side screw (2), it will not be necessary to install upon reassembly.
5. Remove the air distributor duct.

Installation Procedure

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1. Install the air distributor duct and the left screw (1) ensure the right tab is seated properly.

Tighten
Tighten the screw to 1.4 N·m (12 lb in).

2. Install the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.
3. Install the right side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Right Side in Instrument Panel, Gauges and Console.
4. Install the console assembly. Refer to Front Floor Console Replacement in Instrument Panel,
Gauges and Console.

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Air Temperature Door Replacement - Left Side

9. Peel back the foam from the heater inlet.

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10. Remove the upper case.

11. Remove the left temperature door.

Installation Procedure

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1. Install the left temperature door.

2. Install the upper module case.

3. Install the module case fasteners.

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Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

4. Reapply the foam to the heater inlet.

5. Install the mode actuator and bracket. Refer to Mode Actuator Replacement in HVAC Systems
- Automatic.
6. Install the left temperature actuator. Refer to Air Temperature Actuator Replacement - Left
Side in HVAC Systems - Automatic.
7. Install the right temperature actuator. Refer to Air Temperature Actuator Replacement -
Right Side in HVAC Systems - Automatic.
8. Install the recirculation actuator. Refer to Recirculation Actuator Replacement in HVAC
Systems - Automatic.
9. Install the HVAC module. Refer to HVAC Module Assembly Replacement .

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Air Temperature Door Replacement - Right Side

9. Peel back the foam from the heater inlet.

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10. Remove the upper case.

11. Remove the right temperature door.

Installation Procedure

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1. Install the right temperature door.

2. Install the upper module case.

3. Install the module case fasteners.

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Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

4. Reapply the foam to the heater inlet.

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Auxiliary Air Distributor Duct Replacement

Removal Procedure
1. Remove the front carpet assembly. Refer to Front Floor Panel Carpet Replacement in Interior
Trim.

2. Remove the rear air distribution duct.

Installation Procedure

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1. Install the rear air distribution duct, connecting to the HVAC module and then into the rear
guide slots.
2. Install the front carpet assembly. Refer to Front Floor Panel Carpet Replacement in Interior
Trim.

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Blower Motor Replacement

Removal Procedure
1. Remove the right side sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges and Console.
2. Pull back the carpet near the blower motor.

3. Remove the IP compartment. Refer to Instrument Panel Storage Compartment Replacement

in Instrument Panel, Gauges and Console.
4. Remove the Dash Integration Module (DIM) from bracket.
5. Remove the two rear DIM bracket screws.
6. Reposition the DIM bracket to allow for removal of the blower motor.

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7. Disconnect the electrical connector (2) from the blower motor.

8. Remove the blower motor retaining screws (1).

9. Lower the blower motor and rotate counter clockwise to remove from the vehicle.

Installation Procedure

1. Install the blower motor. Blower motor will need to be rotated to install into the housing.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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2. Install the blower motor retaining screws (1).

Tighten
Tighten the screw to 1.4 N·m (12 lb in).

3. Connect the electrical connector (2) to the blower motor.

4. Reposition the DIM bracket to its original position.

5. Install the two rear DIM bracket screws.
6. Install the DIM into the bracket.
7. Install the IP compartment. Refer to Instrument Panel Storage Compartment Replacement in
Instrument Panel, Gauges and Console.
8. Reposition the carpet.
9. Install the right side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Right Side in Instrument Panel, Gauges and Console.

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Condenser Tube Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Loosen the Condenser tube nut (2).

3. Disconnect the condenser tube (2) from the orifice valve hose.
4. Remove the right headlamp. Refer to Headlamp Replacement in Lighting Systems.

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5. Disconnect the condenser tube from the condenser.

6. Remove the condenser tube.

Installation Procedure
Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

1. Install the condenser tube.

2. Connect the condenser tube to condenser.

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3. Install the condenser tube nut.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

4. Install the right headlamp. Refer to Headlamp Replacement in Lighting Systems.

5. Install the hose (2) to the orifice solenoid.

Tighten
Tighten the connection to 20 N·m (15 lb ft).

6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

7. Leak test the fittings of the component using the J 39400-A .

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Defroster Door Replacement

Removal Procedure
1. Remove the HVAC Module. Refer to HVAC Module Assembly Replacement .
2. Remove the mode actuator. Refer to Mode Actuator Replacement in HVAC Systems -
Automatic.
3. Remove the left temperature actuator. Refer to Air Temperature Actuator Replacement - Left
Side in HVAC Systems - Automatic.
4. Remove the fasteners that retain the mode actuator bracket.
5. Remove the mode actuator bracket.
6. Remove the upper module case fasteners in order to access the door.
7. Open the module.

8. Remove the actuator cam from the door.

9. Remove the defroster door.

Installation Procedure
1. Install the defroster door.

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2. Install the actuator cam to the door.

3. Close the module case.

4. Install the module case fasteners.

Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

5. Install the mode actuator and bracket. Refer to Mode Actuator Replacement in HVAC Systems
- Automatic.
6. Install the HVAC module. Refer to HVAC Module Assembly Replacement .

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Discharge Hose Replacement

Tools Required
J 39400-A Halogen Leak Detector

Remove Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Remove the nut (1) and discharge hose from the condenser.
3. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle
4. Remove the lower radiator air deflector. Refer to Front Air Deflector Replacement in Body
Front End.
5. Disconnect the electrical connector from the A/C refrigerant pressure sensor (1).

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6. Disconnect the discharge hose (3) from the compressor and remove.
7. Remove the discharge hose.

Installation Procedure
Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

1. Position the discharge hose into the vehicle.

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2. Install the discharge hose (3) and nut (2) to the compressor.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

3. Connect the electrical connector to the A/C refrigerant pressure sensor (1).
4. Lower the vehicle.

5. Install the discharge hose nut (1) to the condenser.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

7. Leak test the fittings of the component using the J 39400-A .
8. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

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Heater Core Replacement

Tools Required
• J 38185 Spring Hose Clamp Pliers
• J 39400 Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

3. Remove the heater hoses (1, 2) from the heater core.

4. Remove the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauges and Console.
5. Remove the right side sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges and Console.
6. Remove the console assembly. Refer to Front Floor Console Replacement in Instrument
Panel, Gauges and Console.
7. Remove the lower dash support bracket.

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8. Remove the auxiliary air distribution duct adapter.

9. Remove the air distributor duct screws (1, 2). Due to the difficulty in the removal of the right
side screw (2), it will not be necessary to install upon reassembly.
10. Remove the air distributor duct.

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11. Remove the heater core heat shield screws.

12. Remove the heater core heat shield.
13. Remove the heater core cover screws (1).
14. Remove the heater core cover.
15. Remove the retaining screw and strap from the heater core.
16. Remove the heater core.

1. Install the heater core into the HVAC module using the attaching straps and screws.

Tighten
Tighten the screw to 1.4 N·m (12 lb in).

2. Install the heater core cover.

3. Ensuring the seals at the front of dash are in the proper positions, install the heater core
cover screws.

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

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4. Install the heater core heat shield and screws (1).

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

5. Install the air distributor duct and the left screw (1). Ensure the right tab is seated properly.

Tighten
Tighten the screw to 1.4 N·m (12 lb in).

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6. Install the auxiliary air distribution duct adapter.

7. Install the lower dash support bracket.
8. Install the console assembly. Refer to Front Floor Console Replacement in Instrument Panel,
Gauges and Console.
9. Install the left side sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.
10. Install the right side sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Right Side in Instrument Panel, Gauges and Console.

11. Install the heater hoses and clamps using the J 38185 .
12. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
13. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component using J 39400 .

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Heater Hoses Replacement (L47)

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

2. Loosen the clamp and remove the outlet surge tank hose from the heater hose assembly.

3. Loosen the inlet (2) and outlet (1) hose clamps and remove the heater pipes.

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4. Loosen the heater hose inlet and outlet clamps and remove the hoses (1, 2) from the heater
core.
5. Remove the hose assembly.

Installation Procedure

1. Position the heater hose assembly into the vehicle.

2. Install the inlet and outlet hoses (1, 2) to the heater core and reposition the clamp.

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3. Install the surge tank outlet hose and reposition the clamp.

4. Install the inlet (2) and outlet (1) hoses to the heater pipes and reposition the clamps.
5. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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Heater Inlet Hose Replacement (LX5)

Tools Required
J 38185 Spring Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

2. Loosen the inlet heater hose clamp from the heater core.
3. Remove the inlet heater hoses from the heater core.

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4. Loosen the clamp and remove the inlet heater hose from the heater pipe adapter.

Installation Procedure

1. Install the inlet heater hose to the heater pipe adapter.

2. Reposition the clamp.

3. Install the inlet heater hose to the heater core.

4. Reposition the clamp.
5. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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Heater Inlet Pipe Replacement (L47)

Tools Required
J 38185 Spring Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0L.

3. Loosen the heater inlet hose clamp and remove from the heater pipe (2).

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4. Remove the inlet pipe (2) nut from the transaxle.

5. Squeeze the quick connect release tabs (1) on the inlet pipe and pull out on the inlet heater
pipe to remove.

Installation Procedure

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1. Install the inlet pipe (2) into the adapter (3) by pushing together. Pull back to ensure a good
connection

2. Position the inlet pipe (2) on the transaxle stud and install the nut.

Tighten
Tighten the nut to 24 N·m (18 lb ft).

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3. Install the heater inlet hose (2) to the heater pipe and reposition the clamp.
4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0L.
5. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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Heater Outlet Hose Replacement

Tools Required
J 38185 Spring Hose Clamp Pliers

Removal Procedure
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

2. Loosen the clamp and remove the outlet heater hose from the thermostat housing.

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3. Remove the outlet hose from the surge tank.

4. Loosen the outlet hose clamp and remove the hose from the heater core.
5. Remove the nut from the outlet hose mounting bracket.
6. Remove the hose assembly.

Installation Procedure

1. Position the outlet heater hose assembly into the vehicle and onto the stud.

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2. Install the nut.

Tighten
Tighten the nut to 9 N·m (80 lb in).

3. Install the outlet hose to the heater core and reposition the clamp.

4. Install the outlet hose to the surge tank and reposition the clamp.

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5. Install the outlet hose to the thermostat housing and reposition the clamp.
6. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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Heater Outlet Pipe Replacement (L47)

Tools Required
J 38185 Spring Hose Clamp Pliers

3. Loosen the heater outlet hose clamp in order to remove the hose (1) from the heater pipe.

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4. Remove the outlet pipe (1) nut from the transaxle.

5. Loosen the clamp from the back side of the thermostat housing and remove the outlet pipe
assembly (1).

Installation Procedure

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1. Install the outlet pipe assembly (1) to the thermostat housing and reposition the clamp.

2. Position the outlet pipe (1) on the transaxle stud and install the nut.

Tighten

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Tighten the nut to 24 N·m (18 lb ft).

3. Install the heater outlet hose (1) to the heater pipe and reposition the clamp.
4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0L.
5. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

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HVAC Module Assembly Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Remove the evaporator hose nut.

3. Disconnect the evaporator hose connection from the evaporator.

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4. Remove the heater hoses (1, 2) from the heater core.

5. Plug the heater core and evaporator openings to prevent leaking into the vehicle when
removing module assembly.
6. Pinch off the hoses in order to prevent leaking.
7. Remove the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument
Panel, Gauges and Console.
8. Remove the lower IP support bracket.

9. Remove the defroster duct retaining screws (1,2) and nut (3).
10. Remove the defroster duct.
11. Remove the air distributor duct screws and duct.

12. Disconnect the blower control module (1) connection.

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13. Disconnect the I/P to HVAC module (2) connection.

14. Remove the HVAC module retaining nuts (1-5).

15. Remove the HVAC module.

Installation Procedure

1. Install the HVAC module.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the HVAC module nuts to the cowl (1-5). Refer to the illustration for the HVAC module
fastener torque sequence.

Tighten
Tighten the nuts to 9 N·m (80 lb in).

3. Connect the blower control module (1) connection.

4. Connect the I/P to HVAC module connector (2).

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5. Install the defroster duct and the module mounting screws (1, 2).

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

6. Install the defroster duct mounting nut (3) to the front of dash.

Tighten
Tighten the nut to 9 N·m (80 lb in).

7. Install the air distributor duct and screws.

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

8. Install the lower IP support bracket.

9. Install the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel,
Gauges and Console.

10. Install the heater hoses (1, 2) to the heater core.

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11. Connect the evaporator hose connection to the evaporator.

12. Install the evaporator hose nut.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

13. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component using the J 39400-A .
15. Refill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.

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Instrument Panel Center Air Outlet Deflector

Replacement
Removal Procedure
1. Remove the I/P center trim panel. Refer to Instrument Panel Center Trim Panel Replacement
in Instrument Panel, Gages, and Console.

2. Remove the center air deflector by pushing firmly from the rear while pulling the air deflector
out from the front of the I/P.

Installation Procedure

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1. Position the center air deflector to the opening in the I/P.

2. Push the air deflector into the I/P until the retaining clips engage securing the air deflector to
the I/P.
3. Install the I/P center trim panel. Refer to Instrument Panel Center Trim Panel Replacement in
Instrument Panel, Gages, and Console.

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Instrument Panel Outer Air Outlet Deflector

Replacement - Left Side
Removal Procedure
1. Remove the left I/P outer trim cover. Refer to Instrument Panel Outer Trim Cover
Replacement in Instrument Panel, Gages, and Console.

2. Remove the left air deflector by pushing from the rear and pulling out from the I/P cluster
trim plate.

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3. Disconnect the electrical connector from the dimmer switch.

Installation Procedure

1. Connect the electrical connector to the dimmer switch.

2. Install the left air deflector by pushing into the I/P cluster trim plate.
3. Install the left I/P outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement
in Instrument Panel, Gages, and Console.

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Instrument Panel Outer Air Outlet Deflector

Replacement - Right Side
Removal Procedure
1. Remove the right I/P accessory trim panel. Refer to Instrument Panel Accessory Trim Plate
Replacement - Right Side in Instrument Panel, Gages, and Console.

2. Depress the retaining tabs (1) in order to remove the right air deflector.

Installation Procedure

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1. Install the air deflector until the retaining tabs (1) are seated into the trim panel.
2. Install the right I/P accessory trim panel. Refer to Instrument Panel Accessory Trim Plate
Replacement - Right Side in Instrument Panel, Gages, and Console.

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Mode Door Replacement

7. Open the module.

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8. Remove the actuator cam from the door.

9. Remove the mode door.

Installation Procedure

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1. Install the mode door.

2. Install the actuator cam to the mode door.

3. Close the module case.

4. Install the module case fasteners.

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Tighten
Tighten the fasteners to 1.4 N·m (12 lb in).

5. Install the mode actuator and bracket. Refer to Mode Actuator Replacement in HVAC Systems
- Automatic.
6. Install the HVAC module. Refer to HVAC Module Assembly Replacement .

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Odor Correction
Odors may be emitted from the air conditioning system at startup in hot climates. Debris in the
heater/evaporator case or growth of mold on the evaporator core may cause this odor. A service
kit is available through GM SPO.

A single application of this deodorizer, GM P/N 12377951, will remove the odor from the air
conditioning system. However, to prevent the odor from returning, enabling the blower control
function with the scan tool is recommended. Refer to Afterblow Enabling in HVAC-Automatic.

1. Clear all the debris from the plenum that draws air from the outside.
2. Disconnect the clutch coil. This will disable the A/C compressor clutch operation.
3. Dry the evaporator core by turning the engine on. In addition, run the blower motor on high
and in a recirculating mode, with the temperature control on maximum heat for 10 minutes.

4. Drill an 1/8 inch hole (1) in the HVAC module at the recessed area above the gas pedal as
shown.

Important: Use safety goggles and latex gloves for the following step.

5. Keep the blower motor on high and insert the extension tube of the deodorizer,
GM P/N 12377951, into the hole past the mark on the tube.
6. Spray the area with short bursts. Dispense the contents of the can over a 2-3 minute period.
Vary the direction of the spray into the duct.
7. Turn the engine off.
8. Let the engine sit for 3-5 minutes.
9. Seal the 1/8 inch hole with body sealer or RTV gasket compound.
10. Start the engine and run the fan on high for 15-20 minutes to dry.
11. Reconnect the air conditioning compressor clutch coil and verify the operation.

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Orifice Solenoid Replacement

Tools Required
J 39400-A Halogen Leak Detector

Remove Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Disconnect the electrical connector from the orifice solenoid.

3. Disconnect the orifice solenoid from the accumulator cover.
4. Disconnect the hose fittings (1, 2) at each end of the valve.
5. Remove the valve.

Installation Procedure
Important: Lubricate the new expansion tube O-ring with mineral base 525 viscosity
refrigerant oil before installing into the evaporator hose.

1. Inspect the orifice valve screen and clean or replace as necessary.

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2. Install the orifice valve to the lines (1, 2) and hand tighten to ensure a good connection.

Tighten
Tighten the fittings to 27 N·m (20 lb ft).

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3. Install the orifice valve into the accumulator cover and connect the electrical connector.
4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
5. Leak test the fittings of the component using theJ 39400-A .

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Orifice Solenoid Screen Replacement

Tools Required
J 39400-A Halogen Leak Detector

Remove Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Disconnect the evaporator hose from the accumulator cover.

3. Disconnect the fitting (2) from the front end of the valve.

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4. Remove the filter from the orifice solenoid.

Installation Procedure
Important: Lubricate the new expansion tube O-ring with mineral base 525 viscosity
refrigerant oil before installing into the evaporator hose.

1. Install the filter into the orifice solenoid.

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2. Install the orifice valve to the line (2) and hand tighten to ensure a good connection.

Tighten
Tighten the fitting (1) to 27 N·m (20 lb ft).

3. Install the assembly into the accumulator cover and connect the electrical connector.
4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
5. Leak test the fittings of the component using the J 39400-A .

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Passenger Compartment Air Filter Replacement

Removal Procedure

1. Lift up the access cover in the air inlet panel.

2. Remove the filter from the filter housing.

Installation Procedure

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1. Install the filter in to the filter housing.

2. Close the access cover.

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Refrigerant Recovery and Recharging

Tools Required
J 43600 ACR 2000 Air Conditioning Service Center

Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to
remove R-134a from the A/C system, use service equipment that is certified to meet the
requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge
occurs, ventilate the work area before continuing service. Additional health and safety information
may be obtained from the refrigerant and lubricant manufacturers.

Caution: For personal protection, goggles and lint-free gloves should be worn and a clean cloth
wrapped around fittings, valves, and connections when doing work that includes opening the
refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and
personal injury can result. The exposed area should be flushed immediately with cold water and
prompt medical help should be obtained.

Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.

Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation
through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor
failure is likely to occur. Refer to the manufacturer instructions included with the service equipment
before servicing.

The J 43600 is a complete air conditioning service center for R-134a. It recovers, recycles,
evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a
display screen that contains the function controls and displays prompts that will lead the technician
through the operations. A/C refrigerant is recovered into and charged out of an internal storage
vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to
maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built--in A/C refrigerant identifier that will test for contamination prior to
recovery and will notify the technician if there are foreign gases present. The unit also features
automatic air purge, single pass recycling and automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the
A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the
correct amount.

A/C Refrigerant System Oil Charge Replenishing

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If oil was removed from the A/C system during the recovery process or due to component
replacement, the oil must be replenished. For the proper quantities of oil to add to the A/C
refrigerant system, refer to Refrigerant System Capacities .

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Service Ports Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

2. Remove the service fitting from the line.

Installation Procedure
1. Lubricate the O-ring using 525 refrigerant oil.

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2. Install the service fitting to the line.

Tighten
Tighten the fitting to 12 N·m (9 lb ft).

3. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

4. Leak test the fittings of the component using the J 39400-A .

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Suction Hose Replacement (L47)

Tools Required
J 39400-A Halogen Leak Detector

Remove Procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the lower radiator air deflector. Refer to Front Air Deflector Replacement in Body
Front End.

4. Disconnect the suction hose from the compressor.

5. Lower the vehicle.
6. Disconnect the upper radiator hose from the clip on the upper tie bar.

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7. Disconnect the suction hose (1) from the accumulator.

8. Disconnect the suction hose from the clips at the fan shroud.
9. Remove the hose from the vehicle.

Installation Procedure
Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

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1. Position the suction hose into the vehicle.

2. Install the suction hose (1) and nut to the accumulator.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

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3. Install the suction hose into the clips at the fan shroud.
4. Install the upper radiator hose into the clip and fasten.
5. Raise the vehicle.

6. Install the suction hose and nut to the compressor.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

7. Lower the vehicle.

8. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
9. Leak test the fittings of the component using the J 39400-A .
10. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

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Suction Hose Replacement (LX5)

Tools Required
J 39400-A Halogen Leak Detector

4. Disconnect the suction hose from the compressor.

5. Lower the vehicle.

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6. Disconnect the suction hose from the accumulator (1).

7. Remove the hose from the vehicle.

Installation Procedure
Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.

1. Position the suction hose into the vehicle (1).

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2. Install the suction hose nut to the accumulator.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

3. Raise the vehicle.

4. Install the suction hose and nut to the compressor.

Tighten
Tighten the nut to 20 N·m (15 lb ft).

5. Lower the vehicle.

6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
7. Leak test the fittings of the component using the J 39400-A .
8. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

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Windshield Defroster Duct Replacement

Removal Procedure
1. Remove the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument
Panel, Gauges and Console.

2. Remove the defroster duct retaining screws (1, 2).

3. Remove the defroster duct nut from the front of dash (3).
4. Remove the defroster duct.

Installation Procedure

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1. Install the defroster duct.

2. Install the module attaching screws (1, 2).

Tighten
Tighten the screws to 1.4 N·m (12 lb in).

3. Install the defroster duct mounting nut (3) to the front of dash.

Tighten
Tighten the nut to 9 N·m (80 lb in).

4. Install the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel,
Gauges and Console.

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Fastener Tightening Specifications

Specification
Application Metric English
Brake Hose Bracket Bolt 17 N·m 13 lb ft
Brake Hose to Caliper Bolt 44 N·m 32 lb ft
Brake Pedal Assembly to Booster Stud Mounting Nuts 23 N·m 17 lb ft
Brake Pedal Assembly to Cowl Stud Mounting Nuts 16 N·m 12 lb ft
Brake Pipe Fitting Tube Nut 15 N·m 11 lb ft
Brake Pipe Fittings at Master Cylinder Tube Nut 33 N·m 24 lb ft
Brake Master Cylinder Mounting Nuts 25 N·m 18 lb ft

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Component Specifications
Specification
Application Metric English
Brake Pedal Travel
57.00 mm 2.25 in
Brake pedal travel maximum with 445 N (100 lb) force applied to the
pedal with ignition OFF and vacuum or hydraulic assist depleted.
Front Caliper Bore Diameter 63.50 mm 2.50 in
Master Cylinder Bore Diameter 25.40 mm 1.000 in
Rear Caliper Bore Diameter 38.00 mm 1.50 in

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Brake Warning System Schematics

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Passenger Compartment, Lower Left Front Corner

(1) C215
(2) S215
(3) S216
(4) P100
(5) Inflatable Restraint Steering Wheel Module Coil
(6) C200
(7) C202
(8) To Stop Lamp Switches
(9) C500
(10) G200
(11) S217
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(12) Park Brake Switch

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Left Front Shock Tower

(1) Brake Fluid Level Switch

(2) Cruise Control Module (CCM)
(3) C101

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Hydraulic Brake Connector End Views

Table 1: Park Brake Switch
Table 2: Brake Fluid Level Switch

Park Brake Switch

• 12004267
Connector Part Information
• 1-Way F 56 Series Lock Type (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 1134 Park Brake Switch Signal

Brake Fluid Level Switch

• 12162192
Connector Part Information
• 2-Way F Metri-Pack 150.2 Series (BLK)
Pin Wire Color Circuit No. Function
A PPL 333 Brake Fluid Level Switch Signal
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B BLK/WHT 151 Ground

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Brake Fluid Level Indicator Switch Replacement

Removal Procedure

1. Disconnect the electrical connector (1) from the brake fluid level sensor.

2. Using a needle nose pliers carefully depress the retaining tabs (1) on the end of the brake
fluid level sensor and press the sensor through the reservoir to remove.

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Installation Procedure

1. Align the brake fluid level sensor to the master cylinder reservoir.
2. Press the brake fluid level sensor into the master cylinder reservoir.
3. Connect the electrical connector to the brake fluid level sensor.

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Brake Pedal Bracket Replacement

Removal Procedure
1. Remove the IP carrier assembly, to gain access to the brake pedal assembly to cowl
mounting bolts. Refer to Instrument Panel Carrier Replacement in Instrument Panel, Gauges
and Console.

2. Disconnect the electrical connectors from the stoplamp/ABS/shift lock switch (2).
3. Remove the stoplamp/ABS/shift lock switch from the brake pedal assembly. Refer to Stop
Lamp Switch Replacement .
4. Remove the TCC/cruise control release switch from the brake pedal assembly. Refer to Cruise
Control Release Switch Replacement in Cruise Control.

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5.Remove the vacuum brake booster pushrod retainer.

6.Remove the pushrod foam spacer.
7.Remove the vacuum brake booster pushrod from the brake pedal.
8.Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in
Engine Controls - 3.5L.
9. Remove the brake pedal assembly to cowl mounting nuts.
10. Remove the brake pedal assembly to booster stud mounting nuts.
11. Remove the brake pedal bracket and pedal assembly.

Installation Procedure

1. Install the brake pedal assembly onto the booster studs.

2. Install the booster stud mounting nuts.

Tighten
Tighten the brake pedal to booster stud mounting nuts to 23 N·m (17 lb ft).

3. Install the brake pedal to cowl studs mounting nuts.

Tighten

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Tighten the brake pedal to cowl studs mounting nuts to 16 N·m (12 lb ft).

4. Apply lubricant, GM P/N 1050109 or equivalent, to brake pedal clevis pin .

5. Install the pushrod onto brake pedal clevis pin.
6. Install the brake pedal foam spacer to the brake pedal clevis pin.
7. Install the pushrod retainer to the brake pedal clevis pin.
8. Install the accelerator control cable. Refer to Accelerator Control Cable Replacement in
Engine Controls - 3.5L.

9. Install the electrical connectors to the stoplamp/ABS/shift lock switch (2).

10. Install the stoplamp/ABS/shift lock switch (2). Refer to Stop Lamp Switch Replacement .
11. Install the TCC/cruise control release switch. Refer to Cruise Control Release Switch
Replacement in Cruise Control.
12. Install the IP assembly. Refer to Instrument Panel Carrier Replacement in Instrument Panel,
Gauges and Console.

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Front Brake Hose Replacement

Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
3. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to
prevent brake fluid loss and contamination.

4. Disconnect the brake pipe fitting from the brake hose, than cap or plug the brake pipe fitting
end.

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5. Using a flat-bladed tool, remove the brake hose retainer from the brake hose.
6. Remove the brake hose from the brake hose bracket.

7. Remove the brake hose to caliper bolt from the brake caliper.
8. Remove the brake hose from the brake caliper.
9. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the
brake caliper and/or the brake hose end.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to
prevent brake fluid loss and/or contamination.

10. Install a rubber plug into the brake hose to caliper bolt hole of the brake caliper.

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11. Remove the hose bracket bolt from the strut assembly and remove the hose.

Installation Procedure
1. Remove the rubber plug from the brake hose to caliper bolt hole of the brake caliper.

Important: Install NEW copper brake hose gaskets.

2. Assemble the brake hose, the NEW copper brake hose gaskets, and the brake hose bolt to
the brake hose.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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3. Install the brake hose to caliper bolt to the brake caliper.

Tighten
Tighten the brake hose to caliper bolt to 44 N·m (32 lb ft).

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the
hose could result.

4. Install the brake hose to the brake hose bracket.

5. Install the brake hose retainer to the brake hose.

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6. Remove the rubber cap or plug from the exposed brake pipe fitting end.
7. Install the brake pipe fitting to the brake hose.

Tighten
Tighten the brake pipe fitting to 15 N·m (11 lb ft).

8. Install the hose bracket and bolt to the strut assembly.

Tighten
Tighten the brake hose bracket bolt to 17 N·m (13 lb ft).

9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

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10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
11. Lower the vehicle.

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Hydraulic Brake System Bleeding

Tools Required
• J 29532 Diaphragm Pressure Bleeder
• J 35589-A Brake Pressure Bleeder Adapter

Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can
cause loss of brakes with possible personal injury.

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 personal
injury.

Notice: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or
electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled
on the vehicle, immediately flush the area with water to minimize the potential for damage.

Notice: If any brake component is repaired or replaced such that air is allowed to enter the brake
system, the entire bleeding procedure must be followed.

Notice: Prior to bleeding the brakes, the front and rear displacement cylinder pistons must be
returned to the topmost position. The preferred method uses a Scan Tool to perform the rehoming
procedure. If a Scan Tool is not available, the second procedure may be used, but it is extremely
important that the procedure be followed exactly as outlined.

1. Apply the brakes several times with the engine off to remove the vacuum reserve.
2. Remove the master cylinder reservoir cap. Replace it with the J 35589-A Brake Pressure
Bleeder Adapter.
3. Charge the bleeder to 210-245 kPa (30-35 psi).
4. Connect the hose to the J 35589-A Brake Pressure Bleeder Adapter.
5. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.

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6. If it is necessary to bleed all of the brake calipers, the following sequence should be used:
6.1. Right rear
6.2. Left rear
6.3. Right front
6.4. Left front
7. 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.
8. Open the brake caliper bleed screw at least ¾ 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.

9. Close the brake caliper bleed screw.

Tighten
Tighten the brake caliper bleed screw to 13 N·m (115 lb in).

10. Repeat steps 6 through 8 until all of the calipers have been bled.
11. Lower the vehicle.
12. When pressure bleeding is completed, bleed the brake system using a Scan Tool. Refer to
Antilock Brake System Automated Bleed Procedure in Antilock Brake System.
13. Remove the brake bleeding equipment from the master cylinder.

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Hydraulic Brake System Flushing

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®,
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed
brake fluid container. The use of any type of fluid other than the recommended type of brake fluid,
may cause contamination which could result in damage to the internal rubber seals and/or rubber
linings of hydraulic brake system components.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface
section.

1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
• Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
- Swirled appearance - oil-based substance
- Layered appearance - silicone-based substance
• Fluid discoloration, indicating the presence of moisture or particles that have been
introduced into the brake hydraulic system
- Cloudy appearance - moisture
- Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance,
indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm
and/or swollen reservoir-to-master cylinder grommets, perform the following:
3.1. Remove ALL of the following components listed from the vehicle. Each component
contains internal rubber seals/linings which have been contaminated by the
contaminated brake fluid in the brake hydraulic system.

Refer to the procedures indicated:

• Master Cylinder Replacement

• Front Brake Hose Replacement
• Rear Brake Hose Replacement
• Front Brake Caliper Replacement in Disc Brakes
• Rear Brake Caliper Replacement in Disc Brakes
• Brake Pressure Modulator Valve Replacement in Antilock Brake System
3.2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
3.3. Dry the brake pipes using non-lubricated, filtered air.
3.4. Repair or replace ALL of the following components listed and install them to the
vehicle. Each component contains internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system.

Refer to the procedures indicated:

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• Master Cylinder Overhaul or Master Cylinder Replacement ; also perform the following:
• Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then
dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks
and/or damage and replace if necessary. Refer to Master Cylinder Reservoir
Replacement .
• Replace the brake master cylinder reservoir cap diaphragm.
• Front Brake Hose Replacement
• Rear Brake Hose Replacement
• Front Brake Caliper Overhaul or Front Brake Caliper Replacement in Disc Brakes
• Rear Brake Caliper Replacement in Disc Brakes
• Brake Pressure Modulator Valve Replacement in Antilock Brake System
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but
WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake
master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or
particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®,
GM U.S. P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to
Hydraulic Brake System Bleeding .

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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.

1. Obtain the correct size pipe and the correct size steel fitting nuts.

Use the outside diameter of the pipe in order to specify the size.

2. Cut the pipe square and to the correct length using a hack saw.
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 .

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7. Clamp the J 29803-A in a vise.

8. Select the correct size collet (2) and forming mandrel for the pipe size used.

9. Insert the properly formed mandrel (3) into the J 29803-A .

10. Hold the forming mandrel (3) in place using your finger.
11. Thread in the forcing screw (2) until contact is made and the screw begins to move the
forming mandrel (3).

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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 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. Measure the flare diameter. It should fall between 6.92 mm and 7.28 mm (0.272 in and
0.286 in).
20. The flare is now ready for use.

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21. Use a tube bender in order to bend the new pipe to match the old pipe.
22. Maintain the following clearances:
• Maintain the minimum clearance of 19 mm (0.75 in) to all moving components.
• Maintain the minimum clearance of 13 mm (0.50 in) to all vibrating components.
• Maintain the minimum clearance of 7 mm (0.25 in) to any shielded lines, unless clipped to
a component.

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Master Cylinder Bench Bleeding

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface
section.

1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of
the primary piston is accessible.
2. Remove the master cylinder reservoir cap and diaphragm.
3. Install suitable fittings to the master cylinder ports that match the type of flare seat required
and also provide for hose attachment.
4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the
hoses into the master cylinder reservoir.
5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid
from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are
fully submerged in the brake fluid.
7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will
travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from
the ports.

As air is bled from the primary and secondary pistons, the effort required to depress the
primary piston will increase and the amount of travel will decrease.

8. Continue to depress and release the primary piston until fluid flows freely from the ports with
no evidence of air bubbles.
9. Remove the transparent hoses from the master cylinder reservoir.
10. Install the master cylinder reservoir cap and diaphragm.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the
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master cylinder with a clean shop cloth to prevent brake fluid spills.
12. Remove the master cylinder from the vise.

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Master Cylinder Overhaul

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface
section.

Disassembly Procedure

1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder Replacement.
2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of
the primary piston is accessible.
3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to
removing the cap and diaphragm.
4. Remove the reservoir cap and diaphragm from the reservoir.
5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these
conditions are present, replace the affected components.
• Cuts or cracks
• Nicks or deformation
6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder
Reservoir Replacement.
7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston
retainer.
8. Remove the primary piston assembly from the cylinder bore.
9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated,
filtered air into the front outlet port, in order the remove the secondary piston (1) with the
primary (6) and secondary (5) seals, and the return spring.
10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer
from the secondary piston.
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Assembly Procedure

Important: Do not use abrasives to clean the brake master cylinder bore.

1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the
return spring in denatured alcohol, or equivalent.
2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the
return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any
of these conditions exist.
3. Dry the master cylinder and the individual components with non-lubricated, filtered air.
4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the
individual overhaul components with GM approved brake fluid from a clean, sealed brake
fluid container. Refer to Fluid and Lubricant Recommendations.
5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto
the secondary piston.
6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore.
7. Install the lubricated, new primary piston assembly (2) into the cylinder bore.
8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston
retainer.
9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder
Reservoir Replacement.
10. Install the reservoir cap and diaphragm to the reservoir.
11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement.

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Master Cylinder Replacement

Removal Procedure
1. Disconnect the electrical connector from the brake fluid level sensor.
2. Disconnect the brake pipes from the master cylinder.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to
prevent brake fluid loss and contamination.

3. Plug the open brake pipe fitting ends.

4. Remove the 2 master cylinder mounting nuts.

5. Remove the master cylinder.
6. Remove the reservoir from the master cylinder if it is to be reused on a replacement master
cylinder. Refer to Master Cylinder Reservoir Replacement .

Installation Procedure
1. Install the brake master cylinder reservoir to the master cylinder if it was removed
previously. Refer to Master Cylinder Reservoir Replacement .
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .

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3. Install the master cylinder to the vacuum brake booster.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the 2 brake master cylinder mounting nuts.

Tighten
Tighten the 2 brake master cylinder mounting nuts to 25 N·m (18 lb ft).

5. Remove the plugs from the brake pipes.

6. Install the brake pipes to the master cylinder.

Tighten
Tighten the brake pipe fittings at the master cylinder to 33 N·m (24 lb ft).

7. Connect the electrical connector to the brake fluid level sensor.

8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

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Master Cylinder Reservoir Filling

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface
section.

1. Visually inspect the brake fluid level through the brake master cylinder reservoir.
2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake
system should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may
be topped-off up to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the
maximum-fill level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended
under normal conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only
GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and
Lubricant Recommendations.

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Master Cylinder Reservoir Replacement

Removal Procedure
1. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement .

2. Remove the fluid level sensor. Refer to Brake Fluid Level Indicator Switch Replacement .
3. Drain the brake fluid from the master cylinder reservoir.
4. Carefully tap out the reservoir retaining pins until clear of reservoir.
5. Remove the reservoir from the master cylinder.
6. Remove the seals from the master cylinder reservoir.

Installation Procedure
1. Inspect the reservoir for cracks or deformities. If found, replace the reservoir.
2. Clean the reservoir with clean denatured alcohol, or equivalent.
3. Dry the reservoir with non-lubricated, filtered air.

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4. Lubricate the new seals and the reservoir bayonets with new Delco Supreme 11®,
GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid.
5. Install the seals, making sure they are fully seated.
6. Install the reservoir onto the master cylinder by pressing straight down by hand until pin
holes are aligned.

7. Carefully tap in the reservoir retaining pins to secure the reservoir.

8. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling .
9. Install the brake fluid level sensor. Refer to Brake Fluid Level Indicator Switch Replacement .
10. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement .

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Power Vacuum Brake Booster Replacement (L47)

Removal Procedure
1. Place the vehicle on a level surface.
2. Block the front wheels.
3. Apply the park brake.
4. Shift the vehicle into low gear.
5. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gages, and Console.
6. Remove the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.

7. Remove the retainer clip for the from the brake pedal clevis pin.
8. Remove the foam spacer from the brake pedal clevis pin.
9. Disconnect the vacuum brake booster pushrod from the brake pedal clevis pin.
10. Remove the brake pedal to booster mounting nuts.
11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 4.0L.

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12. Remove the master cylinder from the vacuum brake booster. Refer to Master Cylinder
Replacement and carefully position the master cylinder out of the way. Do not disconnect the
hydraulic brake pipes.

13. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control
Module Replacement in Cruise Control.
14. Disconnect the electrical connector (2) at the left strut tower. Refer to Master Electrical
Component List in Engine Electrical.
15. Remove the accelerator control cable bracket from the throttle body and position the cables
and bracket out of the way. Refer to Accelerator Control Cable Bracket Replacement in
Engine Mechanical - 4.0L.
16. Remove the left carpet retainer. Refer to Front Carpet Retainer Replacement in Interior Trim.
17. Disconnect the shift control cable from the shaft lever pin. Refer to Range Selector Lever
Cable Replacement in Automatic Transaxle - 4T80 - E.
18. Remove the shift control cable and bracket and position out of the way. Refer to Range

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Selector Lever Cable Replacement in Automatic Transaxle - 4T80 - E.

19. Disconnect the vacuum brake check valve and hose as an assembly from the vacuum brake
booster.
20. Remove the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation
and Air Conditioning.

21. Remove the vacuum brake booster from the vehicle.

22. Remove the vacuum brake booster mounting gasket, if gasket replacement is necessary.

Installation Procedure
1. Install the brake booster mounting gasket to booster, if removed previously.

2. Install the vacuum brake booster to the vehicle.

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3. Install the vacuum brake booster pushrod to the brake pedal clevis pin.
4. Install the foam spacer to the brake pedal clevis pin.
5. Install the retaining clip to the brake pedal clevis pin.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the booster stud mounting nuts to the booster studs.

Tighten
Tighten the brake pedal to booster stud mounting nuts to 23 N·m (17 lb ft).

7. Install the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages,
and Console.
8. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gages, and Console.
9. Install the left carpet retainer. Refer to Front Carpet Retainer Replacement in Interior Trim.
10. Install the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation
and Air Conditioning.
11. Install the shift control cable and bracket. Refer to Range Selector Lever Cable Replacement
in Automatic Transaxle - 4T80 - E.
12. Connect the shift control cable to the shaft lever pin. Refer to Range Selector Lever Cable
Replacement in Automatic Transaxle - 4T80 - E.
13. Shift the vehicle into park.

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14. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder
Replacement .
15. Install the master cylinder mounting nuts.

Tighten
Tighten the master cylinder mounting nuts to 25 N·m (18 lb ft).

16. Reposition and connect the vacuum check valve to the vacuum brake booster.

17. Connect the electrical connector (2) to the left strut tower. Refer to Master Electrical
Component List in Engine Electrical.
18. Install the cruise control module. Refer to Accelerator Control Cable Bracket Replacement in
Cruise Control.
19. Install the accelerator control cables and bracket. Refer to Accelerator Control Cable Bracket

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Replacement in Engine Controls- 4.0L.

20. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls- 4.0L.
21. Remove the blocks from the front wheels.
22. Release the park brake.

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Power Vacuum Brake Booster Replacement (LX5)

Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3 .5 L.
2. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in
Engine Controls - 3.5 L.
3. Remove the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise
Control.
4. Remove the shift control cable from the shaft lever pin. Refer to Range Selector Lever Cable
Replacement in Automatic Transaxle - 4T65E.
5. Remove the shift cable from the shift cable bracket. Refer to Range Selector Lever Cable
Replacement in Automatic Transaxle - 4T65E.

6. Disconnect the electrical connector (2) at the left strut tower. Refer to Master Electrical
Component List in Wiring Systems.

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7. Remove the brake master cylinder from the vacuum brake booster and carefully position the
master cylinder out of the way. Refer to Master Cylinder Replacement . Do not disconnect the
hydraulic brake pipes from the master cylinder.
8. Disconnect the vacuum brake booster vacuum check valve and hose as an assembly from the
vacuum brake booster.

9. Remove the support brace bolt (5) attaching the secondary AIR injection pump tube (2) to
the secondary AIR injection valve bracket.
10. Loosen the support brace nut (5) attaching the secondary AIR injection pump tube (2) to the
transaxle.
11. Disconnect the secondary AIR injection pump hose (1) from the secondary AIR injection
valve (6).
12. Position the secondary air tube (2) down and out of the way.
13. Remove the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine
Controls - 3.5L.

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14. Remove the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 3.5L.
15. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gages and Console.
16. Remove the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.

17. Remove the retaining clip from the brake pedal clevis pin.
18. Remove the foam spacer from the brake pedal clevis pin.
19. Remove the vacuum brake booster pushrod from the brake pedal clevis pin.
20. Remove the vacuum brake booster mounting nuts.

21. Remove the vacuum booster from the vehicle.

22. Remove the vacuum brake booster mounting gasket, if gasket replacement is necessary.

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Installation Procedure
1. Install the vacuum brake booster gasket to booster, if removed previously.

2. Install the booster to the vehicle.

3. Install the booster pushrod to the brake pedal clevis pin.

4. Install the brake pedal foam spacer to the brake pedal clevis pin.
5. Install the retaining clip to the brake pedal clevis pin.

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may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

6. Install the brake pedal to booster mounting stud nuts onto the booster studs.

Tighten
Tighten the brake pedal to booster mounting stud nuts to 23 N·m (17 lb ft).

7. Install the accelerator control cable. Refer to Accelerator Control Cable Replacement In
Engine Controls - 3.5 L.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement In Engine
Controls - 3.5 L.
9. Install the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.
10. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side In Instrument Panel, Gages and Console.

11. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder
Replacement .

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12. Connect the secondary AIR injection pump hose (1) to the secondary AIR injection valve (6).
13. Install the support brace bolt (5) attaching the secondary AIR injection pump tube (2) to the
secondary AIR injection valve bracket.

Tighten
Tighten the support brace bolt to 9 N·m (80 lb in).

14. Tighten the support brace nut (5) attaching the secondary AIR injection pump tube (2) to the
transaxle.

Tighten
Tighten the support brace nut to 9 N·m (80 lb in).

15. Install the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine
Controls - 3.5L
16. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical - 3.5L.

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17. Connect the electrical connector (2) at the left strut tower. Refer to Master Electrical
Component List in Wiring Systems.
18. Install the shift cable to the shift cable bracket. Refer to Range Selector Lever Cable
Replacement in Automatic Transaxle - 4T65E.
19. Connect the shift control cable to the shaft lever pin. Refer to Range Selector Lever Cable
Replacement in Automatic Transaxle - 4T65E.
20. Reposition and connect the vacuum check to the vacuum brake booster.
21. Install the cruise control cable. Refer to Cruise Control Cable Replacement In Cruise Control.

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Rear Brake Hose Replacement

Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to
prevent brake fluid loss and/or contamination.

4. Disconnect the brake pipe fitting from the brake hose and cap or plug the brake pipe fitting
end.

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5. Using a flat-bladed tool, remove the brake hose retainer from the brake hose.
6. Remove the brake hose from the brake hose bracket.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end in order to
prevent brake fluid loss and/or contamination.

10. Install a rubber plug into the brake hose to caliper bolt hole of the brake caliper.

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Installation Procedure
1. Remove the rubber plug from the brake hose to caliper bolt hole of the brake caliper.

Important: Install NEW copper brake hose gaskets.

2. Assemble the brake hose, the NEW copper brake hose gaskets and the brake hose bolt to the
brake hose.

3. Install the brake hose to caliper bolt to the brake caliper.

Tighten
Tighten the brake hose to caliper bolt to 44 N·m (32 lb ft).

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Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the
hose could result.

4. Install the brake hose to the brake hose bracket.

5. Install the brake hose retainer to the brake hose.

6. Remove the rubber cap or plug from the exposed brake pipe fitting end.
7. Install the brake pipe fitting to the brake hose.

Tighten
Tighten the brake pipe fitting to 15 N·m (11 lb ft).

8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

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9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
10. Lower the vehicle.

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Stop Lamp Switch Adjustment

The stop lamp switches are self adjusting when they are installed properly in the fully locked
position. The twist lock type switches do not need any further adjustment.

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Stop Lamp Switch Replacement

Removal Procedure

1. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.
2. Rotate the stoplamp/ABS/shift lock switch (2) counterclockwise, then pull to remove the
switch.
3. Disconnect the electrical connectors from the switch.

Installation Procedure

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1. Connect the stoplamp/ABS/shift lock switch electrical connectors to the stoplamp switch (2).
2. Install the stoplamp switch into the retainer.
3. Press the switch (2) into the retainer until the switch plunger is fully depressed into the
switch barrel.
4. Rotate the switch (2) clockwise until travel has stopped and the switch locks fully into
position.
5. Install sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in
Instrument Panel, Gauges and Console.

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Assist Handle Replacement

Removal Procedure

1. Disengage the assist handle end cap covers (2).

2. Remove the fasteners (1) from the assist handle (3).
3. Remove the handle assembly.

Installation Procedure

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1. Position the assist handle (3) in the headliner.

2. Install the fasteners (1) in order to secure the assist handle.

Tighten
Tighten the fasteners to 3 N·m (27 lb in).

3. Snap the end cap covers (2) into position.

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Carpet Retainer Replacement

Removal Procedure
1. Open the door.

2. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
3. Carefully lift upwards in order to release the retaining clips securing the carpet retainer to the
body.
4. Remove the carpet retainer from the vehicle.

Installation Procedure

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1. Position the carpet retainer retaining clips to the openings in the body.
2. Push downward in order to engage the retainer clips securing the carpet retainer to the
vehicle.
3. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
4. Close the door.

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Center Pillar Garnish Molding Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the front carpet retainer. Refer to Front Carpet Retainer Replacement .
3. Remove the rear carpet retainer. Refer to Carpet Retainer Replacement .

4. Pull out on the center trim panel in order to disengage the clips.

Installation Procedure

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1. Position the center pillar trim panel and spoon the weatherstrip flipper over the trim edge,
push in on the trim panel in order to secure the clips.
2. Install the front carpet retainers. Refer to Front Carpet Retainer Replacement .
3. Install the rear carpet retainer. Refer to Carpet Retainer Replacement .
4. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Fastener Tightening Specifications

Specification
Application Metric English
Assist Handle Fasteners 3 N·m 27 lb in
Rear Shelf Carrier Fasteners 9 N·m 80 lb in
Sunshade Fasteners 3 N·m 27 lb in

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Floor Carpet Drying

If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the
components:

• For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire
assembly.
• For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only.
While the carpet is out of the vehicle, dry the carpet using the method described below.
• For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding,
dry the carpet using the method described below.
• For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method
described below.

Drying Method
1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess
moisture.
2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible.
3. Point a fan at the affected area and air dry the carpet.

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Front Floor Panel Carpet Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the front seats. Refer to Bucket Seat Replacement in Seats.
3. Remove the front floor console. Refer to Front Floor Console Replacement in Instrument
Panel, Gages and Console.
4. Remove the center pillar garnish molding. Refer to Center Pillar Garnish Molding
Replacement .
5. Remove the front carpet retainer. Refer to Front Carpet Retainer Replacement .

6. Remove the front carpet (1).

Installation Procedure
Caution: In order to avoid personal injury or vehicle damage when you repair or replace the
carpet, use the same thickness and material size as the original installation. Always return
the carpet to the original location.

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1. Lay the front carpet (1) into the vehicle.

2. Work the front edges of the carpet into place under the instrument panel.
3. Install the floor vent into the floor ducts, if equipped.
4. Install the center console. Refer to Front Floor Console Replacement in Instrument Panel,
Gages and Console.
5. Install the front carpet retainer. Refer to Front Carpet Retainer Replacement
6. Install the center pillar garnish molding. Refer to Center Pillar Garnish Molding Replacement .
7. Install the front seats. Refer to Bucket Seat Replacement in Seats.
8. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Side Door Opening Floor Carpet Retainer

Replacement
Removal Procedure
1. Open the door.

2. Carefully lift upwards in order to release the retaining clips securing the carpet retainer to the
body.
3. Remove the carpet retainer from the vehicle.

Installation Procedure

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1. Position the carpet retainer retaining clips to the openings in the body.
2. Push downward in order to engage the retainer clips securing the carpet retainer to the
vehicle.
3. Close the door.

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Headlining Trim Panel Replacement (with Sunroof)

Removal Procedure

1. Remove the front passenger bucket seat. Refer to Bucket Seat Replacement in Seats.
2. Remove the windshield pillar trim panels. Refer to Windshield Pillar Garnish Molding
Replacement .
3. Remove the center pillar trim panels. Refer to Center Pillar Garnish Molding Replacement .
4. Remove the rear quarter upper trim panels. Refer to Quarter Upper Trim Panel Replacement .
5. Remove the sunshades. Refer to Sunshade Replacement .
6. Remove the overhead console. Refer to Roof Console Replacement .
7. Pull the door opening moldings down to clear headliner. Refer to Rear Door Opening
Weatherstrip Replacement in Doors.
8. Remove the assist handles. Refer to Assist Handle Replacement .
9. Remove the high mounted stop lamp. Refer to High Mount Stop Lamp Replacement in
Lighting Systems.
10. Disconnect the headliner wiring harness connectors.

Notice: Use care when removing and installing the headliner. If reusing the headliner lay the
headliner down flat on a clean surface. Excessive bending will damage the headliner.

11. Pull the headliner down in order to release the headliner.

12. With the add of an assistant, remove the headliner through the rear passenger door opening.

Installation Procedure

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Notice: Use care when removing and installing the headliner. If reusing the headliner lay the
headliner down flat on a clean surface. Excessive bending will damage the headliner.

1. With the add of an assistant, load the headliner into the vehicle through the rear passenger
door opening.
2. Raise the headliner into position.
3. Install the assist handles. Refer to Assist Handle Replacement .
4. Install the high mounted stop lamp. Refer to High Mount Stop Lamp Replacement in Lighting
Systems.
5. Install the sunshades. Refer to Sunshade Replacement .
6. Install the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding
Replacement .
7. Install the center pillar garnish moldings. Refer to Center Pillar Garnish Molding
Replacement .
8. Connect the headliner wiring harness connectors.
9. Install the rear quarter upper trim panels. Refer to Quarter Upper Trim Panel Replacement .

Important: Ensure that the inside lip of the door opening weather-strip is properly seated to
close out the headliner, sail panel and pillar garnish moldings.

10. Install the door opening weatherstrips in the door openings. Refer to Rear Door Opening
Weatherstrip Replacement in Doors.
11. Install the overhead console. Refer to Roof Console Replacement .
12. Install the front passenger bucket seat. Refer to Bucket Seat Replacement in Seats.

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Headlining Trim Panel Replacement (without Sunroof)

Removal Procedure

1. Remove the front passenger bucket seat. Refer to Bucket Seat Replacement in Seats.
2. Remove the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding
Replacement .
3. Remove the center pillar garnish moldings. Refer to Center Pillar Garnish Molding
Replacement .
4. Remove the rear quarter upper garnish moldings. Refer to Quarter Upper Trim Panel
Replacement .
5. Remove the sunshades. Refer to Sunshade Replacement .
6. Remove the overhead console. Refer to Roof Console Replacement .
7. Pull the door opening moldings down in order to clear headliner. Refer to Rear Door Opening
Weatherstrip Replacement in Doors.
8. Remove the assist handles. Refer to Assist Handle Replacement .
9. Remove the High Mounted Stop Lamp. Refer to High Mount Stop Lamp Replacement in
Lighting Systems.
10. Disconnect the headliner wiring harness connectors.
11. Carefully pull the headliner down in order to gain access to the cardboard roof insulator.

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Notice: Use care when removing the cardboard roof insulator. Excessive pressure can cause
dents in the roof panel.

12. Starting in 1 corner of the cardboard insulator, pulling downward, cut the adhesive beads (1)
using a sharp putty knife or equivalent.
13. Separate the cardboard roof insulator from the roof.

Important: It is not necessary to remove all of the old adhesive from the roof panel.

14. Cut off all of the excessive adhesive beads.

Notice: Use care when removing and installing the headliner. If reusing the headliner lay the
headliner down flat on a clean surface. Excessive bending will damage the headliner.

15. With the add of an assistant, remove the headliner through the rear passenger door opening.
16. Carefully separate the cardboard roof insulator from the headliner.

Installation Procedure
Important: Installation of a new cardboard roof insulator is necessary to ensure the
acoustical integrity of the roof system. Use GM P/N 12378192 Headliner adhesive available
through General Motors Service Parts Operations.

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1. Apply 6-9 mm (1/4-3/8 in) (2) beads of adhesive 15 mm (5/8 in) wide (1).

2. Apply the adhesive in the locations marked on the cardboard insulator (1).

Important: Cardboard roof insulator must be installed within 5 minutes of adhesive

application.

3. Install the cardboard roof insulator to the roof panel.

Notice: Use care when removing and installing the headliner. If reusing the headliner lay the
headliner down flat on a clean surface. Excessive bending will damage the headliner.

Important: Gluing the headliner to the cardboard roof insulator during installation is not
required.

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4. With the add of an assistant, load the headliner into the vehicle through the rear passenger
door opening.
5. Raise the headliner into position.
6. Install the assist handles. Refer to Assist Handle Replacement .
7. Install the high mounted stoplamp. Refer to High Mount Stop Lamp Replacement in Lighting
Systems.
8. Install the sunshades. Refer to Sunshade Replacement .
9. Install the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding
Replacement .
10. Install the center pillar garnish moldings. Refer to Center Pillar Garnish Molding
Replacement .
11. Connect the headliner wiring harness connectors.
12. Install the rear quarter upper garnish moldings. Refer to Quarter Upper Trim Panel
Replacement .

Important: Ensure that the inside lip of the door opening weather-strip is properly seated to
close out the headliner, sail panel and pillar garnish moldings.

13. Install the door opening weather-strip in the door openings. Refer to Rear Door Opening
Weatherstrip Replacement in Doors.
14. Install the overhead console. Refer to Roof Console Replacement .
15. Install the front passenger bucket seat. Refer to Bucket Seat Replacement in Seats.

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Quarter Upper Trim Panel Replacement

Tools Required
J 38778 Door Trim Pad Clip Remover

Removal Procedure

1. Use theJ 38778 Door Trim Pad Clip Remover to disengage the push-in retainers.
2. Remove the quarter upper trim from the vehicle.

Installation Procedure

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1. Install the quarter upper trim to the vehicle and line up the retainers with the holes.
2. Push in on the quarter upper trim to engage the clips.

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Rear Floor Panel Carpet Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.

2. Remove the front seats. Refer to Bucket Seat Replacement in Seats.

3. Remove the center console, if equipped. Refer to Front Floor Console Replacement in
Instrument Panel, Gages and Console.
4. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
5. Remove the center pillar garnish moldings. Refer to Center Pillar Garnish Molding
Replacement .
6. Remove the rear carpet retainer. Refer to Carpet Retainer Replacement .
7. Remove the rear carpet (2) from the vehicle.

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1. Lay the rear carpet (2) into the vehicle.

2. Install the rear carpet retainer. Refer to Carpet Retainer Replacement .
3. Install the center pillar garnish moldings. Refer to Center Pillar Garnish Molding
Replacement .
4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
5. Install the center console, if equipped. Refer to Front Floor Console Replacement in
Instrument Panel, Gages and Console.
6. Install the front seats. Refer to Bucket Seat Replacement in Seats.
7. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Rear Seat Back Body Panel Sound Barrier Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
2. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
3. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel
Replacement .

4. Remove the fasteners securing the sound barrier.

5. Remove the sound barrier from the vehicle.

Installation Procedure

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1. Install the sound barrier to the vehicle.

2. Install the push in the fasteners in order to secure the sound barrier.
3. Install the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel
Replacement .
4. Install the rear seat back. Refer Rear Seat Back Replacement in Seats.
5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Rear Shelf Trim Panel Carrier Replacement

Removal Procedure
1. Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .

2. Remove the fasteners securing the carrier.

3. Disconnect the electrical connector.
4. Remove the rear shelf trim panel carrier from the vehicle.

Installation Procedure

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1. Install the rear shelf trim panel carrier into the vehicle.
2. Connect the electrical connector.
3. Install the fasteners in order to secure the carrier.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .

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Rear Window Shelf Trim Panel Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
2. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
3. Remove the push fasteners at the front of the rear window trim panel.

4. Remove the outer shoulder belts (2) from the trim panel (1).
5. If equipped with center shoulder belt, remove the escutcheon from the trim panel.
6. Feed the center shoulder belt and escutcheon through the hole in the trim panel.
7. Remove the rear window trim panel (1) from the vehicle.

Installation Procedure

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1. Position the trim panel inside of the vehicle.

2. If equipped with center shoulder belt, feed the belt and escutcheon though the hole in the
trim panel.
3. Install the center shoulder belt escutcheon.
4. Install the outer shoulder belts to the trim panel (2).
5. Install the push fasteners to secure the rear window trim panel.
6. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
7. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Roof Console Replacement

Removal Procedure

Important: Do not let the overhead console hang from the wire harness.

1. Carefully pull down on the overhead console to release the retainer clips securing the
overhead console to the headliner.
2. Disconnect the wire electrical connectors.
3. Remove the overhead console from the vehicle.

Installation Procedure

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1. Connect the electrical connectors.

2. Position the overhead console to the opening in the headliner.
3. Push in on the overhead console in order to engage the retainer clips securing the overhead
console to the headliner.

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Sunshade Replacement
Removal Procedure

1. Remove the Fasteners from the sunshade center support (1).

2. Remove the fasteners from the outboard side of the sunshade.
3. Pull down on the sunshade in order to remove the sunshade from the headliner.
4. Partially lower the headliner in order to disconnect the wire connector for the lighted vanity
mirror. Refer to Headlining Trim Panel Replacement .

Installation Procedure

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1. Connect the electrical connector for the lighted vanity mirror.

2. Install the headliner. Refer to Headlining Trim Panel Replacement .
3. Position the sunshade to the openings in the headliner.

4. Install the fasteners on the outboard side of the sunshade.

Install the fasteners for the center support (1).

Tighten
Tighten the fasteners to 3 N·m (27 lb in).

5. Reposition the sunshade.

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Vanity Mirror Replacement

1. The vanity mirror (2) can not be serviced separately.

2. Replace the vanity mirror (2) as an assembly with the sunshade (1). Refer to Sunshade
Replacement .

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Windshield Pillar Garnish Molding Replacement

Removal Procedure

1. Pull the windshield pillar garnish molding away from the windshield pillar to disengage the
retainer clips.
2. Remove the windshield pillar garnish molding.

Installation Procedure

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1. Position the lower the end of the windshield pillar garnish molding behind instrument panel
cover.
2. Align the clips to the holes in the windshield pillar.
3. Push in on the windshield pillar garnish molding to engage the retainer clips.

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Keyless Entry Component Views

Below Rear Shelf

(1) Remote Control Door Lock Receiver (RCDLR)

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Keyless Entry Connector End Views

Remote Control Door Lock Receiver

• 12059162
Connector Part Information
• 4-way Micro-Pack 100 Series (BLU)
Pin Wire Color Circuit No. Function
1 ORN 540 Positive Battery Voltage
2 PPL 1807 Class 2 Serial Data Signal - Primary
3 PPL 1807 Class 2 Serial Data Signal - Primary
4 BLK/WHT 751 Ground

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| Aurora (VIN G) Service Manual | Body and Accessories | Keyless Entry |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 566678

Keyless Entry Schematics

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Keyless Entry Transmitter Identification

Keyless Entry Transmitter RPO Number

AU0 and UA6

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Remote Control Door Lock Receiver Replacement

Removal Procedure

1. Remove the front trim from inside of the rear storage compartment. Refer to Rear
Compartment Trim Panel Replacement in Body Rear End.

2. Disconnect the electrical connector.

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Installation Procedure

1. Snap the remote control door lock receiver module (2) into the slots in the rear
compartment.
2. Connect the electrical connector.

3. Install the rear compartment trim. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.
4. Program the remote control door lock receiver module. Refer to Transmitter Programming .

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Transmitter Battery Replacement

Removal Procedure
1. Replace the batteries when the range of the transmitter decreases to less than 7 meters
(23 feet).

2. Insert a small coin between the two halves of the transmitter case at the slot provided near
the key ring hole.
3. Twist the coin in order to open the case.
4. Open the transmitter case.

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5. Remove the battery (2).

Installation Procedure

1. Install the battery (2) with the positive (+) side down.

Use one 3 V CR2032 battery (or the equivalent).

2. Close the transmitter case (6,4).

3. Ensure that the seal is in position. Align the two halves of the case and snap the two halves
together.

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Transmitter Programming
Important: All transmitters which are to be recognized by the remote control door lock receiver
(RCDLR) must be programmed in a single programming sequence. If the system is placed in
program mode, all previously programmed transmitters will be erased upon the receipt of the
programming signal from the first transmitter. Up to four transmitters may be programmed. Do not
operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry
program mode. This prevents the programming of the transmitters to the incorrect vehicle. The
order in which the transmitters are programmed is important. The first transmitter programmed
will be transmitter #1, and the second transmitter programmed will be transmitter #2. The number
on the transmitters are for reference only: #2 can be programmed as #1, or vice versa. Additional
unnumbered transmitters are also available. Use care to program the transmitters correctly.

1. Install a scan tool.

2. Turn ON the ignition, with the engine OFF.
3. Use the scan tool Remote Function Actuation Special Function: Program Key Fobs in order to
place the remote control door lock receiver into Program Mode. The doors will lock and then
unlock in order to confirm program mode.

Important: The scan tool must stay connected until all of the transmitters are programmed.

4. Press and hold the LOCK button and the UNLOCK button simultaneously on one transmitter.
After a delay of 15 seconds, the doors will lock and unlock in order to confirm the
programming of that transmitter.
5. Repeat the previous step in order to program up to 4 transmitters.
6. Remove the scan tool.
7. Operate the transmitter functions in order to verify correct system operation.

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Fastener Tightening Specifications

Specification
Application Metric English
Closeout Insulator Panel Fasteners 2 N·m 18 lb in
Fog Lamp Assembly Fasteners 6 N·m 53 lb in
Headlamp Assembly Fasteners 6 N·m 53 lb in
Instrument Panel Dimmer Switch Fasteners 2 N·m 18 lb in
Tail Lamp to the Body 6 N·m 53 lb in

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Backup Lamps

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License Plate Lamps, Park Lamp Relay

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Park/Tail/Stop Lamps-Left

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Park/Tail/Stop Lamps-Right

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RH Turn Signal/Hazard Lamps

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Tail/Stop Lamps

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Turn Signal/Hazard Flasher Module Inputs

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Turn Signal/Hazard Lamps-Left

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Fog Lamps-Front

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Fog Lamps-Rear

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DRL, High Beam Headlamps, Headlamp Dimmer Switch

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Headlamp Switch and Sunload Assembly

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Low Beam Headlamps

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Courtesy Lamps-Left

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Courtesy Lamps-Right

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Dimming Control

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Door Lock Actuators

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Front Door Dimming

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Instrument Panel/Console Dimming

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Interior and Front Courtesy Lamp Relays

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Overhead Reading, Courtesy, and Vanity Mirror Lamps

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Rear Door Dimming

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Steering Column Dimming

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Document ID: 530547 Page 1 of 18

Lighting Systems Connector End Views

Table 1: Backup Lamp -- Left
Table 2: Backup Lamp -- Right
Table 3: Center High Mounted Stoplamp (CHMSL)
Table 4: Courtesy Lamp -- Left Front Door
Table 5: Courtesy Lamp -- Left Rear Door
Table 6: Courtesy Lamp -- Rear Compartment
Table 7: Courtesy Lamp -- Right Front Door
Table 8: Courtesy Lamp -- Right Rear Door
Table 9: Courtesy/Reading Lamp -- LR (+C96)
Table 10: Courtesy/Reading Lamp -- RR W/C96
Table 11: Fog Lamp -- LF
Table 12: Fog Lamp -- LR
Table 13: Fog Lamp -- RF
Table 14: Fog Lamp -- RR
Table 15: Footwell Courtesy Lamp -- Left
Table 16: Footwell Courtesy Lamp -- Right
Table 17: Headlamp -- High Beam -- Left
Table 18: Headlamp -- High Beam -- Right
Table 19: Headlamp -- Low Beam -- Left
Table 20: Headlamp -- Low Beam -- Right
Table 21: License Lamp
Table 22: Marker Lamp
Table 23: Marker Lamp
Table 24: Park/Turn Signal Lamp -- LF
Table 25: Park/Turn Signal Lamp -- RF
Table 26: Stoplamp Switch C1
Table 27: Stoplamp Switch C2
Table 28: Tail/Stoplamp -- Left
Table 29: Tail/Stoplamp -- Right
Table 30: Turn Signal/Hazard Flasher Module
Table 31: Turn Signal Lamp -- LR
Table 32: Turn Signal Lamp -- RR
Table 33: Vanity Mirror -- Left
Table 34: Vanity Mirror -- Right

Backup Lamp -- Left

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• 12160393
Connector Part
Information • Lamp Socket Wedge Base W3 Right Angle (LT
GRY)
Pin Wire Color Circuit No. Function
A LT GRN 24 Backup Lamp Supply Voltage
G BLK 850 Ground

Backup Lamp -- Right

• 12160393
Connector Part
Information • Lamp Socket Wedge Base W3 Right Angle (LT
GRY)
Pin Wire Color Circuit No. Function
A LT GRN 24 Backup Lamp Supply Voltage
G BLK 1050 Ground

Center High Mounted Stoplamp (CHMSL)

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• 12052832
Connector Part Information
• 2-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A WHT 17 Stoplamp Switch Signal
B BLK 850 Ground

Courtesy Lamp -- Left Front Door

• 12124065
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 149 Courtesy Lamp Supply Voltage
B GRY 157 Interior Lamp Control

Courtesy Lamp -- Left Rear Door

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• 12124065
Connector Part Information
• 2 way F Metri - Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 149 Courtesy Lamp Supply Voltage
B GRY 157 Interior Lamp Control

Courtesy Lamp -- Rear Compartment

• 12047781
Connector Part Information
• 3-Way F Metri-pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A -- -- Not Used
B ORN/BLK 737 Trunk Lamp Control
C DK BLU/WHT 149 Courtesy Lamp Supply Voltage

Courtesy Lamp -- Right Front Door

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• 12124065
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 149 Courtesy Lamp Supply Voltage
B GRY 157 Interior Lamp Control

Courtesy Lamp -- Right Rear Door

• 12124065
Connector Part Information
• 2 way F Metri - Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 149 Courtesy Lamp Supply Voltage
B GRY 157 Interior Lamp Control

Courtesy/Reading Lamp -- LR (+C96)

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• 12047781
Connector Part Information
• 3-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A GRY 157 Interior Lamp Control
B DK BLU/WHT 149 Courtesy Lamp Supply Voltage
C BLK 850 Ground

Courtesy/Reading Lamp -- RR W/C96

Fog Lamp -- LF

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• 12020599
Connector Part Information
• Metri Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A PPL/WHT 34 Front Fog Lamps Supply Voltage
B BLK 1050 Ground

Fog Lamp -- LR

• 12146418
Connector Part Information
• Lamp Socket (LT GRY)
Pin Wire Color Circuit No. Function
A RED 122 Rear Fog Lamp Supply Voltage
B BLK 1050 Ground

Fog Lamp -- RF

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• 12020599
Connector Part Information
• Metri Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A PPL 34 Front Fog Lamps Supply Voltage
B BLK 1050 Ground

Fog Lamp -- RR

• 12146418
Connector Part Information
• Lamp Socket (LT GRY)
Pin Wire Color Circuit No. Function
A RED 122 Rear Fog Lamp Supply Voltage
B BLK 1050 Ground

Footwell Courtesy Lamp -- Left

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• 12064869
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLU)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 149 Courtesy Lamp Supply Voltage
B DK BLU/WHT 1495 Interior Lamp Control

Footwell Courtesy Lamp -- Right

Headlamp -- High Beam -- Left

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• 12059183
Connector Part Information
• 2-Way Metri - Pack 280 Series F (BLK)
Pin Wire Color Circuit No. Function
A DK GRN/WHT 711 Left Headlamp High Beam Supply Voltage
B PNK 1200 Headlamp High Beam Lamp Output

Headlamp -- High Beam -- Right

• 12059183
Connector Part Information
• 2-Way Metri - Pack 280 Series F (BLK)
Pin Wire Color Circuit No. Function
A DK GRN/WHT 311 Right Headlamp High Beam Supply Voltage
B PNK 1050 Ground

Headlamp -- Low Beam -- Left

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• 12059181
Connector Part Information
• 2-Way Metri - Pack 280 Series F (GRY)
Pin Wire Color Circuit No. Function
A YEL 712 Left Headlamp Low Beam Supply Voltage
B BRN 250 Ground

Headlamp -- Low Beam -- Right

• 12059181
Connector Part Information
• 2-Way Metri - Pack 280 Series F (GRY)
Pin Wire Color Circuit No. Function
A YEL 312 Right Headlamp Low Beam Supply Voltage
B BRN 1050 Ground

License Lamp

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• 15317651
Connector Part Information
• Lamp Socket BB W2 (LT GRY)
Pin Wire Color Circuit No. Function
A YEL 32 Instrument Panel Lamp Fuse Supply Voltage - 1
B BLK 1050 Ground

Marker Lamp

• 15317651
Connector Part Information
• Lamp Socket BB W2 (LT GRY)
Pin Wire Color Circuit No. Function
A BRN 709 Left Park Lamp Supply Voltage
B DK BLU/WHT 15 Right Turn Signal Lamps Supply Voltage

Marker Lamp

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• 15317651
Connector Part Information
• Lamp Socket BB W2 (LT GRY)
Pin Wire Color Circuit No. Function
A PPL 709 Left Park Lamp Supply Voltage
B LT BLU 14 Left Turn Signal Lamps Supply Voltage

Park/Turn Signal Lamp -- LF

• 15324404
Connector Part Information
• 3 way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 14 Left Turn Signal Lamps Supply Voltage
B PPL 709 Left Park Lamp Supply Voltage
G BLK 250 Ground

Park/Turn Signal Lamp -- RF

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• 15324404
Connector Part Information
• 3 way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 15 Right Turn Signal Lamps Supply Voltage
B PPL 309 Right Park Lamp Supply Voltage
G BLK 250 Ground

Stoplamp Switch C1

• 12033701
Connector Part Information
• 2-Way F Metri-pack 480 Series (GRY)
Pin Wire Color Circuit No. Function
A ORN 1640 Battery Positive Voltage
B WHT 17 Stoplamp Switch Signal

Stoplamp Switch C2

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• 12033706
Connector Part Information
• 4-Way F Metri-pack 280 Series (BLU)
Pin Wire Color Circuit No. Function
A LT GRN 275 Neutral Safety Switch Park Signal
B DK GRN/WHT 1135 A/T Shift Lock Solenoid Supply Voltage
C-D -- -- Not Used

Tail/Stoplamp -- Left

• 12160395
Connector Part
Information • Lamp Socket Wedge Base W3 Right Angle (MD
GRY)
Pin Wire Color Circuit No. Function
A WHT 17 Stoplamp Switch Signal
B PPL 709 Left Park Lamp Supply Voltage
G BLK 850 Ground

Tail/Stoplamp -- Right

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• 12160395
Connector Part
Information • Lamp Socket Wedge Base W3 Right Angle (MD
GRY)
Pin Wire Color Circuit No. Function
A WHT 17 Stoplamp Switch Signal
B PPL 309 Right Park Lamp Supply Voltage
G BLK 1050 Ground

Turn Signal/Hazard Flasher Module

• 12064769
Connector Part Information
• 8-Way F 280 Series Metri Pack (BLK)
Pin Wire Color Circuit No. Function
A BLK 450 Ground
B LT GRN 1427 Turn Signal Switch Output Left
C DK GRN 1428 Turn Signal Switch Output Right
D LT BLU 14 Left Turn Signal Lamps Supply Voltage
E -- -- Not Used
F DK BLU 15 Right Turn Signal Lamps Supply Voltage

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G TAN 2144 Hazard Switch Signal

H ORN 1740 Battery Positive Voltage

Turn Signal Lamp -- LR

• 12160394
Connector Part Information
• Lamp Socket Wedge Base W3 Right Angle (NAT)
Pin Wire Color Circuit No. Function
A LT BLU 14 Left Turn Signal Lamps Supply Voltage
B -- -- Not Used
G BLK 850 Ground

Turn Signal Lamp -- RR

• 12160394
Connector Part Information
• Lamp Socket Wedge Base W3 Right Angle (NAT)
Pin Wire Color Circuit No. Function
A LT BLU 14 Left Turn Signal Lamps Supply Voltage
B -- -- Not Used

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G BLK 850 Ground

Vanity Mirror -- Left

• 12047662
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 850 Ground
B DK BLU/WHT 149 Courtesy Lamp Supply Voltage

Vanity Mirror -- Right

• 12047662
Connector Part Information
• 2-Way F Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 850 Ground
B DK BLU/WHT 149 Courtesy Lamp Supply Voltage

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Ambient Light Sensor Replacement

Removal Procedure

1. Remove the defroster grille (1) by carefully prying upward to release the retainers.
2. Disconnect the electrical connector from the ambient light sensor (2).
3. Remove the ambient light sensor (2) from the defroster grille (1) by turning counterclockwise
1/4 turn.

Installation Procedure

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1. Install the ambient light sensor (2) into the defroster grille (1).
2. Turn the ambient light sensor 1/4 turn clock wise in order to secure the sensor to the
defroster grill.
3. Connect the electrical connector to the ambient light sensor (2).
4. Align defroster grille with I/P upper trim pad.
5. Secure the defroster grille to I/P upper trim pad by pressing downward in order to engage
the retainers.

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Backup Lamp Bulb Replacement

Removal Procedure

1. Open the compartment lid.

2. Remove the appropriate side trim panel. Refer to Rear Compartment Trim Panel Replacement
in Body Rear End.
3. Remove the tail lamp assembly (3). Refer to Tail Lamp Replacement .
4. Twist the back up bulb socket counter clockwise 1/4 turn to remove the socket from the tail
lamp assembly (3).
5. Remove the back up bulb from the socket.

Installation Procedure

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1. Install the backup lamp bulb into the socket.

2. Twist the backup bulb socket clockwise 1/4 turn in order to install the socket into the tail
lamp assembly (3).
3. Install the tail lamp assembly (3). Refer to Tail Lamp Replacement .
4. Install the side trim panel. Refer to Rear Compartment Trim Panel Replacement in Body Rear
End.

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Dome Lamp Replacement

Removal Procedure

1. Using a thin-bladed tool, insert the edge of the tool under the dome lamp lens.
2. Carefully snap the dome lamp lens out of the overhead console assembly.
3. Carefully remove the metal shield covering the bulb in the dome lamp.
4. Remove the dome lamp bulb.

Installation Procedure

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1. Insert the dome lamp bulb into the dome lamp assembly.
2. Install the metal shield over the dome lamp bulb.
3. Install the lens into the overhead console assembly.

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Door Lamp Replacement

Removal procedure

1. Insert a small, flat-bladed tool between the rear edge of the door lamp and the door trim
panel and gently pry the lamp out of the door trim panel.
2. Disconnect the electrical connector.
3. Remove the bulb from the door lamp housing.

Installation Procedure

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1. Install the bulb into the door lamp housing.

2. Connect the electrical connector.
3. Press the door lamp into the door trim panel.

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Fog Lamp Aiming

Adjustment Procedure
The front fog lamps must be aimed for proper illumination of the road. The front fog lamp aim
should be checked when a new front fog lamp assembly is installed, or if service or repairs in the
front end area may have disturbed the front fog lamp mounting.

There is no horizontal adjustment for aiming the front fog lamp assemblies on this vehicle.

1. To ensure accurate vertical front fog lamp aiming, first perform the following steps to prepare
the vehicle.
• Make sure that all the components are in place on the vehicle, if other service has been
performed on the vehicle.
• Make sure the fuel level is 1/2 full or less.
• Place the vehicle on a level surface 7.6 m (25 ft) away from a target screen.
• Stop all other operations of work on the vehicle.
• Jounce the vehicle to settle the suspension.
2. Turn the front fog lamps ON.
3. Remove the front lower air deflector. Refer to Front Air Deflector Replacement in Body Front
End.

4. Reach under the rear lower edge of the front fascia to access the fog lamp vertical
adjustment screw (plastic wingnut).

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5. Adjust the fog lamp up or down until the top edge of the high intensity zone on the screen is
102 mm (4 in) below the horizontal centerline (2).
6. Turn OFF the front fog lamps.

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Front Fog Lamp Bulb Replacement

Replacement Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the air deflector. Refer to Front Air Deflector Replacement in Body Front End.
3. Disconnect the electrical connector from the back of the bulb.
4. Remove the fog lamp bulb from the lamp housing by turning 1/4 turn counterclockwise.

Installation Procedure

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1. Install the fog lamp bulb into the lamp housing by turning 1/4 turn clockwise.
2. Connect the electrical connector.
3. Install the air deflector. Refer to Front Air Deflector Replacement in Body Front End.
4. Lower the vehicle.

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Front Fog Lamp Replacement

Replacement Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the air deflector. Refer to Front Air Deflector Replacement in Body Front End.

3. Remove the fasteners securing the front fog lamp assembly to the front bumper fascia.
4. Position the fog lamp forward in order to access the electrical connector.
5. Disconnect the electrical connector from the front fog lamp assembly.
6. Remove the fog lamp assembly.

Installation Procedure

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1. Connect the electrical connector to the fog lamp assembly.

2. Install the fog lamp to the front bumper fascia.

3. Install the front fog lamp mounting fasteners.

Tighten
Tighten the front fog lamp mounting fasteners to 6 N·m (53 lb in).

4. Install the air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Lower the vehicle.

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Hazard and Turn Signal Flasher Replacement

Removal Procedure
1. Remove the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.

2. Remove the hazard and turn signal flasher module (1) from the I/P carrier.
3. Disconnect the electrical connector.

Installation Procedure

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1. Connect the electrical connector.

2. Install the hazard and turn signal flasher module (1) to the I/P carrier.
3. Install the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.

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Hazard Warning Switch Replacement

The Hazard Warning Switch is part of the Drivers Information Center which is serviced in
Instrument Panel, Gages and Console. Refer to Driver Information Center Module Replacement in
Instrument Panel, Gages and Console.

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Headlamp Aiming
The screen method is preferred for aiming headlamps.

Headlamp aiming is done with the low beam lamps. The high beam lamps will be correctly aimed if
the low beam lamps are aimed properly.

Screen Method for Headlamp Aiming (Visual Aim)

The screen method requires an area set up specifically for headlamp aim.

The area should consist of a level surface large enough to allow for a vehicle and an additional
7.62 m (25 ft) as measured from the face of the headlamps to the aiming screen.

The screen should be a wall or other flat surface at least 1.52 m (5 ft) high by 3.66 m (12 ft) wide
with a matte white surface well shaded from extraneous light, and 90 degrees to the floor. The
screen should be provided with a permanent vertical reference line 61 cm (2 ft) from the left edge
of the screen, 2 laterally adjustable vertical tapes, and one vertically adjustable horizontal tape.

After the aiming screen has been set up and located, paint or tape a reference line on the floor
15.24 m (50 ft) from the vertical reference line on the screen. This line should be perpendicular to
the aiming screen and a mark placed at 7.62 m (25 ft) from the screen.

Headlamp Aiming Procedure

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2. Align the left tires of the vehicle with the reference line extending from the screen with the
headlamps aligned with the reference line.
3. Remove any snow, ice or mud from the vehicle.
4. The vehicle should be fully assembled and all other work stopped while the headlamp aiming
is being done.
5. The vehicle should be loaded to represent normal vehicle use.
6. Tires should be properly inflated.
7. Rock the vehicle to stabilize the suspension.
8. Measure from the reference line on the floor to the left headlamp bulb centerline.
9. At the screen, measure from the reference line and place the vertical tape at the measured
distance.
10. Measure from the reference line on the floor to the right headlamp bulb centerline.
11. At the screen, measure from the reference line and place the second vertical tape at the
measured distance.
12. Adjust the left and right headlamp horizontal aim to the vertical lines on the screen by
turning the horizontal aiming screws.

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13. Measure from the floor to the aim dot marked on the left headlamp lens and subtract
51 mm (2 in).
14. At the screen, measure from the floor and place the horizontal line at the previously
calculated distance.
15. Adjust the left headlamp to the horizontal line on the screen by turning the vertical aiming
screw.
16. Measure from the reference line on the floor to the aim dot marked on the right headlamp
lens.
17. At the screen, measure from the floor and place the horizontal line at the measured distance.
18. Adjust the right headlamp to the horizontal line on the screen by turning the vertical aiming
screw.

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Headlamp Bulb Replacement

Removal Procedure
1. Remove the headlamp assembly from the vehicle. Refer to Headlamp Replacement .

2. Remove the headlamp bulb (3 or 4) from the headlamp assembly (1) by turning 1/4 turn
counter clockwise.
3. Disconnect the electrical connector from the bulb.

Installation Procedure

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1. Connect electrical connector to the headlamp bulb (3 or 4).

2. Install the headlamp bulb (3 or 4) into the headlamp assembly (1) by turning 1/4 turn
clockwise.
3. Install the headlamp assembly to the vehicle. Refer to Headlamp Replacement .

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Headlamp Replacement
Removal Procedure

1. Remove headlamp fasteners (1, 2) securing the headlamp to the vehicle.

2. Using a pry bar, carefully pry in the center area of the headlamp.

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3. Pry the headlamp assembly straight forward in order to unsnap the headlamp ball stud (3)
from its ball stud socket.
4. Slide the headlamp (4) straight forward and disconnect the headlamp connector from the
forward lamp wiring harness.
5. Remove the headlamp from the vehicle.

Installation Procedure

1. Position the headlamp (4) to the vehicle and connect the electrical connector.
2. Press the headlamp rearward in order to engage the ball stud into the ball stud socket.

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3. Install the headlamp fasteners (1, 2).

Tighten
Tighten the headlamp mounting fasteners (1, 2) to 6 N·m (53 lb in).

4. Aim the headlamps. Refer to Headlamp Aiming .

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Headlamp Switch Replacement

The Headlamp Switch Assembly is part of the Multifunction Turn Signal Assembly which is serviced
in steering. Refer to Multifunction Turn Signal Lever Replacement - On Vehicle in Steering Wheel
and Column-Tilt.

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High Mount Stop Lamp Replacement

Removal Procedure

1. Pull downward in order to disengage the fasteners (2) securing the high mounted stop lamp
assembly (1) to the roof inner panel.
2. Disconnect the electrical connector (4).

Installation Procedure

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1. Connect the electrical connector (4) to the high mounted stop lamp assembly.
2. Position the high mounted stoplamp assembly to the inner roof panel.
3. Push upward in order to engage the retainers (2) securing the mounted stoplamp
assembly (1) to the inner roof panel.

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Ignition Lock Cylinder Bulb Replacement

Removal procedure

1. Remove the Ignition Switch. Refer to Ignition and Start Switch Replacement in Instrument
Panel, Gages, and Console.
2. Remove the Ignition lock cylinder lamp bulb socket (1) by turning counterclockwise 1/4 turn.
3. Remove the bulb from the socket.

Installation Procedure

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1. Install the Ignition lock cylinder lamp bulb into the lamp socket (1).
2. Install the Ignition lock cylinder lamp bulb socket by turning clockwise 1/4 turn.
3. Install the Ignition Switch. Refer to Ignition and Start Switch Replacement in Instrument
Panel, Gages, and Console.

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Instrument Panel Compartment Lamp Replacement

Removal Procedure
1. Remove the instrument panel storage compartment. Refer to Instrument Panel Storage
Compartment Replacement in Instrument Panel, Gages and Console.

2. Using a small flat bladed tool release the retainer tabs securing the IP storage compartment
lamp to the IP storage compartment.
3. Disconnect the electrical connector from the IP storage compartment lamp .

4. Remove the bulb from

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Installation Procedure

1. Install the bulb into the IP storage compartment lamp .

2. Install the IP storage compartment lamp into the IPstorage compartment.

3. Connect the electrical connector to the IP storage compartment lamp.
4. Install the instrument panel storage compartment. Refer to Instrument Panel Storage
Compartment Replacement in Instrument Panel, Gages and Console.

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Instrument Panel Compartment Lamp Switch

Replacement
Removal Procedure

1. Open the instrument panel storage compartment door (1).

2. Reach inside the instrument panel storage compartment and squeze the retaining tabs
together while pushing down firmly on back of the instrument panel storage compartment
lamp switch (2) in order to disengage the instrument panel storage compartment lamp
switch from the instrument panel.
3. Disconnect the electrical connector from the instrument panel storage compartment lamp
switch (2).

Installation Procedure

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1. Connect the electrical connector to the instrument panel storage compartment lamp
switch (2).
2. Position the instrument panel storage compartment lamp switch (2) to the opening in the
instrument panel.
3. Firmly push the instrument panel storage compartment lamp switch (2) inward until an
audible click is heard.
4. Close the instrument panel storage compartment door (1).

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Instrument Panel Courtesy Lamp Bulb Replacement

(Left Side)
Removal Procedure

1. Remove the fasteners (1) securing the left closeout insulator panel to the instrument panel
retainer.

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3. Disconnect the electrical connector (1) from the courtesy lamp.

4. Unclip the courtesy lamp from the closeout insulator panel (2).

Installation Procedure

1. Position the courtesy lamp to the opening in the closeout insulator panel (2).
2. Push inward in order to engage the retaining clip securing the courtesy lamp to the closeout
insulator panel (2).
3. Connect the electrical connector (1) to the courtesy lamp.

4. Align the closeout insulator panel with the instrument panel retainer.

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5. Install the closeout insulator fasteners (1).

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

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Instrument Panel Courtesy Lamp Bulb Replacement

(Right Side)
Removal Procedure

1. Remove the fasteners (1) securing the right closeout insulator panel (3) to the instrument
panel retainer.

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3. Disconnect the electrical connector (1) from the courtesy lamp.

4. Unclip the courtesy lamp from the closeout insulator panel (3).

Installation Procedure

1. Position the courtesy lamp to the opening in the closeout insulator panel (3).
2. Push inward on the courtesy lamp in order to engage the retaining clip.
3. Connect the electrical connector (1) to the courtesy lamp.

4. Position the closeout insulator panel with the instrument panel retainer.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the

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5. Install the closeout insulator panel fasteners (1) in order to secure the panel to the retainer.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

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Instrument Panel Lamp Dimmer Switch Replacement

Removal Procedure

1. Remove the left I/P endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gages and Console.
2. Remove the left air deflector. Refer to Instrument Panel Outer Air Outlet Deflector
Replacement - Left Side in Heating, Ventilation, and Air Conditioning.

3. Disconnect the electrical connector

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4. Remove the I/P dimmer switch knob by pulling outward removing it from the switch.
5. Remove the fasteners securing the I/P dimmer switch to the air deflector.
6. Remove the I/P dimmer switch.

Installation Procedure
1. Position the I/P dimmer switch to the air deflector.

2. Install the fasteners in order to secure the I/P dimmer switch to the air deflector.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

3. Connect the electrical connector to the I/P dimmer switch.

4. Install the I/P dimmer switch knob.

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5. Install the left air deflector. Refer to Instrument Panel Outer Air Outlet Deflector Replacement
- Left Side in Heating, Ventilation, and Air Conditioning.
6. Install the left I/P endcap. Refer to Instrument Panel Outer Trim Cover Replacement in
Instrument Panel, Gages and Console.

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Interior Lamp Switch Replacement

Removal Procedure

Important: Do not let the overhead console hang from the flat wire harness.

1. Carefully pull down on the overhead console to release the retainer clips.
2. Disconnect the electrical connector (1) from the switch.
3. Remove the fasteners (2) securing the interior lamp switch to the overhead console.
4. Remove the interior lamp switch.

Installation Procedure

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1. Position the interior lamp switch to the opening in the overhead console.
2. Install the fasteners in order to secure the switch to the overhead console.
3. Connect the electrical connector (1) to the interior lamp switch.
4. Install the overhead console into the opening in the headliner.
5. Push in on the overhead console to engage the retainer clips securing the overhead console
to the headliner.

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Parking and Turn Signal Lamp Bulb Replacement

Removal Procedure

1. Remove the headlamp assembly (1). Refer to Headlamp Replacement .

2. Disconnect the electrical connector from the bulb socket (2).
3. Remove the bulb and socket (2) from the headlamp assembly (1).
4. Remove the bulb from the socket.

Installation Procedure

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1. Install the bulb into the socket (2).

2. Install the socket with the bulb (2) to the headlamp assembly (1).
3. Connect the electrical connector to the bulb socket (2).
4. Install the headlamp assembly to the vehicle. Refer to Headlamp Replacement .

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Rear Fog Lamp Replacement

Removal Procedure

1. Remove the fog lamp bulb socket from the fog lamp assembly by turning the socket
counterclockwise.
2. Remove the nut securing the lamp assembly to the fascia.
3. Push the inboard edge of the lamp rearward to disengage the lamp from the fascia.
4. Remove the lamp assembly from the fascia.

Installation Procedure

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1. Position the outboard edge of the fog lamp into the fascia.
2. Push the inboard edge of the fog lamp into the fascia.

3. Install the nut.

Tighten
Tighten the nut to 4 N·m (35 lb in).

4. Install the fog lamp bulb socket to the fog lamp assembly by turning clockwise.

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Rear License Plate Lamp Replacement (L47

Engine/Aluminum Lid)
Removal Procedure

1. Open the rear compartment lid.

2. Remove the compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.
3. Disconnect the lamp socket (1) from the license lamp housing (2) by turning 1/4 turn
counterclockwise.
4. Remove the fasteners (3) securing the license lamp housing (2) to the rear compartment lid.
5. Remove the license lamp housing (2) from the rear compartment lid.

Installation Procedure

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1. Position the license lamp housing (2) into the rear compartment lid.
2. Install the license lamp housing fasteners (3) in order to secure the license lamp housing to
the rear compartment lid.
3. Install the lamp socket (1) into the licence lamp housing (2) by turning 1/4 turn clockwise in
order to secure.
4. Install the compartment lid trim. Refer to Rear Compartment Lid Inner Panel Trim
Replacement in Body Rear End.
5. Close the rear compartment lid.

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Rear License Plate Lamp Replacement (LX5

Engine/SteelLid)
Removal Procedure

1. Remove the fasteners (3) securing the license lamp housing (1) to the compartment lid.
2. Remove the license lamp housing (1) from the rear compartment lid.
3. Remove the license lamp bulb socket (2) from the license lamp housing (1) by turning 1/4
turn counterclockwise.

Installation Procedure

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1. Install the license lamp bulb socket (2) into the license lamp housing (1) by turning 1/4 turn
clockwise to secure.
2. Position the license lamp housing (1) into the rear compartment lid.
3. Install the license lamp housing fasteners (3) in order to secure the license lamp housing (1)
to the rear compartment lid.

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Roof Rail Rear Courtesy Lamp Replacement

Removal Procedure

1. Using a small flat-bladed tool, release the retaining clip at the rear of the rear quarter
courtesy lamp.
2. Remove the rear quarter courtesy lamp from the headliner.
3. Disconnect the electrical harness.

Installation Procedure

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1. Connect the electrical harness to the rear quarter courtesy lamp.

2. Reposition the rear quarter courtesy lamp to the opening in the headliner.
3. Using firm pressure, push inward on the rear portion of the rear quarter courtesy lamp until
an audible click is heard.

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Tail Lamp Bulb Replacement

Removal Procedure

1. Open the rear compartment lid.

2. Remove the appropriate rear compartment side trim panel. Refer to Rear Compartment Trim
Panel Replacement in Body Rear End.
3. Remove the tail lamp housing assembly. Refer to Tail Lamp Replacement .
4. Remove the tail lamp socket from the tail lamp housing assembly (3) by turning counter
clockwise 1/4 turn.
5. Remove the tail lamp bulb from the socket.

Installation Procedure

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1. Install the tail lamp bulb into the socket.

2. Install the tail lamp socket into the tail lamp housing assembly (3).
3. Turn the tail lamp socket clockwise 1/4 turn in order to secure the socket to the tail lamp
housing assembly (3).
4. Install the tail lamp assembly (3) to the vehicle. Refer to Tail Lamp Replacement .
5. Install the rear compartment side trim panel. Refer to Rear Compartment Trim Panel
Replacement in Body Rear End.
6. Close the rear compartment lid.

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Tail Lamp Replacement

Removal Procedure

1. Open the rear compartment lid.

2. Remove the compartment trim panels. Refer to Rear Compartment Trim Panel Replacement
in Body Rear End.

Disconnect the tail lamp harness connector (1).

3. Remove the tail lamp fasteners.

4. Remove the tail lamp assembly (3) from the vehicle.
5. While supporting the tail lamp assembly (3), remove the tail lamp harness grommet (2).

Installation Procedure

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1. While supporting the tail lamp assembly (3), install the tail lamp harness grommet (2).
2. Install the tail lamp assembly (3) to the vehicle.

3. Install the tail lamp fasteners to the tail lamp studs in sequence: 1, 2 then 3.

Tighten
Tighten the tail lamp fasteners to 6 N·m (53 lb in).

4. Connect the tail lamp harness connector (1).

5. Install the compartment trim panels. Refer to Rear Compartment Trim Panel Replacement in
Body Rear End.
6. Close the rear compartment lid.

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Vanity Mirror Lamp Replacement

Removal Procedure

1. Open the vanity cover (1) and, using a thin-bladed tool, insert the edge of the tool under the
lamp lens (4).
2. Carefully snap the lamp lens out of its retaining slots.
3. Replace the bulb (3).

Installation Procedure

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1. Insert the bulb (3).

2. Install the lens (4) into the vanity mirror assembly.

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Fastener Tightening Specifications

Specification
Application Metric English
Park Brake Cable Bracket Bolt 24 N·m 18 lb ft
Park Brake Cable Guide Bolt 24 N·m 18 lb ft
Park Brake Lever Assembly Nuts 24 N·m 18 lb ft
Park Brake Warning Lamp Switch Bolt 1.9 N·m 17 lb in

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Park Brake Cable Service/Adjustment (Automatic

AdjustmentSystem)
The adjustment for the automatic adjustment park brake system is incorporated into the park
brake pedal assembly. Refer to Parking Brake Lever Pedal Assembly Replacement .

The park brake cable is self-adjusting. No adjustment is needed.

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Park Brake Cable Service/Adjustment (Manual

AdjustmentSystem)
Adjustment of manual adjustment park brake cable system is necessary whenever the rear brake
cables have been disconnected. A need for park brake cable adjustment is indicated if the hydraulic
brake system operates with good reserve, but a firm park brake pedal feel cannot be achieved with
less than one full stroke of the park brake pedal.

1. Cycle brake system.

1.1. Apply the service brake with a pedal force of approximately 660 N (150 lb) and
release.
1.2. Fully apply the park brake using approximately 550 N (125 lb) pedal force and release.
1.3. Apply and release the park brake two additional times as described above.
1.4. Park brake light should be illuminated after park brake has been depressed slightly.
2. Check park brake pedal assembly for full release by turning the ignition on and inspecting
PARK BRAKE warning light. Light should be off. If PARK BRAKE warning light is on and park
brake appears to be fully released, pull the pedal back by hand and continue with the
adjustment procedure.
3. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
4. Check park brake levers on rear calipers. Levers should be against the stops on the caliper
housing. If levers are not against stops, check for binding in rear brake cables and position
levers against stops.
5. Tighten park brake cable at adjuster until either the left or right lever begins to move off
stop.
6. Loosen adjuster until lever which moved off of stop in step 5 is again resting on stop. Both
levers should be resting on caliper stops after completing this step.
7. Operate park brake several times to check adjustment. A firm pedal feel should be obtained
by depressing the pedal less than one full stroke.
8. Inspect left and right caliper levers. Both levers must be resting on stops after adjustment of
parking brake.
9. Check the operation of the park brake. Refer to Owner Checks and Services in Maintenance
and Lubrication.

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Parking Brake Front Cable Replacement (Automatic

Adjustment System)
The front park brake cable is serviced with the automatic adjustment park brake pedal assembly.
Refer to Parking Brake Lever Pedal Assembly Replacement . There is no threaded equalizer on the
automatic adjustment park brake cable system.

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Parking Brake Front Cable Replacement (Manual

Adjustment System)
Removal Procedure
Important: The front manual adjustment park brake cable is serviced as a separate unit. The
front park brake cable has a threaded equalizer rod for adjustment.

1. Remove the left door carpet retainer. Refer to Front Carpet Retainer Replacement in Interior
Trim.
2. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.

3. Pull the edge of the carpet back enough to access grommet.

4. Loosen the grommet from the floor pan.
5. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.

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6. Disconnect the park brake cable adjuster from the front cable.
7. Release the retaining tabs holding the front park brake cable housing in the floor pan and
push the cable upward.
8. Lower the vehicle.

9. Disconnect the park brake cable from the lever assembly.

10. Remove the park brake front cable assembly.

Installation Procedure

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1. Route the front park brake cable through the floor pan.

2. Install the cable housing retainer and grommet into the floor pan.

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3. Connect the park brake cable to the lever assembly and install the retainer.
4. Reposition the carpet.
5. Install the driver door carpet retainer. Refer to Front Carpet Retainer Replacement in Interior
Trim.
6. Install the left sound insulator panel. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauges and Console.
7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

8. Install the park brake cable into the cable guides.

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9. Connect the park brake adjuster to the front cable.

10. Adjust the park brake cable. Refer to Park Brake Cable Service/Adjustment .
11. Lower the vehicle.

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Parking Brake Indicator Switch Replacement

Removal Procedure

1. Remove the left sound insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gages and Console.
2. Disconnect the electrical connector from the park brake warning lamp switch.
3. Remove the park brake warning lamp switch retaining bolt.
4. Remove the park brake warning lamp switch.

Installation Procedure

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1. Install the park brake warning lamp switch to the park brake lever assembly. Align the
locator pin to the locator hole.

2. Install the park brake switch retaining bolt.

Tighten
Tighten the bolt to 1.9 N·m (17 lb in).

3. Connect the park brake warning lamp electrical connector to the park brake warning lamp
switch.
4. Install the left sound insulator panel. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gages and Console.

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Parking Brake Intermediate Cable Replacement

Removal Procedure

1. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.
2. Pull down on the intermediate park brake cable (2) near the park brake connector (1).
3. Remove the intermediate park brake cable (2) from the park brake cable connector (1).

4. Disconnect the intermediate cable (3) from the rear equalizer (1).
5. Disconnect the intermediate park brake
© 2014 General Motors cable housing
Corporation. All rights the rear park brake cable housing
from reserved.

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connector.
6. Remove the intermediate park brake cable.

Installation Procedure

1. Route and install the intermediate park cable into park brake cable connector.
2. Connect the left (2) and right (5) rear park brake cables to the intermediate park brake
cable (3), using the equalizer (1).
3. Install the intermediate park brake cable (3) to the equalizer (1).

4. Insert the intermediate park brake cable (2) into the park brake cable connector (1) and lock
the cable into place.

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Parking Brake Lever Pedal Assembly Replacement

(Automatic Adjustment System)
Removal Procedure
Important: The automatic adjustment park brake pedal assembly and the front park brake cable
are serviced as a unit. The front park brake cable does not have a threaded equalizer rod.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.

2. Pull down on the intermediate park brake cable near the park brake connector (2).
3. Remove the front park brake cable from the cable connector (1).
4. Lower the vehicle.
5. Remove the left closeout/insulator panel to access the park brake lever assembly. Refer to
Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and
Console.
6. Pull the carpet back to expose the park brake cable.

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7. Disconnect the electrical connector from the park brake warning lamp switch.

8. Remove the park brake lever assembly attaching nuts.

9. Remove the park brake lever and cable assembly from the vehicle.

Installation Procedure

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1. Install the park brake lever and cable assembly to the mounting studs.

2. Install the park brake lever assembly attaching nuts.

Tighten
Tighten the park brake lever nuts to 24 N·m (18 lb ft).

3. Connect the electrical connector to the park brake warning lamp switch.
4. Install the carpet.

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5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Connect the front park brake cable (3) to the park brake cable connector (1) on the
Intermediate park brake cable (2).
7. Lower the vehicle.

8. To set tension in the park brake cable system, twist and pull down on the tension release pin
to remove.
9. Apply the park brake pedal 3 full cycles to complete the tension set.
10. Install the left sound insulator panel. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauge and Console.

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Parking Brake Lever Pedal Assembly Replacement

(Manual Adjustment System)
Removal Procedure
The manual adjustment park brake pedal assembly and the front park brake cable are serviced as
separate units. The front park brake cable uses a threaded equalizer for adjustment.

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.

2. Loosen and disconnect the front park brake cable at the adjuster.
3. Lower the vehicle.
4. Remove left closeout insulator panel to access lever assembly. Refer to Instrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
5. Remove the left front carpet retainer. Refer to Front Carpet Retainer Replacement in Interior
Trim.
6. Pull back carpet to expose park brake cable.

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7. Disconnect the electrical connector from the park brake warning switch.

8. Disconnect the front park brake cable from lever assembly.

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9. Remove the park brake lever assembly attaching nuts.

10. Remove the park brake lever assembly from the vehicle.

Installation Procedure

1. Install the park brake lever assembly to the mounting studs.

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2. Install the lever attaching nuts.

Tighten
Tighten the park brake lever nuts to 24 N·m (18 lb ft).

3. Connect the front park brake cable to the lever assembly.

4. Connect the electrical connector to the park brake warning switch.

5. Reposition the carpet.

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6. Install the left front carpet retainer. Refer to Front Carpet Retainer Replacement in Interior
Trim.
7. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.

8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
9. Connect the front park brake cable and adjuster to the Intermediate cable.
10. Adjust the park brake. Refer to Park Brake Cable Service/Adjustment .
11. Lower the Vehicle.

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Parking Brake Rear Cable Replacement

Removal Procedure
1. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.

3. Pull down on the park brake cable near the park brake connector (1).
4. Disconnect the right (5) and left (2) rear park brake cables from the rear equalizer (1).
5. Remove both park brake cables from their connectors by depressing retaining tabs on the
cable housings and pulling the cables out of the brackets.

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6. Disconnect the park brake cables from the park brake levers.
7. Remove the right and left cable from the caliper support brackets by depressing the retainer
tabs.

8. Remove the park brake rear cable bracket bolt from the control arm.
9. Remove the rear park brake cable.

Installation Procedure

1. Install both park brake cables (2), (5) into their brackets by snapping them into place.

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2. Connect both park brake cables to the equalizer (1).

3. Install the right and left cables into the caliper support brackets by snapping into place.
4. Connect the park brake cables to the park brake levers.
5. Pull on the intermediate park brake cable.
6. Install the park brake intermediate cable.

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7. Install the park brake cable bracket bolt.

Tighten
Tighten the park brake cable bracket bolt to 24 N·m (18 lb ft).

8. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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Fastener Tightening Specifications

Specification
Application Metric English
Adjuster Plug Lock Nut 68 N·m 50 lb ft
Cylinder End Fitting 27 N·m 20 lb ft
Inner Tie Rod 100 N·m 74 lb ft
Intermediate Steering Shaft Pinch Bolt 47 N·m 35 lb ft
Power Steering Gear Heat Shield Retaining Bolts 10 N·m 89 lb in
Power Steering Gear Mounting Bolts 95 N·m 70 lb ft
Power Steering Hose Fittings 30 N·m 22 lb ft
Power Steering Pressure Hose Bolt 3.5L 9 N·m 80 lb in
Power Steering Pressure Hose Retaining Nut 4.0L 8 N·m 71 lb in
Power Steering Pump Housing Bolts 25 N·m 18 lb ft
Power Steering Pump Mounting Bolts 25 N·m 18 lb ft
Power Steering Return Hose Bolt 17 N·m 13 lb ft
Tie Rod to Steering Knuckle
l First Pass 30 N·m 22 lb in
l Second Pass + 180 Degrees
Valve Bore Plug 55 N·m 41 lb in

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Power Steering Gear Disassembled View (Aurora)

Power Rack and Pinion-End Take Off

(1) Hexagon Slotted Nut

(2) Cotter Pin
(3) Tie Rod Seal
(4) Outer Tie Rod
(5) Hexagon Jam Nut
(6) Tie Rod End Clamp
(7) Rack and Pinion Boot
(8) Large Boot Retaining Clamp
(9) Inner Tie Rod
(10) Adjuster Plug Lock Nut© 2014 General Motors Corporation. All rights reserved.

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(11) Shock Dampener Ring

(12) Cylinder Line (LH)
(13) Cylinder Line (RH)
(14) O-ring Seals
(15) Rack and Pinion Gear Assembly (Partial)
(16) Dust Cover
(17) Shock Dampener Ring
(18) Breather Tube
(19) Inner Tie Rod
(20) Large Boot Retaining Clamp
(21) Rack and Pinion Boot
(22) Tie Rod End Clamp
(23) Hexagon Jam Nut
(24) Outer Tie Rod
(25) Cotter Pin
(26) Hexagon Slotted Nut
(27) Tie Rod Seal

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Power Steering Pump Disassembled View

Power Steering Pump Components

(1) Reservoir Assembly Cap

(2) Reservoir Assembly
(3) Retaining Clip
(4) Retaining Clip
(5) O-ring Seal
(6) Hydraulic Pump Assembly

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Power Steering Pump Specifications

High Flow Pressure Relief
Engine Code Engine Size LPM GPM kPa PSI
LX5 3.5L
7.8/9.5 2.1/2.5 11722/12411 1700/1800
L47 4.0L

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Checking and Adding Power Steering Fluid

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 and seal damage and fluid leaks.

1. Clean the area surrounding the reservoir cap.

2. Remove the reservoir cap.
3. Inspect the power steering pump fluid level at regular intervals. Add fluid when required.
Refer to Fluid and Lubricant Recommendations .
• If the fluid level is being checked cold, perform the following steps:
1. Remove the reservoir cap.
2. Inspect the fluid level on the dipstick.

The fluid level should be between the bottom of the COLD/FULL mark and the end of the
dipstick.

• If the fluid level is being checked hot, perform the following steps:
1. Run the engine until the fluid reaches about 80°C (170°F).
2. Shut the engine OFF.
3. Remove the reservoir cap.
4. Inspect the fluid level on the dipstick.

The fluid level should be between the HOT/FULL and the COLD/FULL marks on the dipstick.

4. If the fluid level is low, add the power steering fluid to the proper level.
5. Install the reservoir cap.
6. When checking the fluid level after servicing the steering system, bleed the air from the
system. Refer to Power Steering System Bleeding .

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Power Steering Fluid Reservoir Replacement - Off

Vehicle
Disassembly Procedure

1. Remove the mounting bracket bolts (3) from the mounting bracket assembly (2).
2. Remove the mounting bracket assembly (2) from the pump (1).

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the release clip tang. Tap the clip off with a hammer.

4. Remove reservoir (1) from the hydraulic pump housing (3).

5. Remove the O-ring seal (2) from the reservoir (1).
6. Discard the O-ring seal (2).

Assembly Procedure
Notice: Refer to Fastener Notice in the Preface section.

1. Check the TORX® head bolts (1) on the hydraulic pump housing (2) for tightness.

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Tighten
Tighten the TORX® head bolts (1) to 20-25 N·m (15-18 lb ft).

2. Check the valve bore plug (1) and the O-ring union fitting.

Tighten
Tighten the valve bore plug (1) to 50-60 N·m (37-44 lb ft).

3. Lubricate the new O-ring seal (2) with power steering fluid.
4. Connect the O-ring seal (2) to the reservoir (1).

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Important: Align the mounting hole on the reservoir (2) correctly with the hole on the top of
the pump housing assembly (3) to prevent damage.

5. Connect the reservoir assembly (1) to the hydraulic pump housing (4).

Important: Make sure the retaining clip (2) is fully seated on the reservoir assembly (1), so
the reservoir assembly (1) and the pump housing (3) are securely fastened.

6. Tap retaining clips (2) with a hammer.

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7. Attach the pump (1) to the mounting bracket assembly (2).

Tighten
Tighten the mounting bracket bolts (3) to 28-38 N·m (21-28 lb ft).

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Power Steering Pressure Pipe/Hose Replacement (L47)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield
Replacement .

3. Remove the power steering pressure hose retainer (2) from the engine frame at gear.
4. Remove the power steering pressure hose from the power steering gear.

5. Remove the power steering pressure

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6. Lower the vehicle.

7. Disconnect the power steering pressure hose at the power steering pump.
8. Remove the power steering pressure hose from the vehicle.

Installation Procedure
1. Install the power steering pressure hose to the vehicle.

2. Install the power steering pressure hose to the power steering pump.

Tighten
Tighten the power steering pressure hose to the power steering pump to 30 N·m (22 lb ft).

3. Install the power steering pressure hose bracket and retaining nut to the cylinder head.

Tighten
Tighten the power steering pressure hose retaining nut to 8 N·m (71 lb in).

4. Raise the vehicle.

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5. Install the power steering pressure hose to the retainer (2).

6. Install the power steering pressure hose (1) to the power steering gear.

Tighten
Tighten the power steering pressure hose to the power steering gear to 30 N·m (22 lb ft).

7. Install the power steering gear heat shield.

8. Lower the vehicle.
9. Bleed the power steering system. Refer to Power Steering System Bleeding .

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Power Steering Pressure Pipe/Hose Replacement (LX5)

Removal Procedure

1. Install a drain pan under the vehicle

2. Remove the power steering pressure hose (1) from the power steering pump.
3. Remove the power steering pressure hose retaining bolt (2) from the engine.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the power steering gear heat shield.

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6. Remove the power steering pressure hose retainer (2) from the frame.
7. Remove the power steering pressure hose (1) from the power steering gear.
8. Remove the power steering pressure hose from the vehicle.

Installation Procedure

1. Install the power steering pressure hose (1) to the vehicle.

2. Install the power steering pressure hose to the power steering gear.

Tighten
Tighten the power steering pressure hose to the power steering gear to 30 N·m (22 lb ft).

3. Install the power steering pressure hose retainer (2) to the frame.
4. Install the power steering gear heat shield.
5. Lower the vehicle.

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6. Install the power steering pressure hose (1) to the power steering pump.

Tighten
Tighten the power steering pressure hose to the power steering pump to 30 N·m (22 lb ft).

7. Install the power steering pressure hose retaining bolt (2) to the engine.

Tighten
Tighten the power steering pressure hose retaining bolt to 9 N·m (80 lb in).

8. Bleed the power steering system. Refer to Power Steering System Bleeding in Power
Steering.
9. Inspect the power steering system for leaks.

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Power Steering Pump Assemble

Assembly Procedure

1. After replacing the damaged pump assembly (1) with the new pump assembly (1), assemble
the pump reservoir.
2. Refer to Power Steering Fluid Reservoir Replacement - Off Vehicle .

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Power Steering Pump Disassemble

Disassembly Procedure

1. Inspect the hydraulic pump (1) for leaks.

2. If pump (1) needs replacement, remove the reservoir assembly. Refer to Power Steering
Fluid Reservoir Replacement - Off Vehicle .

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Power Steering Pump Pulley Replacement (L47)

Tools Required
• J 25034-C Pulley Remover
• J 25033-C Pulley Installer

Removal Procedure
1. Remove the power steering pump. Refer to Power Steering Pump Replacement .

2. Install J 25034-C to the power steering pulley.

3. Using J 25034-C remove the power steering pump pulley.

Installation Procedure

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1. Install the power steering pulley to the power steering pump using J 25033-C .

2. Ensure that the axial tolerance of the power steering pulley on the power steering pump is
within 0.25 mm (0.010 in).
3. Install the power steering pump. Refer to Power Steering Pump Replacement .

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Power Steering Pump Pulley Replacement (LX5)

Tools Required
• J 25034-C Pulley Remover
• J 25033-C Pulley Installer

Removal Procedure
1. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical-3.5L.

2. Install J 25034-C to the power steering pulley.

3. Using J 25034-C remove the power steering pump pulley.

Installation Procedure

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1. Install the power steering pulley to the power steering pump using J 25033-C .

2. Ensure that the axial tolerance of the power steering pulley on the power steering pump is
within 0.25 mm (0.010 in).
3. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 3.5L.

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Power Steering Pump Replacement (L47)

Removal Procedure
1. Place a drain pan under the vehicle.
2. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical-4.0L.

3. Remove the power steering pressure line from the power steering pump.

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5. Remove the power steering pump bracket mounting bolt.

6. Remove the power steering pump assembly.
7. Remove the power steering pulley from the power steering pump. Refer to Power Steering
Pump Pulley Replacement .
8. Remove the power steering pump reservoir from the power steering pump. Refer to Power
Steering Fluid Reservoir Replacement - Off Vehicle .

Installation Procedure
1. Install the power steering pump reservoir to the power steering pump. Refer to Power
Steering Fluid Reservoir Replacement - Off Vehicle .
2. Install the power steering pulley to the power steering pump. Refer to Power Steering Pump
Pulley Replacement .
3. Install the power steering pump to the vehicle.

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4. Install the power steering pump mounting bolt.

Tighten
Tighten the power steering pump mounting bolts to 25 N·m (18 lb ft).

5. Install the power steering return hose to the power steering pump.

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6. Install the power steering pressure line to the power steering pump.

Tighten
Tighten the hose to 30 N·m (22 lb ft).

7. Install the power steering pump pulley to the power steering pump. Refer to Power Steering
Pump Pulley Replacement .
8. Install the accessory drive belt to the pump. Refer to Drive Belt Replacement in Engine
Mechanical-4.0L.
9. Bleed the power steering system. Refer to Power Steering System Bleeding .
10. Inspect the power steering system for leaks. Refer to Power Steering Fluid Leaks .
11. Remove the drain pan from under the vehicle.

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Power Steering Pump Replacement (LX5)

Removal Procedure
1. Place a drain pan under the vehicle.
2. Remove the fuel injector site shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical-3.5L.
3. Remove the power steering pump pulley from the power steering pump. Refer to Power
Steering Pump Pulley Replacement .

4. Remove the power steering pump pressure hose (1) from the power steering pump.

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5. Remove the power steering pump return hose from the power steering pump.

6. Remove the power steering pump mounting bolts.

7. Remove the power steering pump.
8. Remove the power steering pump reservoir from the power steering pump. Refer to Power
Steering Fluid Reservoir Replacement - Off Vehicle .

Installation Procedure

1. Install the power steering pump reservoir to the power steering pump. Refer to Power
Steering Fluid Reservoir Replacement - Off Vehicle .
2. Install the power steering pump to the vehicle.

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3. Install the power steering pump mounting bolts.

Tighten
Tighten the power steering pump mounting bolts to 25 N·m (18 lb ft).

4. Install the power steering pump return hose to the power steering pump.

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5. Install the power steering pump pressure hose (1) to the power steering pump.

Tighten
Tighten the power steering pump pressure hose to 30 N·m (22 lb ft).

6. Install the power steering pump pulley to the power steering pump. Refer to Power Steering
Pump Pulley Replacement .
7. Install the fuel injector site shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical-3.5L.
8. Bleed the power steering system. Refer to Power Steering System Bleeding .
9. Inspect the power steering system for leaks.

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Power Steering Return Hose Replacement (L47)

Removal Procedure

1. Install a drain pan under the vehicle.

2. Remove the power steering return hose from the power steering pump.
3. Remove the power steering return hose retaining bolt from the engine.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the power steering gear heat shield.

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6. Remove the power steering return hose from the engine frame.
7. Remove the power steering return hose from the power steering gear.
8. Remove the power steering return hose from the vehicle.

Installation Procedure

1. Install the power steering return hose to vehicle.

2. Install the power steering return hose to the power steering gear.

Tighten
Tighten the power steering return hose to the power steering pump to 30 N·m (22 lb ft).

3. Install the power steering return hose to the engine frame.

4. Lower the vehicle.

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5. Install the power steering return hose to the power steering pump.
6. Install the power steering return hose retaining bolt to the engine.

Tighten
Tighten the power steering return hose retaining bolt to 17 N·m (13 lb ft).

7. Bleed the power steering system. Refer to Power Steering System Bleeding .

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Power Steering Return Hose Replacement (LX5)

Removal Procedure

1. Install a drain pan under the vehicle.

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6. Remove the power steering return hose from the engine frame.
7. Remove the power steering return hose from the power steering gear.
8. Remove the power steering return hose from the vehicle.

Installation Procedure

1. Install the power steering return hose to vehicle.

2. Install the power steering return hose to the power steering gear.

Tighten
Tighten the power steering return hose to the power steering pump to 30 N·m (22 lb ft).

3. Install the power steering return hose to the engine frame.

4. Lower the vehicle.

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5. Install the power steering return hose to the power steering pump.
6. Install the power steering return hose retaining bolt to the engine.

Tighten
Tighten the power steering return hose retaining bolt to 17 N·m (13 lb ft).

7. Bleed the power steering system. Refer to Power Steering System Bleeding .

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Power Steering System Bleeding

Important:
• Use clean, new power steering fluid type only. See the Maintenance and Lubrication
subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations .
• Hoses touching the frame, body or engine may cause system noise. Verify that the
hoses do not touch any other part of the vehicle.
• Loose connections may not leak, but could allow air into the steering system. Verify that
all hose connections are tight.

Important: Power steering fluid level must be maintained throughout bleed procedure.

1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash
mark on cap stick fluid level indicator.

Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost
accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will
discharge the hydro-boost accumulator.

2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following
procedure:
2.1. Start the engine.
2.2. Firmly apply the brake pedal 10-15 times.
2.3. Turn the engine OFF.
3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the
Vehicle in General Information.
4. Key on engine OFF, turn the steering wheel from stop to stop 12 times.

Vehicles equipped with hydro-boost systems or longer length power steering hoses may
require turns up to 15 to 20 stop to stops.

5. Verify power steering fluid level per operating specification. Refer to Checking and Adding
Power Steering Fluid .
6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid
aeration (pump noise/whining).
7. Verify the fluid level. Repeat the bleed procedure if necessary.

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Power Steering System Flushing

Important: Do not reuse any drained power steering fluid regardless of appearance or condition.

1. Turn OFF the engine.

2. Raise the front end of the vehicle off the ground until the tires and wheels turn freely. Refer
to Lifting and Jacking the Vehicle.
3. Place a large container under the fluid return hose in order to collect the draining fluid.
4. Remove the fluid return hose at the power steering pump reservoir inlet connection.
5. Plug the reservoir return hose inlet connection on the power steering pump.

Important: This step may require 4 L (4 qt) of power steering fluid until the draining fluid
appears clear.

6. With the key on engine off, turn the steering wheel fully to the left and to the right while an
assistant maintains the minimum fluid level in the reservoir using new approved power
steering fluid. Continue until the fluid from the return hose runs clear.
7. Remove the plug from the pump reservoir inlet connection and install the fluid return hose to
the pump reservoir.

Important: Do NOT run the engine without the power steering fluid at a minimum system
level.

8. Bleed the power steering system. Refer to Power Steering System Bleeding.
9. Inspect the power steering fluid for the following indications of contamination:
• Milky fluid - water
• Brown fluid - burnt
• Plastic debris or dirt chunks
10. If the fluid is contaminated, repeat steps 2-9.
11. Lower the vehicle and check the Power Steering system for leaks.

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Steering Gear Boot and Breather Tube Replacement -

Off Vehicle
Disassembly Procedure

1. To remove the outer tie rod, refer to Rack and Pinion Outer Tie Rod End Replacement .
2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1).

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4. Remove the boot clamp (1) from the rack and pinion boot with side cutters.
5. Discard the boot clamp (1).

Important: Prior to removing the breather tube or the rack and pinion boot, mark the
location of the breather tube on the gear assembly.

6. Remove the rack and pinion boot (1) and the breather tube from the rack and pinion gear
assembly.

Assembly Procedure
Tools Required

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J 22610 Keystone Clamp Plier

1. Install the new boot clamp (2) onto the rack and pinion boot (1).

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).
4. Install the breather tube while aligning the breather tube with the mark made during removal
and the molded nipple of the rack and pinion boot.

Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in
any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion
boot (3) by hand before installing the boot clamp.

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5. 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.

6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610 .
7. Crimp the boot clamp (1).
8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end
clamp.

9. Install the hexagon jam nut (2) to the inner tie rod assembly (1).
10. To assemble the outer tie rod assembly; refer to Rack and Pinion Outer Tie Rod End
Replacement .

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Steering Gear Cylinder Pipe Assembly and Seals

Replacement - Off Vehicle
Disassembly Procedure

1. Loosen both cylinder line fittings (1) on the cylinder end of the gear assembly.
2. Loosen both fittings on the cylinder line assemblies (3) at the valve end of the gear
assembly.

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3. Remove both cylinder line assemblies (1) from the rack and pinion gear assembly (2).

4. Remove the O-ring seals (1) from the valve end of line.
5. Discard the O-ring seals (1).

Assembly Procedure

1. Inspect the cylinder lines (1) for the following conditions. Replace the parts as needed:
• Cracks
• Dents
• Damage to the threads

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2. Install the new O-ring seals (1) to the valve end of the cylinder lines.

3. Install the cylinder line assemblies (1) to the gear assembly (2).

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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 PN 1050017 (or equivalent meeting GM Specification #9985010).

4. Refer to Power Steering System Bleeding .

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Steering Gear Heat Shield Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
3. Rotate the stabilizer shaft downward.
4. Remove the electrical harness clip from the power steering gear heat shield.
5. Remove power steering gear heat shield mounting bolts.
6. Remove the power steering gear heat shield.

Installation Procedure

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1. Install the power steering gear heat shield.

2. Install the power steering gear heat shield mounting bolts.

Tighten
Tighten the power steering gear heat shield mounting bolts to 10 N·m (89 lb in).

3. Install the electrical harness clip to the power steering gear heat shield.
4. Rotate the stabilizer shaft into position.
5. Install the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
6. Lower the vehicle.

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Steering Gear Rack Bearing Preload Adjustment - Off

Vehicle (Adjust Magna Valve)

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).
4. Install the adjuster plug lock nut (1) to the adjuster plug.

Tighten
Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) 68 N·m
(50 lb ft).

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Steering Gear Replacement

Tools Required
J 42640 Steering Column Anti Rotation Pin

Removal Procedure

1. Lock the steering column by installing the J 42640 into the underside of the steering column.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield
Replacement .

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Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can
result in damage to the steering gear and/or intermediate shaft. This damage can cause loss
of steering control which could result in personal injury.

5. Remove the intermediate shaft lower pinch bolt.

6. Separate the intermediate shaft from the power steering gear.

7. Remove the outer tie rod retaining nuts.

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8. Using J 24319-B separate the outer tie rods from the steering knuckles.

9. Remove the power steering pressure hose (2) from the power steering gear.
10. Remove the power steering return hose (1) from the power steering gear.

11. If equipped, disconnect the variable effort steering electrical connector

12. Remove the left stabilizer shaft insulator. Refer to Stabilizer Shaft Insulator Replacement in
Front Suspension.

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13. Remove the power steering gear mounting bolts.

14. Remove the power steering gear through the left wheel opening.
15. Transfer the outer tie rods if replacing the power steering gear.

Installation Procedure

1. Install the power steering gear through the left wheel opening.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the power steering gear mounting bolts.

Tighten
Tighten the power steering gear mounting bolts to 95 N·m (70 lb ft).

3. If equipped, connect the variable effort steering electrical connector.

4. Install the left stabilizer shaft insulator. Refer to Stabilizer Shaft Insulator Replacement in
Front Suspension.

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5. Install the power steering pressure hose (2) to the power steering gear.
6. Install the power steering return hose (1) to the power steering gear.

Tighten
Tighten the power steering pressure and return hoses to 30 N·m (22 lb ft).

7. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement .

8. Install the outer tie rods to the steering knuckles.

9. Install the outer tie rods retaining nuts.

Tighten
Tighten the nuts to 30 N·m (22 lb ft) plus an additional 180 degrees.

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10. Install the intermediate shaft to the power steering gear.

11. Install the intermediate shaft pinch bolt.

Tighten
Tighten the intermediate shaft pinch bolt to 47 N·m (35 lb ft).

12. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
13. Lower the vehicle.

14. Remove the J 42640 from the steering column.

15. Bleed the power steering system. Refer to Power Steering System Bleeding .
16. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.

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Steering Linkage Inner Tie Rod Replacement

(Magnasteer)
Tools Required
J 34028 Inner Tie Rod Wrench

Disassembly Procedure

1. To remove the rack and pinion boot and the breather tube. Refer to Steering Gear Boot and
Breather Tube Replacement - Off Vehicle .
2. Place the gear in a vise.

Notice: Do not change the steering gear preload adjustment before moving the inner tie rod
from the steering gear. Changing the steering gear preload adjustment before moving the
inner tie rod could result in damage to the pinion and the steering gear.

3. Remove the shock dampener (6) from the inner tie rod assembly (4).
4. Slide the shock dampener (6) back on the rack (5).

Notice: The pipe wrench must be placed at the valve end of the steering gear and positioned
up against the inner tie rod housing. Placing the pipe wrench in any other location will cause
damage to the steering gear.

5. Place a pipe wrench on the rack (5) next to the inner tie rod housing (4).
6. Place a wrench on the flats of the inner tie rod housing (4).
7. Rotate the inner tie rod housing (4) counterclockwise, while holding the rack stationary, until
© 2014 General Motors Corporation. All rights reserved.

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the inner tie rod separates from the rack (5).

8. Remove the shock dampener (3) from the inner tie rod housing (2).
9. Slide the shock dampener (3) back on the rack (5).

10. Place a pipe wrench on the rack.

11. Place a wrench on the flats of the inner tie rod housing (2).
12. Rotate the inner tie rod housing (2) counterclockwise, while holding the rack stationary, until
the inner tie rod (1) separates from the rack (5).

13. If female rack (1) and male inner tie rod (3), remove the old LOCTITE® from the threads (2)

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of the inner tie rod (3) and the rack (1).

If male rack (5) and female inner tie rod (4) LOCTITE® will not be present.

Assembly Procedure

1. Slide the shock dampener (4) forward onto the rack (3).

Important: Threads must be clean prior to LOCTITE® application. Check LOCTITE® (or
equivalent) container for expiration date. Use only enough LOCTITE® to evenly coat threads.

If male rack (3) and female inner tie rod (2) do not apply LOCTITE®.

2. If female rack (3) and male inner tie rod (2), apply LOCTITE® 262 (or equivalent) to the
inner tie rod threads.
3. Attach the inner tie rod onto the rack (3).

4. Place a pipe wrench on the rack (3) next to the inner tie rod housing (2).

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5. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (2).

Tighten
Tighten the inner tie rod to 100 N·m (74 lb ft).

6. Slide the shock dampener (2) forward onto the rack.

Important: Threads must be clean prior to LOCTITE® application. Check LOCTITE® (or
equivalent) container for expiration date. Use only enough LOCTITE® to evenly coat threads.

If male rack and female inner tie rod (1) do not apply LOCTITE®.

7. If female rack and male inner tie rod (1), apply LOCTITE® 262 (or equivalent) to the inner
tie rod threads.
8. Attach the inner tie rod (1) onto the rack.

9. Place a pipe wrench on the rack next to the inner tie rod housing (4).
10. Place a torque wrench and J 34028 on the flats of the inner tie rod housing (7).

Tighten
Tighten the inner tie rod to 100 N·m (74 lb ft).

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11. Place the inner tie rod assembly (2) in a vise.

Important: If female rack (1) and male inner tie rod (2) do not stake. If male rack (1) and
female inner tie rod (2) you must stake.

12. Stake both sides of the female inner tie rod assembly housing to the male rack (1).

13. Insert a 0.25 mm gage (1) between the male rack (2) and the female inner tie rod housing in
order to check both stakes. The feeler gauge (1) must not pass between the rack and the
housing stake.

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14. 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).
15. To assemble the rack and pinion boot and the breather tube. Refer to Steering Gear Boot and
Breather Tube Replacement - Off Vehicle .

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Steering Linkage Outer Tie Rod Replacement

Tools Required
J 24319-B Universal Steering Linkage Puller

3. Remove the outer tie rod retaining nut (3).

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4. Loosen the jam nut (2) on the inner tie rod (1).

5. Using J 24319-B remove the outer tie rod from the steering knuckle .

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6. Remove the outer tie rod (3) from the inner tie rod (1).

Installation Procedure

1. Install the outer tie rod (3) to the inner tie rod (1). Do not tighten the jam nut (2).

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2. Install the outer tie rod (1) to the steering knuckle (2).

3. Install the outer tie rod retaining nut (3).

Tighten

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Tighten the outer tie rod retaining nut to 30 N·m (22 lb ft) plus an additional 180 degrees.

4. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
5. Lower vehicle.
6. Adjust the toe alignment. Refer to Front Toe Adjustment in Wheel Alignment.

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Fastener Tightening Specifications

Specification
Application Metric English
Adjustment link retaining nut
l First Pass 30 N·m 22 lb ft
l Second Pass +180 degrees
Adjustment Link to Rear Suspension Support Assembly 91 N·m 67 lb ft
Control Arm Nuts 106 N·m 78 lb ft
Hub and Bearing Bolts 70 N·m 52 lb ft
Rear Body Mount Bolts 51 N·m 38 lb ft
Rear Suspension Support Assembly to Body Front Bolts 191 N·m 141 lb ft
Rear Suspension Support Assembly to Body Rear Bolts 191 N·m 141 lb ft
Rear Suspension Support Assembly to Bracket Bolts 86 N·m 63 lb ft
Shock to Control Arm Bolts Rear 24 N·m 18 lb ft
Shock Tower Mounting Nut 20 N·m 15 lb ft
Stabilizer Shaft Clamp Bolt 33 N·m 24 lb ft
Stabilizer Shaft Link Bolt 15 N·m 11 lb ft

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Adjust Link Replacement

Tools Required
J 24319-B Steering Linkage and Tie Rod Puller

3. Remove the adjustment link to lower control arm retaining nut.

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4. Using J 24319-B separate the adjustment link form the knuckle.

5. Support the rear support with a transmission jack.
6. Lower the rear support for access to the inner adjustment link bolt.
7. Remove the rear support mounting bolts.

8. Remove the inner adjustment link nut and bolt.

9. Remove the adjustment link assembly.

Installation Procedure

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1. Install the adjustment link to the vehicle.

2. Install the adjustment link inner bolt and nut.
3. Raise the rear support to the vehicle.

4. Install the rear support mounting bolts.

Tighten
Tighten the rear support mounting bolts to 191 N·m (141 lb ft).

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5. Install the adjustment link to the lower control arm.

6. Install the adjustment link retaining nut.

Tighten
Tighten the adjustment link retaining nut to 30 N·m (22 lb ft) plus an additional 180 degrees.

7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
8. Lower the vehicle.
9. Adjust the rear toe. Refer to Wheel Alignment Specifications in Wheel Alignment.

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Coil Spring Replacement

Tools Required
J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Support the control arm with a suitable jack.
4. Remove the automatic level control air tube from the shock.
5. Remove the lower shock absorber retaining bolts.

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6. Remove the adjustment link retaining nut.

7. Using J 24319-B separate the adjustment link from the lower control arm.

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8. Slowly lower the control arm until it bottoms on the support assembly.
9. Using a pry bar, pry under the lower spring insulator and remove the spring with the
insulator.
10. Remove the upper insulator by pulling downward.

Installation Procedure

1. Install the upper insulator in body.

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2. Install the lower insulator in the control arm.

3. Install the spring ensuring the insulator is seated in the control arm.

4. Raise the lower control arm and install the lower shock bolts to the control arm.

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Tighten
Tighten the lower shock retaining bolts to 24 N·m (18 lb ft).

5. Install the adjustment link to the lower control arm.

6. Install the adjustment link retaining nut.

Tighten
Tighten adjustment link retaining nut to 30 N·m (22 lb ft) plus an additional 180 degrees.

7. Connect the automatic level control air tube to the shock.

8. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
9. Lower the vehicle.

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Forward Body Mount Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheels. Refer to Tire and Wheel Removal and Installation in Wheels and
Tires.
3. Remove the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
4. Use a jack stand in order to support the forward end of the rear suspension support
assembly.

5. Remove the brackets from the body retaining bolts.

6. Remove the bolts that secure the front of the support assembly to the body of the vehicle.
7. Lower the front end of the support assembly in order to enable mount removal.

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8. Use a punch in order to perform the following actions:

8.1. Bend the tabs on the inboard mount (2)
8.2. Tap the mount (1) downward and out of the support assembly.

Installation Procedure

1. Tap the mount into the support assembly, ensuring the following conditions upon installation:
• The flat is outboard (2).
• The notch is rearward (1).
2. Use a large pair of channel lock pliers in order to bend the tabs (2) outboard.

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3. Raise the support assembly to the body of the vehicle.

4. Install the bracket and bolts that secure the front of the support assembly to the vehicle
body.
5. Install the brackets retaining bolts to the body at the support assembly forward mounts.

Tighten
• Tighten the bracket bolts to 86 N·m (63 lb ft).
• Tighten the forward body mount retaining bolts to 191 N·m (141 lb ft).
6. Install the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
7. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
8. Lower the vehicle.

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Rear Axle Lower Control Arm Replacement

Tools Required
J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure
1. Remove the rear suspension support assembly. Refer to Support Replacement .
2. Remove the automatic level control height sensor link on the left control arm.

3. Remove the stabilizer link bolt and the nut.

4. Disconnect the antilock brake electrical connector.
5. Remove the wheel bearing and hub . Refer to Rear Wheel Bearing and Hub Replacement .

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6. Remove the adjustment link retaining nut from the lower control arm.

7. Using J 24319-B , separate the adjustment link from the lower control arm.

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8. Remove the bolt and the nut securing the lower control arm to the rear suspension support
assembly.
9. Remove the lower control arm.

Installation Procedure

1. Install the lower control arm to the rear suspension support assembly.

Important: Tighten the control arm nuts with the vehicle unsupported and resting on the
wheels at the normal trim height.

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2. Install the lower control arm bolts and the nuts.

3. Install the wheel bearing and hub, if necessary. Refer to Rear Wheel Bearing and Hub
Replacement .
4. Connect the antilock brake electrical connector.

5. Install the adjustment link to the lower control arm.

6. Install the adjustment link retaining nut.

Tighten
Tighten the adjustment link retaining nut to 30 N·m (22 lb ft) plus an additional 180 degrees.

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7. Install the stabilizer link bolt and the nut.

Tighten
Tighten the stabilizer link nut to 15 N·m (11 lb ft).

8. Install the automatic level control height sensor link on the left control arm.
9. Install the rear suspension support assembly. Refer to Support Replacement .
10. Lower the vehicle.

Tighten
Tighten the control arm nuts to 106 N·m (78 lb ft).

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Rear Body Mount Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Use a block of wood at least seven inches long in order to support the exhaust and the rear
of the support assembly.
4. Remove the rear exhaust hangers.
5. Remove the rear support assembly bolts and lower the support assembly and exhaust
together.

6. Remove the rear body mount bolts.

7. Remove the rear body mounts.

Installation Procedure

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1. Install the rear body mount and the bolts ensuring that OUT is toward the outboard of the
vehicle.

Tighten
Tighten the rear body mount bolts to 51 N·m (38 lb ft).

2. Raise the rear support .

3. Install the bolts that secure the support assembly to the body of the vehicle.

Tighten
Tighten the rear support bolts to 191 N·m (141 lb ft).

4. Install the rear exhaust hangers

5. Install the tires and the wheels. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
6. Lower the vehicle.

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Rear Spring Insulator Replacement

Tools Required
J 24319-B Steering Linkage and Tie Rod Puller

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the control arm with a jack stand.
3. Remove the automatic level control air tube from the shock.
4. Remove the lower shock absorber lower retaining bolts.

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5. Remove the adjustment link retaining nut.

Notice: When separating a linkage joint, DO NOT try to disengage the joint by driving a
wedge between the joint and the attached part. Seal Damage may result.

6. Using J 24319-B separate the adjustment link from the lower control arm.
7. Slowly lower the control arm onto the support assembly.

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8. Pry under the lower spring insulator. Remove the spring with the insulator.
9. Remove the jounce bumper, if necessary, by pulling downward.

Installation Procedure

1. Install the jounce bumper by inserting the retainer into the body of the vehicle.
2. Install the spring and the lower insulator. Ensure that the insulator is seated in the control
arm.

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3. Raise the lower control arm.

4. Install the lower shock absorber retaining bolts.

Tighten
Tighten the lower shock absorber retaining bolts to 24 N·m (18 lb ft).

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5. Install the adjustment link to the lower control arm.

6. Install the adjustment link retaining nut.

Tighten
Tighten the nut to 30 N·m (22 lb ft) plus an additional 180 degrees.

7. Install the automatic level control air tube to the shock.

8. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
9. Lower the vehicle.

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Rear Wheel Bearing and Hub Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
4. Remove the antilock brake sensor wire connector.

5. Remove the wheel bearing and hub bolts from the lower control arm.
6. Remove the wheel bearing and hub from the lower control arm.
7. Remove the brake shield from the lower control arm.
8. Clean the control arm face and the bore before installing the wheel bearing hub.

Installation Procedure

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1. Install the brake shield and the wheel bearing and hub to the lower control arm with the four
bolts.
2. Install the wheel bearing and hub retaining bolts.

Tighten
Tighten the wheel bearing and hub retaining bolts to 70 N·m (52 lb ft).

3. Connect the antilock brake sensor electrical connector.

4. Install the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
6. Lower the vehicle.

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Shock Absorber Disposal

Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring
from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will
come out with extreme force which may result in personal injury.

Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the
shock absorber. Use care not to puncture the shock absorber tube with the centerpunch.

1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a
centerpunch.
2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely
extended.
3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas
or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop
towels in order to contain the escaping oil.
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch.
5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill
bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order
to contain the escaping oil.
© 2014 General Motors Corporation. All rights reserved.

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6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan
horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely
drain the oil from the shock absorber.

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Shock Absorber Replacement

3. Support the lower control arm with a jack stand.

4. Disconnect the automatic level control air tube from the shock absorber.
5. Remove the lower shock absorber retaining bolts.
6. Remove the trunk trim to gain access to the shock upper mounting nuts.

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7. Remove the cover, the 2 nuts, and the reinforcement from the top of the shock.

8. Remove the shock from the vehicle.

Installation Procedure

1. Install the shock absorber to the vehicle.

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2. Install the shock reinforcement, and the retaining nuts.

Tighten
Tighten the shock absorber upper retaining nuts to 20 N·m (15 lb ft).

3. Install the shock cover.

4. Install the trunk trim.

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5. Install the shock absorber lower retaining bolts.

Tighten
Tighten the shock absorber lower retaining bolts to 24 N·m (18 lb ft).

6. Connect the automatic level control air tube to the shock.

7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
8. Lower the vehicle.

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Stabilizer Shaft Insulator Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the stabilizer shaft link assembly bolt and nut.

3. Remove the retainer and insulators from the control arm.

4. Remove the stabilizer shaft clamp bolt.

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5. Bend the open end of the clamp upward.

6. Remove the stabilizer shaft and insulators.

Installation Procedure

1. Install the stabilizer shaft and insulators. Install the insulator into the clamp with slit forward.

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2. Bend the stabilizer shaft bend link downward to close around the insulator. Ensure that the
stabilizer shaft is centered and install the clamp bolt.

3. Install the link assembly insulators, retainers and the support bolt and nut.

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Tighten
• Tighten the link assembly nut and bolt to 15 N·m (11 lb ft).
• Tighten the clamp bolt to 33 N·m (24 lb ft).
4. Lower the vehicle.

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Stabilizer Shaft Link Replacement

Removal Procedure

1. Raise the vehicle and support by the frame allowing the control arms to hang free. Refer to
Lifting and Jacking the Vehicle in General Information.
2. Remove the stabilizer link bolts.
3. Remove the stabilizer link.

Installation Procedure

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1. Loosely install the stabilizer link insulators, washers, nut and bolt.

Tighten
Tighten the stabilizer link nut to 17 N·m (13 lb ft).

2. Lower the vehicle.

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Stabilizer Shaft Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Remove the automatic level control height sensor link from the control arm (2).
• The stabilizer shaft link assembly bolt (7)
• The nut (13)
• The retainers (8, 11)
• The sleeve (10)
• The insulators (9, 12)
3. Remover the clamp bolt (6). Bend the open end of the clamp (5) upward.
4. Remove the stabilizer shaft (4) and the insulator (3).

Installation Procedure

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1. Install the stabilizer shaft (4) and the insulator (3).

2. Install the insulator (3) into the clamp (5) with the slit forward.
3. Bend the link downward to close around the insulator. Center the stabilizer shaft (4).
4. Install the clamp bolt (6).
5. Install the link assembly insulators (9, 12), the sleeve (10), and the retainers (8, 11).

6. Install the support bolt (7) and the nut (13).

Tighten
• Tighten the link assembly bolt (7) to 15 N·m (11 lb ft).
• Tighten the clamp bolt (6) to 33 N·m (24 lb ft).
7. Install the height sensor link to the control arm (2).
8. Lower the vehicle.

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Support Replacement
Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
4. Remove the coil springs. Refer to Coil Spring Replacement .
5. Remove the brake calipers and support. Refer to Rear Brake Caliper Replacement in Disc
Brakes.
6. Disconnect the wheel speed sensor electrical connector from each wheel.

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7. Release the park brake cable from brake calipers.

8. Loosen the parking brake cable (1) and then disconnect the cable at the rear suspension
support assembly.

9. Disconnect the electrical connectors from the support assembly.

10. Remove the automatic level control electrical connector and vent hose.
11. Disconnect the automatic level control link from the left and right control arm.
12. Remove the automatic level control vent tube from the electronic level control compressor.
13. Support the rear suspension support assembly with a transmission jack.

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14. Remove the support bracket retaining bolts.

15. Remove the front and rear mounting bolts securing the support assembly to the body.
16. Lower transmission jack and remove the support assembly.

Installation Procedure
1. Raise and support the rear support into position

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2. Install the support brackets at the forward support assembly mounts.

3. Install the forward mount bracket bolts. Do not tighten at this time.

4. Install rear and front bolts at the mounts.

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Tighten
• Tighten the front support assembly bolts to 191 N·m (141 lb ft).
• Tighten the rear support assembly bolts 191 N·m (141 lb ft).
• Tighten the support bracket bolts to 86 N·m (63 lb ft).

5. Connect the automatic level control air tube to the automatic level control compressor.
6. Connect the automatic level control electrical connector and vent tube.
7. Connect the electrical connectors to the support assembly.
8. Connect the automatic level control links to both control arms.

9. Attach the parking brake cable at the support assembly.

10. Install the parking brake cable (1) to the brake calipers.
11. Install the brake calipers. Refer to Rear Brake Caliper Replacement in Disc Brakes.
12. Install the coil springs. Refer to Coil Spring Replacement .

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13. Install the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
14. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
15. Lower the vehicle.

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Wheel Stud Replacement

Tools Required
J 35917 Ball Joint Remover

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
4. Using J 35917 press the wheel stud from the wheel bearing and hub assembly.

Installation Procedure

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1. Install the new stud from the back side of the hub.
2. Install flat washers (1) on the wheel stud (2).

Important: Ensure that the wheel stud is fully seated against the wheel hub flange.

3. With the flat side of a wheel nut against the washers, tighten the wheel nut until the wheel
stud head seats against the wheel hub flange.
4. Install the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
6. Lower the vehicle.

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Fastener Tightening Specifications

Specification
Application Metric English
Child Tether Anchor Fastener 30 N·m 22 lb ft
Lap Retractor Fastener 35 N·m 26 lb ft
Lower Seat Belt Fastener - Rear Seat Center 41 N·m 30 lb ft
Lower Seat Belt Fastener - Rear Seat Outer 41 N·m 30 lb ft
Seat Belt Buckle Fasteners - Front Seat 41 N·m 30 lb ft
Seat Belt Buckle Fasteners - Rear Seat 26 N·m 19 lb ft
Shoulder Belt Fastener - Rear Seat Center 41 N·m 30 lb ft
Shoulder Belt Retractor Fastener - Front Seat 35 N·m 26 lb ft
Shoulder Belt Retractor Fastener - Rear Seat 41 N·m 30 lb ft
Shoulder Belt Retractor Fastener - Rear Seat Center 30 N·m 22 lb ft

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Seat Belt Schematics

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Seat Belt Component Views

Left Front of the Passenger Compartment, Side of the
Seat

(1) Seat Belt Switch -- LF

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Seat Belt Connector End Views

Seat Belt Switch -- LF

• 12047663
Connector Part Information
• 2-Way M Metri - Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU 1363 Left Seat Belt Switch Low Reference
B BLK/WHT 238 Left Seat Belt Switch Signal

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Child Restraint Tether Anchor

Removal Procedure
1. Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .

2. Remove the rear shelf trim panel carrier. Refer to Rear Shelf Trim Panel Carrier
Replacement .

3. Remove the fasteners from the child tethor anchors.

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Installation Procedure

1. Install the child tethor anchors to the vehicle.

2. Install the child tether anchor fasteners.

Tighten
Tighten the fastener to 30 N·m (22 lb ft).

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3. Install the rear shelf trim panel carrier. Refer to Rear Shelf Trim Panel Carrier Replacement .
4. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement .

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Driver or Passenger Seat Belt Buckle Replacement

Removal Procedure
Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the front seat assembly. Refer to Bucket Seat Replacement in Seats.
2. Remove the seat adjuster track cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement in Seats.
3. Disconnect the electrical connector from the buckle.

4. Remove the fastener securing the buckle to the seat frame.

5. Remove the buckle assembly.

Installation Procedure

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1. Install the buckle assembly.

2. Install the fastener.

Tighten
Tighten the fastener to 26 N·m (19 lb ft).

3. Connect the electrical connector to the buckle.

4. Install the seat adjuster track cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement in Seats.
5. Install the seat assembly. Refer to Bucket Seat Replacement in Seats.

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Front Seat Belt Replacement

Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to
follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or near
the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable the
SIR system. Refer to Disabling the SIR System.

Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the front seat. Refer to Bucket Seat Replacement in Seats.

2. Remove the seat belt tower rear trim cover by inserting a small rounded tool in the access
hole in order to release the retainer.

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3. Remove the seat belt tower front trim cover fasteners (1).

4. Remove the front seat back cover and pad enough to expose the shoulder belt retractor
fastener (1). Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement in Seats.
5. Remove the shoulder belt retractor fastener (1).
6. Remove the shoulder belt retractor.
7. Remove the seat adjuster track cover . Refer to Front Seat Adjuster Track Finish Cover
Replacement in Seats.

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8. Remove the lap retractor fastener (3).

9. Remove the lap belt retractor.

Installation Procedure

1. Install the lap belt retractor over the stud. Align the tab on the retractor with the notch in the
seat frame.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the lap belt retractor fastener (3).

Tighten
Tighten the fastener (3) to 35 N·m (26 lb ft).

3. Install the seat adjuster track cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement in Seats.

4. Install the shoulder belt retractor over the stud. Align the tab on the retractor with the notch
in the seat back frame.
5. Ensure the seat belt is not twisted.
6. Install the shoulder retractor fastener (1).

Tighten
Tighten the fasteners to 35 N·m (26 lb ft).

7. Install the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement in Seats.

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8. Install the seat belt tower front trim cover fastener (1).

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

9. Install seat belt tower rear cover.

10. Install the front seat. Refer to Bucket Seat Replacement in Seats.

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Rear Seat Belt Buckle Replacement

Removal Procedure
Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

2. Remove the rear seat belt buckle anchor fasteners.

3. Slide the rear seat belt buckle anchor plate out from under the rear seat back hold-down.
4. Remove the rear seat belt buckles.

Installation Procedure

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1. Install the rear seat belt buckle anchor plate under the rear seat back hold-down.

Important: Assure that the fastener threads and fastener hole are free of any sealer patch
material.

2. Install the rear seat belt buckle anchor fasteners.

Tighten
Tighten the rear seat belt buckle anchor fasteners to 41 N·m (32 lb ft).

3. Insert the seat belt buckles into the seat back pockets.
4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Rear Seat Belt Replacement

Removal Procedure
Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
2. Remove the center shoulder belt anchor and right side buckle fastener.
3. Remove the left side seat buckle fastener.
4. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.

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5. Remove the rear seat belt anchor fasteners from the floor.
6. Remove the rear quarter trim panels. Refer to Rear Quarter Upper Trim Panel Replacement .
7. Remove the rear shelf trim panel Refer to Rear Window Shelf Trim Panel Replacement .

8. Remove the rear seat back retractor fastener.

9. Remove the rear seat belt retractor.

Installation Procedure
1. Install the rear seat belt retractor.

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2. Install the rear seat belt retractor fastener.

Tighten
Tighten the fastener to 41 N·m (30 lb ft).

3. Install the rear seat belt anchor fastener to the floor.

Tighten
Tighten the anchor fastener to 41 N·m (30 lb ft).

4. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
5. Install the rear quarter trim panels. Refer to Rear Quarter Upper Trim Panel Replacement in
Interior Trim.

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6. Install the rear seat back . Refer to Rear Seat Back Replacement in Seats.
7. Install the center shoulder belt anchor and right and left buckle fasteners.

Tighten
Tighten the center shoulder belt anchor and buckle fasteners to 41 N·m (30 lb ft).

8. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Rear Seat Center Retractor Side Belt Replacement

Removal Procedure
Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

2. Remove the rear center shoulder belt anchor fastener.

3. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.

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4. Release the push-in retainers securing the rear shelf trim (1).

5. Release the center shoulder belt escutcheon by prying upward on the front corner.

6. Carefully lift up-ward on the rear shelf trim enough to expose the retractor fastener (2) .
7. Remove the fastener (2).
8. Remove the rear compartment front trim panel. Refer to Rear Compartment Trim Panel
Replacement in Body Rear End.
9. Remove the retractor through the rear compartment.
10. Feed the center shoulder belt and escutcheon through the hole in the rear shelf trim panel.

Installation Procedure
1. From the rear compartment, feed the rear seat center shoulder belt and escutcheon through
opening in the rear shelf trim panel.

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2. Install the retractor to the cross brace.

3. Carefully lift upward on the rear shelf trim panel.

4. From inside the vehicle, install the rear seat center shoulder retractor fastener (2).

Tighten
Tighten the rear seat center shoulder belt retractor fastener (2) to 30 N·m (22 lb ft).

5. Install the push-in fastener (1) in order to secure the rear shelf trim panel.

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6. Install the rear seat center belt escutcheon to the rear shelf opening.
7. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.

Important: Ensure that the fastener threads and fastener hole are free of any sealer patch
material.

8. Install the rear center seat belt lower fastener.

9. Ensure the seat belt anchor is facing forward and the seat belt is not twisted.

Tighten
Tighten the rear center seat belt lower fastener to 41 N·m (30 lb ft).

10. Install the rear compartment front trim. Refer to Rear Compartment Trim Panel Replacement

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in Body Rear End.

11. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Repairs and Inspections Required After a Collision

Caution: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all
parts in need of replacement are replaced:
• Replace any seat belt system that was in use during the collision serious enough to deploy
any automatic restraint device such as air bags and seat belt pretensioners. This not only
includes seat belt systems in use by people of adult size, but seat belt systems used to secure
child restraints, infant carriers and booster seats, including LATCH system and top tether
anchorages.
• Replace any seat belt system that has torn, worn, or damaged components. This not only
includes adult seat belt systems, but built-in child restraints and LATCH system components,
if any.
• Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a
yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible.
• Replace any seat belt system if you are doubtful about its condition. This not only includes
adult seat belt systems, but built-in child restraints, LATCH system components, and any
restraint system used to secure infant carriers, child restraints, and booster seats.
Do NOT replace single seat belt system components in vehicles that have been in a collision as
described above. Always replace the entire seat belt system with the buckle, guide and retractor
assembly, which includes the latch and webbing material.

After a minor collision where no automatic restraint device was deployed, seat belt system
replacement may not be necessary, unless some of the parts are torn, worn, or damaged.

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Seat Belt Latch Stop Installation

Callout Component Name

Preliminary Procedure
1. Locate the hole in the seat belt webbing where the original seat belt stop button was
located.
2. If the original hole in the seat belt webbing is not visible, perform the following:
• If either the right or left stop button is missing use the opposing seat belt as a
reference.
• With the opposing seat belt fully stowed, measure the distance between the seat
belt lower anchor and the stop button.
• Using the measurement obtained above, measure and mark the location of the
missing stop button on the center of the seat belt webbing.
3. Ensure the seat belt latch plate is located above the mark or original hole.

Seat Belt Stop Button

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2. Align the female half of the stop button with the male half of the stop button.
3. Snap the two halves together.
4. Trim off any access of the male half of the stop button flush with the female
half of the stop button.
1
Tip
Ensure the male half of the stop button is facing forward in the vehicle in order to
ensure the stop button will not snag customers clothing.

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Seat Belt Replacement - Center Rear

Removal Procedure
Notice: Refer to Servicing and Replacing Seat Belts Notice in the Preface section.

1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

2. Remove the center rear seat belt anchor fastener.

3. Slide the center rear seat belt anchor plate out from under the rear seat back hold-down.
4. Remove the center rear seat belt from the vehicle.

Installation Procedure

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1. Install the center rear seat belt anchor plate under the rear seat back hold-down.
2. Ensure the center rear shoulder belt is not twisted.

Important: Assure that the fastener threads and fastener hole are free of any sealer patch
material.

3. Install the center rear seat belt anchor fastener.

Tighten
Tighten the center rear seat belt anchor fastener to 41 N·m (32 lb ft).

4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.

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Fastener Tightening Specifications

Specification
Application Metric English
Front Seat Adjuster Reinforcement Bracket Fasteners 9 N·m 80 lb in
Front Seat Adjuster Track Cover Fasteners 2 N·m 18 lb in
Front Seat Adjuster Track Reinforcement Bracket Fasteners 50 N·m 37 lb ft
Front Seat Anchor Fasteners 30 N·m 22 lb ft
Front Seat Back Frame Fasteners 28 N·m 21 lb ft
Front Seat Back Recliner Fasteners 50 N·m 37 lb ft
Front Seat Back Recliner Handle Fasteners 2 N·m 18 lb in
Front Seat Cushion Fasteners 9 N·m 80 lb in
Heated Seat Module Fasteners 2 N·m 18 lb in
Memory Seat Module Fasteners 2 N·m 18 lb in
Rear Seat Armrest Fasteners 5 N·m 44 lb in
Rear Seatback Fasteners 41 N·m 30 lb ft
Replacement Seat Motor Bolts 4 N·m 36 lb in

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Driver Seat Lumbar (w/ A45)

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Driver Seat Recline Motor and Sensor

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Driver Seat Vertical and Horizontal Motors and Sensors

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Front Heated Seats (Partial)

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LH Heated Seat Switch

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LH Seat Switch and Motors (w/AG1, A80)

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Lumbar Support (w/o A45)

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Memory Function Switch

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Power, Ground, Driver Seat Adjuster Switch and MSM

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RH Heated Seat Switch

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RH Seat Switch amd Motors (w/AG2, A81, AL2)

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Power Seat Connector End Views

Table 1: Heated Seat Back Element-Driver
Table 2: Heated Seat Back Element-Front Passenger
Table 3: Heated Seat Cushion Element-Driver
Table 4: Heated Seat Cushion Element-Front Passenger
Table 5: Heated Seat Module (C1)-Driver (w/AG1,A80,KA1)
Table 6: Heated Seat Module (C2)-Driver (w/AG1,A80,KA1)
Table 7: Heated Seat Module (C1)-Front Passenger (w/AG2,A81,KA1)
Table 8: Heated Seat Module (C2)-Front Passenger (w/AG1,A80,KA1)
Table 9: Heated Seat Switch-Driver
Table 10: Heated Seat Switch-Front Passenger
Table 11: Memory/Personalization Function Switch
Table 12: Memory Seat Module (C1)-Driver (w/A45)
Table 13: Memory Seat Module (C2)-Driver (w/A45)
Table 14: Memory Seat Module (C3)-Driver (w/A45)
Table 15: Seat Adjuster Switch-Driver (w/AG1)
Table 16: Seat Adjuster Switch-Driver (w/AG1 and A80)
Table 17: Seat Adjuster Switch-Driver (w/AG1, A80 and A45)
Table 18: Seat Adjuster Switch-Front Passenger (w/AG2)
Table 19: Seat Adjuster Switch-Front Passenger (w/AG2 and A81)
Table 20: Seat Front Vertical Motor-Driver
Table 21: Seat Front Vertical Position Sensor-Driver (w/A45)
Table 22: Seat Horizontal Motor-Driver
Table 23: Seat Horizontal Motor-Front Passenger
Table 24: Seat Horizontal Position Sensor-Driver (w/A45)
Table 25: Seat Lumbar Horizontal Motor-Driver
Table 26: Seat Lumbar Horizontal Motor-Front Passenger
Table 27: Seat Lumbar Horizontal Position Sensor-Driver
Table 28: Seat Lumbar Switch-Driver (w/A45 and AL9)
Table 29: Seat Lumbar Switch-Front Passenger
Table 30: Seat Lumbar Vertical Motor-Driver
Table 31: Seat Lumbar Vertical Motor-Front Passenger
Table 32: Seat Lumbar Vertical Position Sensor-Driver
Table 33: Seat Rear Vertical Motor-Driver
Table 34: Seat Rear Vertical Motor-Front Passenger
Table 35: Seat Rear Vertical Position Sensor-Driver (w/A45)
Table 36: Seat Recline Motor-Driver (w/A45)
Table 37: Seat Recline Motor-Driver (w/AG1)
Table 38: Seat Recline Motor-Front Passenger
Table 39: Seat Recline Position Sensor-Driver (w/A45)
Table 40: Seat Recline Switch-Front Passenger
© 2014 General Motors Corporation. All rights reserved.

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Table 41: Seat Vertical Motor-Front Passenger

Heated Seat Back Element-Driver

• 12059249
Connector Part Information
• 2-Way F Micro-Pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A BLK -- Heater Control
B BLK -- Controlled Ground

Heated Seat Back Element-Front Passenger

• 12059249
Connector Part Information
• 2-Way F Micro-Pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A BLK -- Heater Control
B BLK -- Controlled Ground

Heated Seat Cushion Element-Driver

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• 12059253
Connector Part Information
• 2-Way F Micro-Pack 150 Series (LT GRN)
Pin Wire Color Circuit No. Function
A BLK -- Temperature Sensor Signal
B BLK -- Ground

Heated Seat Cushion Element-Front Passenger

• 12059253
Connector Part Information
• 2-Way F Micro-Pack 150 Series (LT GRN)
Pin Wire Color Circuit No. Function
A BLK -- Temperature Sensor Signal
B BLK -- Ground

Heated Seat Module (C1)-Driver (w/AG1,A80,KA1)

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Connector Part • 12064769

Information • 10-Way F Metri-Pack 150 Series (NAT)
Circuit
Pin Wire Color No. Function
A ORN 2440 Battery Positive Voltage
B BRN 41 Ignition 3 Voltage
C LT BLU/WHT 181 Heated Seat Control Module Status Signal
D PNK 1501 Driver Heated Seat High/Low Signal
E -- -- Not Used
F LT BLU 2179 Driver Heated Seat Off Signal
G YEL 182 Heated Seat Control Module Enable Signal
Heated Seat Low Temperature Indicator Supply
H BRN 1463
Voltage
J DK BLU 1461 Heated Seat Indicator Supply Voltage
K BLK 650 Ground

Heated Seat Module (C2)-Driver (w/AG1,A80,KA1)

Connector Part Information • 12177194

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• 10-Way F Metri-Pack 150 Series (NAT)

Pin Wire Color Circuit No. Function
A RED -- Heater Control
B -- -- Not Used
C BLK -- Controlled Ground
D PNK -- Ground
E -- -- Not Used
F GRY -- Temperature Sensor Signal

Heated Seat Module (C1)-Front Passenger

(w/AG2,A81,KA1)

Connector Part • 12064769

Information • 10-Way F Metri-Pack 150 Series (NAT)
Circuit
Pin Wire Color No. Function
A ORN 2540 Battery Positive Voltage
B BRN 41 Ignition 3 Voltage
C LT BLU/WHT 181 Heated Seat Control Module Status Signal
D PNK/BLK 1503 Passenger Heated Seat High/Low Signal
E -- -- Not Used
F ORN/BLK 2180 Passenger Heated Seat Off Signal
G YEL 182 Heated Seat Control Module Enable Signal
Passenger Heated Seat Low Temperature Indicator
H BRN/WHT 1506
Supply Voltage
J DK BLU/WHT 1504 Passenger Heated Seat Indicator Supply Voltage
K BLK 650 Ground

Heated Seat Module (C2)-Front Passenger

(w/AG1,A80,KA1)

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• 12177194
Connector Part Information
• 10-Way F Metri-Pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A RED -- Heater Control
B -- -- Not Used
C BLK -- Controlled Ground
D PNK -- Ground
E -- -- Not Used
F GRY -- Temperature Sensor Signal

Heated Seat Switch-Driver

Connector Part • 12064993

Information • 6-Way F Micro-Pack 100 Series (BLK)
Circuit
Pin Wire Color No. Function
Heated Seat Low Temperature Indicator Supply
5 BRN 1463
Voltage

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6 DK BLU 1461 Heated Seat Indicator Supply Voltage

7 PNK 1501 Driver Heated Seat High/Low Signal
8 BLK 450 Ground
9 YEL 1491 Backlight Lamps Control
10 LT BLU 2179 Driver Heated Seat Off Signal

Heated Seat Switch-Front Passenger

Connector Part • 12064993

Information • 6-Way F Micro-Pack 100 Series (BLK)
Circuit
Pin Wire Color No. Function
Passenger Heated Seat Low Temperature Indicator
5 BRN/WHT 1506
Supply Voltage
6 DK BLU/WHT 1504 Passenger Heated Seat Indicator Supply Voltage
7 PNK/BLK 1503 Passenger Heated Seat High/Low Signal
8 BLK 450 Ground
9 YEL 1491 Backlight Lamps Control
10 ORG/BLK 2180 Passenger Heated Seat Off Signal

Memory/Personalization Function Switch

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• 12092162
Connector Part Information
• 4-Way F Micro-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A WHT 615 Memory 1 Switch Signal
B PPL 616 Memory 2 Switch Signal
C BLK/WHT 351 Ground
D YEL 1491 Backlight Lamps Control

Memory Seat Module (C1)-Driver (w/A45)

• 12064749
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A ORN 3740 Battery Positive Voltage
B BLK 650 Ground

Memory Seat Module (C2)-Driver (w/A45)

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Connector Part • 12110114

Information • 32-Way F Micro-Pack 100 Series (WHT)
Circuit
Pin Wire Color Function
No.
C1 DK GRN 1518 Power Seat Front Vertical Up Switch Signal
C2 YEL 1519 Power Seat Rear Vertical Up Switch Signal
C3 DK BLU 1520 Power Seat Front Vertical Down Switch Signal
C4 LT BLU 1521 Power Seat Rear Vertical Down Switch Signal
C5 TAN 1522 Power Seat Horizontal Forward Switch Signal
C6 LT GRN 1523 Power Seat Horizontal Rearward Switch Signal
C7 LT GRN 276 Driver Seat Recline Motor Forward Control
C8 LT BLU 277 Driver Seat Recline Motor Rearward Control
C9 DK BLU 1064 Driver Seat Lumbar Rearward Switch Signal
C10 YEL 1065 Driver Seat Lumbar Forward Switch Signal
C11 WHT 1066 Driver Seat Lumbar Up Switch Signal
C12 YEL/BLK 1067 Driver Seat Lumbar Down Switch Signal
C13 GRY 788 5 Volt Reference
C14 BRN/WHT 557 Front Vertical Seat Motor Position Sensor Signal
C15 BLK 782 Memory Seat/Mirror Sensor Low Reference
C16 DK GRN 569 Horizontal Seat Motor Position Sensor Signal
D1 TAN 568 Rear Vertical Seat Motor Position Sensor Signal
D2 WHT/BLK 570 Driver Seat Recline Motor Position Sensor Signal
Driver Seat Lumbar Horizontal Position Sensor
D3 YEL 1063
Signal
Driver Seat Lumbar Vertical Position Sensor
D4 BLK 1062
Signal
D5-D10 -- -- Not Used
D11 ORN 2840 Battery Positive Voltage
D12-D13 -- -- Not Used
D14 PPL 1807 Class 2 Serial Data
D15 PPL 1807 Class 2 Serial Data
D16 -- -- Not Used

Memory Seat Module (C3)-Driver (w/A45)

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• 12129432
Connector Part Information
• 16-Way F Metri-Pack 280 Series ACT (GRY)
Pin Wire Color Circuit No. Function
A DK GRN 286 Driver Seat Front Vertical Motor Up Control
B DK BLU 611 Driver Seat Lumbar Motor Forward Control
C TAN 768 Driver Seat Lumbar Motor Up Control
D-E -- -- Not Used
F LT GRN 276 Driver Seat Recline Motor Forward Control
G LT BLU 277 Driver Seat Recline Motor Rearward Control
H-J -- -- Not Used
K PPL 767 Driver Seat Lumbar Motor Down Control
L PNK 610 Driver Seat Lumbar Motor Rearward Control
M DK BLU 287 Driver Seat Front Vertical Motor Down Control
N TAN 285 Driver Seat Horizontal Motor Forward Control
P YEL 282 Driver Seat Rear Vertical Motor Up Control
R LT BLU 283 Driver Seat Rear Vertical Motor Down Control
S LT GRN 284 Driver Seat Horizontal Motor Rearward Control

Seat Adjuster Switch-Driver (w/AG1)

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• 12064998
Connector Part Information
• 8-Way F Metri-Pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A DK GRN 286 Driver Seat Front Vertical Motor Up Control
B DK BLU 287 Driver Seat Front Vertical Motor Down Control
C YEL 282 Driver Seat Rear Vertical Motor Up Control
D LT BLU 283 Driver Seat Rear Vertical Motor Down Control
E BLK 650 Ground
F LT GRN 284 Driver Seat Horizontal Motor Rearward Control
G TAN 285 Driver Seat Horizontal Motor Forward Control
H ORN 3740 Battery Positive Voltage

Seat Adjuster Switch-Driver (w/AG1 and A80)

• 15326110
Connector Part Information
• 12-Way F 280 GT Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 277 Driver Seat Recline Motor Rearward Control
B LT GRN 276 Driver Seat Recline Motor Forward Control
C BLK 650 Ground
D LT GRN 284 Driver Seat Horizontal Motor Rearward Control
E TAN 285 Driver Seat Horizontal Motor Forward Control
F ORN 3740 Battery Positive Voltage
G-H -- -- Not Used
J LT BLU 283 Driver Seat Rear Vertical Motor Down Control
K YEL 282 Driver Seat Rear Vertical Motor Up Control
L DK BLU 287 Driver Seat Front Vertical Motor Down Control

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M DK GRN 286 Driver Seat Front Vertical Motor Up Control

Seat Adjuster Switch-Driver (w/AG1, A80 and A45)

• 15326110
Connector Part Information
• 12-Way F 280 GT Series (BLK)
Pin Wire Color Circuit No. Function
A LT BLU 277 Driver Seat Recline Motor Rearward Control
B LT GRN 276 Driver Seat Recline Motor Forward Control
C -- -- Not Used
D LT GRN 1523 Power Seat Horizontal Rearward Switch Signal
E TAN 1522 Power Seat Horizontal Forward Switch Signal
F ORN 2840 Battery Positive Voltage
G-H -- -- Not Used
J LT BLU 1521 Power Seat Rear Vertical Down Switch Signal
K YEL 1519 Power Seat Rear Vertical Up Switch Signal
L DK BLU 1520 Power Seat Front Vertical Down Switch Signal
M DK GRN 1518 Power Seat Front Vertical Up Switch Signal

Seat Adjuster Switch-Front Passenger (w/AG2)

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Connector Part • 12064998

Information • 8-Way F Metri-Pack 280 Series (BLK)
Circuit
Pin Wire Color No. Function
Passenger Seat Front Vertical Motor Down
A DK BLU 298
Control
B DK GRN 297 Passenger Seat Front Vertical Motor Up Control
C LT BLU 289 Passenger Seat Rear Vertical Motor Down Control
D YEL 288 Passenger Seat Rear Vertical Motor Up Control
E BLK 650 Ground
Passenger Seat Horizontal Motor Rearward
F LT GRN 290
Control
G TAN 296 Passenger Seat Horizontal Motor Forward Control
H ORN 3740 Battery Positive Voltage

Seat Adjuster Switch-Front Passenger (w/AG2 and

A81)

Connector Part • 15326110

Information • 12-Way F 280 GT Series (BLK)
Circuit
Pin Wire Color No. Function
A ORN 3740 Battery Positive Voltage
Passenger Seat Horizontal Motor Rearward
B LT GRN 290
Control
C TAN 296 Passenger Seat Horizontal Motor Forward Control
D BLK 650 Ground
E DK BLU 77 Passenger Seat Recline Motor Rearward
F DK GRN 76 Passenger Seat Recline Motor Forward

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Passenger Seat Front Vertical Motor Down

G DK BLU 298
Control
H DK GRN 297 Passenger Seat Front Vertical Motor Up Control
J LT BLU 289 Passenger Seat Rear Vertical Motor Down Control
K YEL 288 Passenger Seat Rear Vertical Motor Up Control
L--M -- -- Not Used

Seat Front Vertical Motor-Driver

• 12020556
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A DK GRN 286 Driver Seat Front Vertical Motor Up Control
B DK BLU 287 Driver Seat Front Vertical Motor Down Control

Seat Front Vertical Position Sensor-Driver (w/A45)

• 12059584
Connector Part Information
• 4-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function

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A -- -- Not Used
B BLK 782 Memory Seat/Mirror Sensor Low Reference
C BRN/WHT 557 Front Vertical Seat Motor Position Sensor Signal
D GRY 788 5 Volt Reference

Seat Horizontal Motor-Driver

• 12052110
Connector Part Information
• 2-Way F Metri-Pack 480 Series (NAT)
Pin Wire Color Circuit No. Function
A TAN 285 Driver Seat Horizontal Motor Forward Control
B LT GRN 284 Driver Seat Horizontal Motor Rearward Control

Seat Horizontal Motor-Front Passenger

Connector Part • 12052110

Information • 2-Way F Metri-Pack 480 Series (NAT)
Circuit
Pin Wire Color No. Function
A TAN 296 Passenger Seat Horizontal Motor Forward Control

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Passenger Seat Horizontal Motor Rearward

B LT GRN 290
Control

Seat Horizontal Position Sensor-Driver (w/A45)

• 12059583
Connector Part Information
• 4-Way F Metri-Pack 150 Series (NAT)
Pin Wire Color Circuit No. Function
A BLK 782 Memory Seat/Mirror Sensor Low Reference
B -- -- Not Used
C DK GRN 569 Horizontal Seat Motor Position Sensor Signal
D GRY 788 5 Volt Reference

Seat Lumbar Horizontal Motor-Driver

• 12020556
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU 611 Driver Seat Lumbar Motor Forward Control
B WHT 610 Driver Seat Lumbar Motor Rearward Control

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Seat Lumbar Horizontal Motor-Front Passenger

• 12020556
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU/WHT 211 Passenger Seat Lumbar Motor Forward Control
B PNK/BLK 210 Passenger Seat Lumbar Motor Rearward Control

Seat Lumbar Horizontal Position Sensor-Driver

Connector Part • 15976041

Information • 4-Way M Molex
Circuit
Pin Wire Color No. Function
1 LT BLU 782 Memory Seat/Mirror Sensor Low Reference
2 -- -- Not Used
Driver Seat Lumbar Horizontal Position Sensor
3 RED 1063
Signal
4 BRN 788 5 Volt Reference

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Seat Lumbar Switch-Driver (w/A45 and AL9)

• 12052854
Connector Part Information
• 7-Way F Metri-Pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU 1064 Driver Seat Lumbar Rearward Switch Signal
B WHT 1066 Driver Seat Lumbar Up Switch Signal
C YEL/BLK 1067 Driver Seat Lumbar Down Switch Signal
D-E -- -- Not Used
F YEL 1065 Driver Seat Lumbar Forward Switch Signal
G ORN 2840 Battery Positive Voltage

Seat Lumbar Switch-Front Passenger

• 12052854
Connector Part Information
• 7-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A WHT 210 Passenger Seat Lumbar Motor Rearward Control
B ORN 792 Passenger Seat Lumbar Motor Down Control

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C PNK 793 Passenger Seat Lumbar Motor Up Control

D -- -- Not Used
E BLK 650 Ground
F DK BLU 211 Passenger Seat Lumbar Motor Forward Control
G ORN 3740 Battery Positive Voltage

Seat Lumbar Vertical Motor-Driver

• 12020556
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A PNK 768 Driver Seat Lumbar Motor Up Control
B ORN 767 Driver Seat Lumbar Motor Down Control

Seat Lumbar Vertical Motor-Front Passenger

• 12020556
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLK)
Pin Wire Color Circuit No. Function

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A TAN/WHT 793 Passenger Seat Lumbar Motor Up Control

B PPL/WHT 792 Passenger Seat Lumbar Motor Down Control

Seat Lumbar Vertical Position Sensor-Driver

Connector Part • 15976041

Information • 4-Way M Molex
Circuit
Pin Wire Color No. Function
1 BRN 788 5 Volt Reference
2 -- Not Used
Driver Seat Lumbar Vertical Position Sensor
3 ORN 1062
Signal
4 LT BLU 782 Memory Seat/Mirror Sensor Low Reference

Seat Rear Vertical Motor-Driver

• 12052109
Connector Part Information
• 2-Way F Metri-Pack 480 Series (BLU)
Pin Wire Color Circuit No. Function

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A LT BLU 283 Driver Seat Rear Vertical Motor Down Control

B YEL 282 Driver Seat Rear Vertical Motor Up Control

Seat Rear Vertical Motor-Front Passenger

Connector Part • 12052109

Information • 2-Way F Metri-Pack 480 Series (BLU)
Circuit
Pin Wire Color No. Function
Passenger Seat Rear Vertical Motor Down
A LT BLU 289
Control
B YEL 288 Passenger Seat Rear Vertical Motor Up Control

Seat Rear Vertical Position Sensor-Driver (w/A45)

• 12059582
Connector Part Information
• 4-Way F Metri-Pack 150 Series (BLU)
Pin Wire Color Circuit No. Function
A BLK 782 Memory Seat/Mirror Sensor Low Reference
B TAN 568 Rear Vertical Seat Motor Position Sensor Signal

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C -- -- Not Used
D GRY 788 5 Volt Reference

Seat Recline Motor-Driver (w/A45)

• 12129081
Connector Part Information
• 2-Way F Metri-Pack 280 Series Flex Lock (BLK)
Pin Wire Color Circuit No. Function
A LT GRN/BLK 276 Driver Seat Recline Motor Forward Control
B LT BLU/BLK 277 Driver Seat Recline Motor Rearward Control

Seat Recline Motor-Driver (w/AG1)

• 12129081
Connector Part Information
• 2-Way F Metri-Pack 280 Series Flex Lock (BLK)
Pin Wire Color Circuit No. Function
A LT GRN 276 Driver Seat Recline Motor Forward Control
B LT BLU 277 Driver Seat Recline Motor Rearward Control

Seat Recline Motor-Front Passenger

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• 12129081
Connector Part Information
• 2-Way F Metri-Pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A DK BLU 77 Passenger Seat Recline Motor Rearward Control
B DK GRN 76 Passenger Seat Recline Motor Forward Control

Seat Recline Position Sensor-Driver (w/A45)

• 12047781
Connector Part Information
• 3-Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A GRY 788 5 Volt Reference
B WHT/BLK 570 Driver Seat Recline Motor Position Sensor Signal
C BLK 782 Memory Seat/Mirror Sensor Low Reference

Seat Recline Switch-Front Passenger

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• 12041429
Connector Part Information
• 5-Way F Metri-Pack 280 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 650 Ground
B DK GRN 76 Passenger Seat Recline Motor Forward Control
C BLK 650 Ground
D ORN 3740 Battery Positive Voltage
E DK BLU 77 Passenger Seat Recline Motor Rearward Control

Seat Vertical Motor-Front Passenger

Connector Part • 12020556

Information • 2-Way F Metri-Pack 480 Series (BLK)
Circuit
Pin Wire Color No. Function
A DK GRN 297 Passenger Seat Front Vertical Motor Up Control
Passenger Seat Front Vertical Motor Down
B DK BLU 298
Control

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Bucket Seat Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Move the seat to the full forward position.

3. Remove the seat track fastener trim cover on the inboard seat track.

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4. Remove the seat track retainer bolts securing the seat to the vehicle.
5. Move the seat to the full rearward position.

6. Remove the front seat track fastener trim covers.

7. Remove the front seat track bolts securing the seat to the vehicle.

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8. With the seat slightly tilted forward, disconnect the electrical connectors.
9. With the aid of an assistant, remove the seat from the vehicle.

Installation Procedure
1. With the aid of an assistant, install the seat into the vehicle.

2. With the seat tilted slightly forward, connect the electrical connectors.

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3. Lower the rear of the seat and install the track retainer fasteners in order to secure the rear
of the seat to the vehicle.

Tighten
Tighten the seat track retainer fasteners to 41 N·m (31 lb ft).

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4. Install the seat fastener trim cover.

5. Position the seat to the full rearward position.

6. Install the seat retainer fasteners in order to secure the front of the seat to the vehicle.

Tighten
Tighten the seat track retainer fasteners to 41 N·m (31 lb ft).

7. Install the seat track retainer fastener trim covers.

8. Reposition the seat.
9. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Driver or Passenger Seat Back Cushion Cover and Pad

Replacement
Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Position the seat cushion out of the way. Refer to Front Seat Cushion Replacement .
3. Remove the head restraint. Refer to Front Seat Head Restraint Replacement .
4. Open the seat back cover zipper from the bottom to the top.
5. Disconnect the double J channel retainer at the bottom of the seat back cover.
6. Remove the inflatable restraint. Refer to Driver and Passenger Seat Side Inflatable Restraint
Module Replacement in SIR.
7. Remove the head restraint retainers. Refer to Front Seat Head Restraint Retainer
Replacement .
8. Remove the shoulder belt retractor. Refer to Front Seat Belt Replacement in Seat Belts.

9. Remove the seat back cover (2) from the seat back pad (1) and the seat back frame.

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10. Remove the seat back pad (2) from the seat back frame (1).

Installation Procedure

1. Install the seat back pad (2) over the seat back frame (1).

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2. Install the seat back cover (2) over the seat back pad (1).
3. Work the foam pad into position so there are no wrinkles or lumps.
4. Ensure the hook and loop fastener on the cover and pad are fully engaged in order to ensure
proper fit of the seat back cover.
5. Install the head restraint retainers. Refer to Front Seat Head Restraint Retainer
Replacement .
6. Install the Inflatable restraint. Refer to Driver and Passenger Seat Side Inflatable Restraint
Module Replacement in SIR.
7. Install the shoulder belt retractor. Refer to Front Seat Belt Replacement in Seat Belts.
8. Connect the double J channel retainer at the bottom of the seat back cover.

9. With the aid of an assistant hold the seat back cover zipper together while closing the zipper
from top to bottom.
10. Install the head restraint. Refer to Front Seat Head Restraint Replacement .
11. Install the seat cushion. Refer to Front Seat Cushion Replacement .

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12. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Driver or Passenger Seat Back Cushion Frame

Replacement
Removal Procedure
Caution: Refer to SIR Handling Caution in the Preface section.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Put the seat back in the full upright position. .
3. Remove the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion
Pad Replacement .
4. Remove the lumbar. Refer to Front Seat Lumbar Support Replacement .

5. Remove the fasteners (3) retaining the seat back frame (1) to the recliner.
6. Lift straight up on the seat back frame (1) in order to disengage the seat back frame from
the recliner.

Installation Procedure

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1. Slide the seat back frame (1) straight down into recliner .

2. Install the seat back frame fasteners (3).

Tighten
Tighten the seat back frame fasteners (3) to 28 N·m (21 lb ft).

3. Install the lumbar. Refer to Front Seat Lumbar Support Replacement .

4. Install the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .
5. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Driver or Passenger Seat Cushion Frame Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the seat cushion. Refer to Front Seat Cushion Replacement .

3. Remove the seat cushion cover (1) and pad (2) from the seat cushion frame (3). Refer to
Front Seat Back Cushion Cover and Cushion Pad Replacement .

Installation Procedure

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1. Install the seat cushion cover (1) and pad (2) onto the seat cushion frame (3). Refer to Front
Seat Back Cushion Cover and Cushion Pad Replacement .
2. Install the seat cushion. Refer to Front Seat Cushion Replacement .
3. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Driver or Passenger Seat Head Restraint Replacement

Removal Procedure
1. Insert a small tool into the access hole in the head restraint retainers (1).

2. Pull straight up on the head restraint in order to remove.

Installation Procedure

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1. Align the head restraint shafts to the holes in the head restraint retainers (1).
2. Slide the head restraint down until fully seated on the top of the seat back.
3. Move the head restraint to the desired position.

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Driver or Passenger Seat Head Restraint Retainer

Replacement
Removal Procedure
1. Remove the head restraint. Refer to Front Seat Head Restraint Replacement .
2. Position the front seat back to the full-up position.
3. Remove the seat back cover enough to gain acess to the head restraint retainers. Refer to
Front Seat Back Cushion Cover and Cushion Pad Replacement .

4. Carefully reach inside the seat back behind the foam cushion and cover.
5. Depress the retaining tabs through the openings (2) in the seat back frame.
6. Grasp the head restraint retainer and pull upward in order to remove the retainer from the
seat back.

Installation Procedure

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1. Position the head restraint retainer to the openings in the seat back frame.
2. Firmly push the head restraint retainer (1) downward until the retaining tabs engage,
securing the retainers to the seat back frame.
3. Install the head restraint. Refer to Front Seat Head Restraint Replacement .
4. Return the seat back to the original position.

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Driver or Passenger Seat Heater Switch Replacement

Removal Procedure

1. Remove the console trim plate. Refer to Console Trim Plate Replacement in Instrument
Panel, Gages and Console.
2. Disconnect the electrical connector.
3. Remove the switch fastener from the underside of the console trim plate.
4. Remove the heated seat switch from the console trim plate.

Installation Procedure

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1. Install the heated seat switch into the console trim plate.
2. Install the fastener.
3. Install the electrical connectors.
4. Install the console trim plate. Refer to Console Trim Plate Replacement in Instrument Panel,
Gages and Console.

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Driver or Passenger Seat Recliner Replacement

(Manual)
Removal Procedure
1. Position the seat to the full forward position.
2. Remove the seat. Refer to Bucket Seat Replacement .
3. Remove the seat cushion. Refer to Front Seat Cushion Replacement .
4. Disconnect the lumbar electrical connector, if equipped.
5. Remove the manual seat recliner handle.
6. Remove the adjuster track covers. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
7. Remove the seat back frame. Refer to Front Seat Back Frame Replacement .
8. Remove the rivets securing the inner seat adjuster track cover.

9. Remove the seat adjuster bracket reinforcement (4) fasteners.

10. Remove the seat adjuster reinforcement bracket (4).
11. Remove the fasteners securing the outboard seat adjuster track reinforcement bracket (3).
12. Remove the outboard seat adjuster track reinforcement bracket (3).
13. Remove the seat back recliner fasteners.
14. Remove the recliner rod (2).
15. Remove the seat back recliner assemblies (1) by sliding the recliners rearwards out of the
seat adjuster tracks.

Installation Procedure

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1. Slide the recliner assemblies (1) into the seat adjuster tracks (5).
2. Install the recliner rod (2).

3. Install the recliner fasteners.

Tighten
Tighten the fasteners to 50 N·m (37 lb ft).

4. Install the seat adjuster reinforcement bracket (4).

5. Install the seat adjuster reinforcement bracket fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

6. Install the outboard seat adjuster track reinforcement bracket (3).

7. Install the reinforcement bracket fasteners.

Tighten
Tighten the fasteners to 50 N·m (37 lb ft).

8. Install the seat back frame. Refer to Front Seat Back Frame Replacement .
9. Connect the lumbar electrical connector, if equipped.
10. Install the adjuster track covers. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
11. Install the manual seat back recliner handle.

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12. Install the manual seat back recliner handle fastener.

Tighten
Tighten the fastener to 2 N·m (18 lb in).

13. Install the seat cushion. Refer to Front Seat Cushion Replacement .
14. Install the seat. Refer to Bucket Seat Replacement .

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Driver or Passenger Seat Recliner Replacement

(Power)
Removal Procedure
1. Position the seat to the full forward position.
2. Remove the front seat. Refer to Bucket Seat Replacement .
3. Remove the seat cushion. Refer to Front Seat Cushion Replacement .
4. Disconnect the lumbar electrical connector.
5. Remove the adjuster track covers. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
6. Remove the seat back frame. Refer to Front Seat Back Frame Replacement .
7. Remove the seat back recliner motor and sensor if equipped. Refer to Front Seat Recliner
Actuator Motor Replacement .

8. Remove the fasteners securing the outboard seat adjuster track reinforcement bracket.
9. Remove the outboard seat adjuster track reinforcement bracket.
10. Remove the seat back recliner fasteners.
11. Remove the recliner assemblies by sliding the recliners rearwards out of the seat adjuster
tracks.

Installation Procedure
1. Slide the recliner assemblies into the seat adjuster tracks.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These
© 2014 coatings
General affect fastener
Motors Corporation. torque
All rights and joint clamping force and
reserved.

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may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the recliner fasteners.

Tighten
Tighten the fasteners to 50 N·m (37 lb ft).

3. Install the outboard seat adjuster track reinforcement bracket.

4. Install the reinforcement bracket fasteners.

Tighten
Tighten the fasteners to 50 N·m (37 lb ft).

5. Install the recliner motor and sensor if equipped. Refer to Front Seat Recliner Actuator Motor
Replacement .
6. Install the seat back frame. Refer to Front Seat Back Frame Replacement .
7. Connect the lumbar electrical connector.
8. Install the adjuster track covers. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
9. Install the seat cushion. Refer to Front Seat Cushion Replacement .
10. Install the front seat. Refer to Bucket Seat Replacement .

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Driver Seat Adjuster Memory Switch Replacement

Removal Procedure

1. Remove the inside handle bezel from the door trim pad. Refer to Door Inside Handle Bezel
Replacement in Doors.
2. Remove the front door switch plate. Refer to Front Door Switch Replacement in Doors.
3. Disconnect the electrical connector for the memory seat switch through the power door
switch opening in the door trim panel.

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4. Remove the memory seat switch from the inside handle bezel by releasing the tabs with a
small flat bladed tool.
5. Gently remove the electrical wiring for the memory seat switch from behind the door trim
panel.

Installation Procedure

1. Snap the memory seat switch to the inside handle bezel.

2. Route the electrical wiring for the memory seat switch behind the door trim panel.
3. Connect the memory seat switch electrical connector.
4. Install the front door switch plate. Refer to Front Door Switch Replacement in Doors.
5. Install the inside handle bezel to the door trim panel. Refer to Door Inside Handle Bezel
Replacement in Doors.

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Front Seat Adjuster Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Remove the front seat. Refer to Bucket Seat Replacement .

2. Remove the front seat cushion. Refer to Front Seat Cushion Replacement .
3. Remove the seat adjuster track covers. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
4. Remove the seat back frame. Refer to Front Seat Back Frame Replacement .
5. Remove the seat back recliners. Refer to Front Seat Recliner Replacement .

Installation Procedure

1. Transfer any remaining seat components to the new adjuster assembly.

• The seat adjuster motors (1, 3, 5)
• The adjuster cables/sensors (2, 4)
• The wiring
• The clips
2. Install the seat back recliners. Refer to Front Seat Recliner Replacement .
3. Install the seat back frame. Refer to Front Seat Back Frame Replacement .
4. Install the front seat cushion. Refer to Front Seat Cushion Replacement .
5. Install the front seat.©Refer to Bucket Seat Replacement .
2014 General Motors Corporation. All rights reserved.

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Front Seat Adjuster Track Finish Cover Replacement

Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.

1. Disable the SIR System. Refer to Disabling the SIR System in SIR.

2. Move the seat to the full forward position.

3. Remove the fasteners (1) securing the seat cushion to the seat adjuster assembly.
4. Lift the front of the seat cushion upwards.
5. Pull the cushion forward in order to disengage the seat cushion from the seat adjuster
assembly.
6. Position the seat cushion out of the way.
7. Remove the seat belt escutcheon from the seat adjuster track cover.

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8. Remove the fasteners that secure the seat adjuster track cover to the seat track.
9. Remove the seat adjuster track cover by lifting upward on the front and rear of the seat
adjuster track cover evenly until the seat adjuster track disengages from the recliner cover.
10. Remove the seat belt through the opening in the seat adjuster track cover.
11. Remove the recliner cover.
11.1. Remove the rivet securing the recliner cover to the recliner.
11.2. Slide the recliner cover rearward in order to release the locks securing the recliner
cover to the adjuster track.

Installation Procedure

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1. Install the recliner cover.

• Align the tabs on the recliner cover to the slots in the bracket.
• Slide the recliner cover forward until the tabs engage, locking the recliner cover to the
bracket.
• Install a new rivet in order to secure the recliner cover to the recliner.
2. Install the seat belt through the opening in the seat adjuster track cover, making sure it is
routed properly and not twisted.

3. Install the seat adjuster track cover to the seat track.

3.1. Align the tabs at the rear of the seat adjuster track cover to the slots in the seat back
recliner cover.
3.2. Firmly push downward on the seat adjuster track cover until the retainer clip engages
into the seat track.
3.3. Install the seat adjuster track cover fasteners.

Tighten
Tighten the fasteners to 2 N·m (9 lb in).

4. Install the seat belt escutcheon to the seat adjuster track cover.
5. Install the seat cushion. Refer to Front Seat Cushion Replacement .
6. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Seat Cushion Cover and Pad Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR System. Refer to Disabling the SIR System in SIR.

2. Move the seat to the full forward position.

3. Remove the fasteners (1) securing the seat cushion to the seat adjuster assembly.
4. Lift the front of the seat cushion upwards.
5. Remove the power seat switch trim bezel. Refer to Power Seat Switch Replacement .
6. Pull the cushion forward in order to disengage the seat cushion from the seat adjuster
assembly.

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7. Release the seat cushion cover J channels from the seat cushion frame.
8. Remove the seat cushion cover (1).
9. Remove the seat cushion pad (2).

Installation Procedure

1. Install the seat cushion pad (2) to the seat cushion frame (3).
2. Install the seat cushion cover (1) over the seat cushion pad (2).
3. Work the cushion pad (2) into position so there are no wrinkles or lumps in the seat cushion
cover.
4. Ensure the hook and loop fasteners on the seat cushion cover and the seat cushion pad are
fully engaged in order to ensure proper fit of the seat cushion cover.

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5. Install the seat cushion cover J channels to the seat cushion frame.
6. Install the power seat switch trim bezel. Refer to Power Seat Switch Replacement .
7. Insert the seat cushion locators, at the rear of the seat cushion frame, into the rectangular
openings in the seat adjuster assembly.
8. Lower the front of the seat cushion down into position onto the seat adjuster assembly.

9. Install the seat cushion fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

10. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Seat Cushion Replacement

Removal Procedure
Caution: Refer to SIR Handling Caution in the Preface section.

1. Disable the SIR System. Refer to Disabling the SIR System in SIR.

2. Move the seat to the full forward position.

3. Remove the fasteners (1) securing the seat cushion to the seat adjuster assembly.
4. Lift the front of the seat cushion upwards.
5. Remove the power seat switches. Refer to Power Seat Switch Replacement

Notice: Refer to Electrical Wiring Routing Notice in the Preface section.

6. Disconnect the wiring harness fastener and retainers securing the wiring harness to the
bottom of the seat cushion frame.
7. Remove the memory seat module from the seat cushion frame, if equipped. Refer to Memory
Seat Control Module Replacement .
8. Pull the cushion forward in order to remove the seat cushion from the seat adjuster
assembly.

Installation Procedure

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1. Insert the seat cushion locators, at the rear of the seat cushion frame, into the rectangular
openings in the seat adjuster assembly.
2. Install the memory seat module to the seat cushion frame, if equipped. Refer to Memory
Seat Control Module Replacement .
3. Secure the wiring harness to the seat cushion frame in the same position in which it was
removed.
4. Install the power seat switches. Refer to Power Seat Switch Replacement .
5. Lower the front of the seat cushion down into position onto the seat adjuster assembly.

6. Install the seat cushion fasteners (1).

Tighten
Tighten the fasteners (1) to 9 N·m (80 lb in).

7. Enable the SIR. Refer to Enabling the SIR System in SIR.

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Front Seat Heater Control Module Replacement

Removal Procedure
Caution: Refer to SIR Handling Caution in the Preface section.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the fasteners securing the seat cushion to the adjuster track. Refer to Front Seat
Cushion Replacement .

3. Lift the front of the seat cushion up in order to gain access to the heated seat module (1).

Notice: Refer to Electrical Wiring Routing Notice in the Preface section.

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4. Disconnect the electrical connectors (3) from the heated seat module.
5. Remove the fasteners (1) securing the heated seat module to the bottom of the seat cushion.
6. Remove the heated seat module (2) from the bottom of the seat cushion.

Installation Procedure

1. Position the heated seat module (2) to the bottom of the seat cushion.

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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.

2. Install the heated seat module fasteners.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

3. Install the electrical connectors (3) to the heated seat module (2).
4. Ensure the wiring harness is positioned in the same location in which it was removed.
5. Install the seat cushion. Refer to Front Seat Cushion Replacement .
6. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Seat Heater Element Replacement

Removal Procedure
Important: ALL of the heating elements in a heated seat MUST be replaced in order for the
heated seat system to function properly.

1. Remove the front seat from the vehicle. Refer to Bucket Seat Replacement .

2. Remove the front seat cushion cover (1). Refer to Front Seat Cushion Cover and Pad
Replacement .

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3. Remove the front seat back cover (2). Refer to Front Seat Back Cushion Cover and Cushion
Pad Replacement .

Important: Do NOT attempt to remove the factory heating element from the front seat
covers.

4. Using a pair of diagonal side cutters, cut the factory heating element wires as close to the
cover as possible.

Installation Procedure
Important: ALL of the heating elements in a heated seat MUST be replaced in order for the
heated seat system to function properly.

1. Install the service heat elements as follows:

1.1. Remove the paper backing.
1.2. Carefully position the replacement heat elements (2,3,4,5,6) harness side down, onto
the seat cushion/back foam pad as indicated.
1.3. Insert the wiring harness through the hole in the foam pad.
1.4. Press the service heat element onto the seat cushion/back foam pad.
1.5. Ensure the heat element is not wrinkled and is laying flat.

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2. Route the heated seat cushion electrical wiring harness as indicated.

3. Install the front seat cushion cover. Refer to Front Seat Cushion Cover and Pad
Replacement .
4. Install the front seat back cover. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .
5. Install the front seat in the vehicle. Refer to Bucket Seat Replacement .

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Front Seat Lumbar Support Replacement (Power)

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Position the seat back to the full upright position.
3. Position the seat cushion out of the way. Refer to Front Seat Cushion Replacement .
4. Remove the seat back cover and pad in order to gain access to the lumbar assembly. Refer
to Front Seat Back Cushion Cover and Cushion Pad Replacement .
5. Lift upward and outward on the inner cardboard panel to remove the panel from the seat.

Notice: Refer to Electrical Wiring Routing Notice in the Preface section.

6.Disconnect the electrical connectors to the lumbar.

7.Note the routing of the wiring for reinstallation.
8.Release the two retainers at the bottom of the lumbar assembly.
9.Pull downward on the lumbar assembly in order to release the lumbar from the seat back
frame.
10. Remove the lumbar assembly from the seat.

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1. Install the power lumbar assembly to the seat back frame.

2. Secure the power lumbar assembly by snapping the retainers onto the bar at the bottom of
the seat back frame.
3. Connect the power lumbar electrical connectors.
4. Install the inner cardboard panel to the seat back frame.
5. Install the seat back cover. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .
6. Install the seat cushion. Refer to Front Seat Cushion Replacement .
7. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Seat Recliner Actuator Motor Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the front seat. Refer to Bucket Seat Replacement .
3. Remove the inner seat adjuster track cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
4. Remove the inner recliner trim cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement .

5. Partially remove the seat back cover and pad in order to gain access to the power recliner
motor. Refer to Front Seat Back Cushion Cover and Cushion Pad Replacement .
6. Remove the cardboard backer from the rear seat back by lifting straight up and out.

Notice: Refer to Electrical Wiring Routing Notice in the Preface section.

7. Disconnect the electrical connectors from the power recliner motor and recliner position
sensor if equipped.

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8. Remove the push-on nut (2) on the end of the recliner rod.
9. Remove the fastener (1) securing the power recliner motor to the seat back frame.

10. Slide the recliner rod (2) out of the seat back recliner and the power recliner motor (4) .
11. Remove the power recliner motor (4) from the seat.
12. Remove the recliner position sensor (5) from the motor (4), if equipped.

Installation Procedure

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1. Install the recliner position sensor (5) to the motor (4), if equipped.
2. Install the power recliner motor (4) into the seat back frame.
3. Slide the recliner rod (2) through the power seat back recliner motor (4) and the recliner
assembly.

4. Install a new push on nut (2) to the end of the recliner rod.

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5. Install the power recliner motor fastener (1).

Tighten
Tighten the recliner motor fastener (1) to 9 N·m (80 lb in).

6. Install the wiring harness in the position in which it was removed.

7. Connect the electrical connector to the power recliner motor and recliner position sensor if
equipped.

8. Install the cardboard backer to the seat back frame.

9. Install the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .
10. Install the inner recliner trim cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
11. Install the inner seat adjuster track cover. Refer to Front Seat Adjuster Track Finish Cover
Replacement .
12. Install the front seat. Refer to Bucket Seat Replacement .
13. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Front Seat Recliner Position Sensor Replacement

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the front seat. Refer to Bucket Seat Replacement .
3. Partially remove the seat back cover and pad in order to gain access to the power recliner
motor and power recliner sensor. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .

Notice: Refer to Electrical Wiring Routing Notice in the Preface section.

4. Disconnect the electrical connector on the power recliner sensor (5).

5. Remove the push-on nut (6) on the end of the recliner rod (2).
6. Slide the recliner rod (2) out of the seat back recliner and the power recliner motor (4) far
enough to clear the sensor (5).
7. Remove the power recliner position sensor (5) from the motor (4).

Installation Procedure

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1. Install the power recliner position sensor (5) to the motor (4).
2. Slide the recliner rod through the power recliner position sensor (5) the seat back recliner
motor (4), and the recliner assembly.
3. Install a new push on nut (6) to the end of the recliner rod (2).
4. Connect the electrical connector to the power recliner position sensor (5).
5. Install the seat back cover and pad. Refer to Front Seat Back Cushion Cover and Cushion Pad
Replacement .
6. Install the front seat. Refer to Bucket Seat Replacement
7. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Lumbar Switch Replacement

Removal Procedure
1. Remove the power seat switch assembly. Refer to Power Seat Switch Replacement .

2. Use a flat bladed tool in order to remove the lumbar switch from the power seat switch
bracket.

Installation Procedure

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1. Install the lumbar switch into the power seat switch bracket.
2. Install the power seat switch assembly. Refer to Power Seat Switch Replacement .

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Memory Seat Calibration

The memory seat module uses position sensor inputs to establish soft stop locations for the
adjuster motors several millimeters ahead of the physical limits of the adjuster assembly. After
replacing a memory seat module or adjuster components, it may be necessary to reset the
adjuster motor soft stop locations. When the repair procedure has been completed, operate the
seat adjuster switch in every direction until the seat adjuster reaches its mechanical hard stop by
repeatedly pressing and releasing the switch as necessary.

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Memory Seat Control Module Replacement

Removal Procedure
Caution: Refer to SIR Handling Caution in the Preface section.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the fasteners securing the seat cushion to the adjuster track. Refer to Front Seat
Cushion Replacement .
3. Lift the front of the seat cushion up in order to gain access to the memory seat module.

Notice: Note the correct routing of the electrical wiring. Failure to reinstall the wiring
properly could result in damage to the wiring.

4. Disconnect the electrical connectors from the memory seat module.

5. Remove the fasteners securing the memory seat module to the seat cushion frame.
6. Remove the memory seat module from the bottom of the seat cushion.

Installation Procedure
1. Position the memory seat module to the bottom of the seat cushion.

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2. Install the memory seat module fasteners.

Tighten
Tighten the fasteners to 2 N·m (18 lb in).

3. Install the electrical connectors to the memory seat module.

4. Ensure the wiring harness is positioned in the same location in which it was removed.
5. Install the seat cushion. Refer to Front Seat Cushion Replacement .
6. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Power Seat Drive Cable Replacement

Removal Procedure
Caution: Refer to SIR Handling Caution in the Preface section.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the seat cushion. Refer to Front Seat Cushion Replacement .
3. If the cable is equipped with a position sensor, remove the sensor retention clip and
disconnect the electrical connector.

4. Squeeze the collars of the cable in order to release the cable.

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5. Pull the cable out of the fittings until the cable ends clear the fittings.
6. Remove the cable or cable/sensor assembly.

Installation Procedure

1. Install the cable or cable/sensor assembly by pushing the ends into the fittings until the cable
retainers snap into place.
2. If the cable is equipped with a position sensor, install the sensor retention clip and connect
the electrical connector.
3. Install the seat cushion. Refer to Front Seat Cushion Replacement .
4. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Power Seat Switch Replacement

Tools Required
J 38778 Door Trim Pad Clip Remover

Removal Procedure
Caution: When you are performing service on or near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment, personal injury, or unnecessary SIR
system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the seat cushion in order to gain access to the power seat switch. Refer to Front
Seat Cushion Replacement .

Important: Do not attempt to remove the lumbar switch knob (2) from the switch as
breakage will occur.

3. Remove the knobs (1) from the switch by gently prying them off using a flat bladed tool.

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4. Use the J 38778 in order to remove the push in retainers located on the underside of the seat
cushion frame.
5. Remove the power seat switch bezel.
6. Release the J channel retainers securing the seat cushion cover to the seat cushion frame in
order to gain access to the power seat switch bracket.

7. Use the J 38778 in order to remove the power seat switch bracket push-in fasteners.
8. Remove the power seat switch and bracket from the seat cushion frame.

Important: Note the routing of the wiring harness for reinstallation, failure to route the
wiring harness properly could result in damage to the wiring.

9. Disconnect the electrical connectors from the power seat switches.

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10. Use a flat bladed tool in order to remove the switch from the bracket.

Installation Procedure
1. Install the power seat switch into the switch bracket.
2. Install the wiring harness in the position in which it was removed.
3. Connect the electrical connectors to the power seat switches.
4. Slide the bracket with the switches upward into the seat cushion frame.
5. Install the retainers in order to secure the bracket and switches to the seat cushion frame.
6. Install the seat cushion cover over the switches aligning the holes in the cover to the switch
assembly.
7. Position the power seat switch bezel over the switches.
8. Install the power seat switch bezel fasteners.

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9. Install the power seat switch knobs (1).

10. Install the seat cushion. Refer to Front Seat Cushion Replacement .
11. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Rear Seat Armrest Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement .
2. Remove the rear seat back. Refer to Rear Seat Back Replacement .
3. Place the seat back facing downward on a clean protected surface.

4. Remove the fasteners (2) securing the rear seat armrest assembly (1) to the rear seat
back (3).
5. Remove the rear seat armrest assembly (1) from the rear seat back (3).

Installation Procedure

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1. Install the rear seat armrest assembly (1) into the opening in the rear seat back (3).

2. Install the fasteners (2) in order to secure the rear seat armrest assembly (1) to the rear
seat back (3).

Tighten
Tighten the fasteners (2) to 11 N·m (97 lb in).

3. Install the rear seat back. Refer to Rear Seat Back Replacement .
4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .

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Rear Seat Back Cushion Cover and Pad Replacement

Removal Procedure
1. Remove the rear seat back. Refer to Rear Seat Back Replacement .

2. Remove the rear seat armrest. Refer to Rear Seat Armrest Replacement .
3. Remove the hog rings securing the seat back cover (1) to the seat back frame assembly.
4. Pull the seat back cover (1) from the seat back frame assembly .
5. Remove the seat back pad (2) from the seat back frame.

Installation Procedure

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1. Install the seat back pad to the seat back frame.

2. Install the seat back cover (1) over the seat back pad and frame assembly.
3. Work the cover (1) and pad into position over the frame so there are no wrinkles or lumps in
the seat back cover or pad.
4. Install the hog rings in order to secure the cover (1) to the rear seat back frame.
5. Install the rear seat armrest to the seat back. Refer to Rear Seat Armrest Replacement .
6. Install the seat back assembly to the vehicle. Refer to Rear Seat Back Replacement .

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Rear Seat Back Cushion Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement .

2. Remove the rear seat belt buckle and center shoulder belt anchor fasteners.
3. Lift the center shoulder belt off of the seat back and store on the rear shelf panel.

4. Insert a flat bladed tool between the top of the rear seat back and the rear shelf trim panel.
5. Push down on the flat bladed tool in order to release the rear seat back retainers.
© 2014 General Motors Corporation. All rights reserved.

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6. Release the 4 retainers and pull the seat back away from the cross car beam.
7. Position the rear shoulder belts in order to clear the rear seat back.
8. Remove the rear seat back.

Installation Procedure

1. Install the rear seat back into the car.

2. Align the rear seat back retainer clips with the slots on the cross car beam.
3. Push in firmly on the rear seat back in order to engage the rear seat back retainer clips.
4. Position the rear shoulder belts over the seat back.

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5. Position the center shoulder belt over the rear seat back.

Important: Ensure that the fastener threads and fastener holes are free of any sealer patch
material.

6. Install the rear seat belt buckle and center shoulder belt anchor fasteners.

Tighten
Tighten the fasteners to 41 N·m (32 lb ft).

7. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .

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Rear Seat Cushion Cover and Pad Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement .

2. Remove the screws from the J channels and disengage the seat cushion cover J channels
from the seat cushion frame.
3. Remove the seat cushion cover (2) from the seat cushion foam pad (1).

Installation Procedure

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1. Position the seat cushion cover (2) over the foam pad (1).
2. Work the cover over the foam cushion and engage the cover J channels to the seat cushion
frame.
3. Install the screws to retain the J channels.
4. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .

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Rear Seat Cushion Replacement

Removal Procedure

1. Push in and up on the front of the rear seat cushion.

2. Lift up and out on the seat cushion.
3. Remove the rear seat cushion from the vehicle.

Installation Procedure

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1. Install the rear seat cushion into the vehicle.

2. Engage 2 locator tabs into the wire loops in the bottom of the rear seat back.

Important: Pull up on the front of the rear seat cushion to ensure that the cushion is secure.

3. Push down and rearward to seat the rear seat cushion into the latches in the number four
bar.

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Seat Adjuster Motor Replacement

Removal Procedure
Caution: Refer to SIR Caution in the Preface section.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the seat from the vehicle. Refer to Bucket Seat Replacement .

3. Remove the seat cushion in order to gain access to the seat adjuster motors. Refer to Front
Seat Cushion Replacement .
4. Determine the applicable seat adjuster motor requiring replacement:
• The rear vertical adjuster motor (1)
• The front vertical adjuster motor (2)
• The horizontal adjuster motor (3)
5. Remove the seat adjuster drive cables from the seat adjuster motor. Refer to Power Seat
Drive Cable Replacement .
6. Disconnect the electrical connector from the seat adjuster motor.

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7. Remove the factory motor inserts securing the seat adjuster motor to the seat adjuster
motor bracket.
7.1. On a clean, dry surface lay the seat on its back.
7.2. Using a 3/16 in drill bit (1), drill the factory motor insert (2) from the bottom side of
the motor plate (4).
8. Remove the seat adjuster motor .
9. Remove the factory motor insert to be reused in the installation of the new motor.

Installation Procedure

1. Position the seat adjuster motor (1,2,3) to the seat adjuster motor plate.

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2. Secure the seat adjuster motor to the seat adjuster motor plate.
2.1. Discard the motor inserts supplied with the new motor.
2.2. Install the previously drilled out factory motor inserts (2), into the rubber grommet (3)
of the new motor.
2.3. Insert the rivet (1) through the motor plate (4) into the motor insert (2) and secure.
3. Connect the electrical connector.
4. Install the seat adjuster drive cables. Refer to Power Seat Drive Cable Replacement .
5. Install the seat cushion. Refer to Front Seat Cushion Replacement .
6. Install the seat into the vehicle. Refer to Bucket Seat Replacement
7. Enable the SIR system. Refer to Enabling the SIR System .
8. If the vehicle is equipped with memory seats, calibrate the seat. Refer to Memory Seat
Calibration .

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Fastener Tightening Specifications

Specification
Application Metric English
Inflatable Restraint Front End Sensor 9 N·m 80 lb in
Inflatable Restraint I/P Module Fastener 9 N·m 80 lb in
Inflatable Restraint Sensing and Diagnostic Module (SDM) Fastener 9 N·m 80 lb in
Inflatable Restraint Side Impact Inflator Module to Seat Fastener 9 N·m 80 lb in
Inflatable Restraint Side Impact Sensor (SIS) Fastener 9 N·m 80 lb in

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Module Controls

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Power, Ground and Sensors

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Inflator Modules

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Power, Grounds and Side Impact Sensors

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SIR Connector End Views

Table 1: Inflatable Restraint Front End Discriminating Sensor
Table 2: Inflatable Restraint IP Module (Standard)
Table 3: Inflatable Restraint IP Module (Dual Stage)
Table 4: Inflatable Restraint Sensing and Diagnostic Module (SDM) (Standard)
Table 5: Inflatable Restraint Sensing and Diagnostic Module (SDM) (Dual Stage)
Table 6: Inflatable Restraint Side Impact Module -- LF
Table 7: Inflatable Restraint Side Impact Module -- RF
Table 8: Inflatable Restraint Side Impact Sensor (SIS) -- Left
Table 9: Inflatable Restraint Side Impact Sensor (SIS) -- Right
Table 10: Inflatable Restraint Steering Wheel Module Coil (Standard)
Table 11: Inflatable Restraint Steering Wheel Module Coil (Dual Stage)

Inflatable Restraint Front End Discriminating Sensor

• 15356720
Connector Part Information
• 2-Way F GT Series Sealed (YEL)
Pin Wire Color Circuit No. Function
A YEL 1834 Forward Discriminating Sensor - Signal
B GRY 2260 Forward Discriminating Sensor - Low Reference

Inflatable Restraint IP Module (Standard)

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• 12110288
Connector Part Information
• 2-Way F Micro-Pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A WHT/BLK 1403 IP Module - High Control
B DK GRN/WHT 1404 IP Module - Low Control

Inflatable Restraint IP Module (Dual Stage)

• 15358741
Connector Part Information
• 4-Way M Metri-Pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A1 YEL 3025 IP Module - Stage 1 - High Control
A2 ORN 3024 IP Module - Stage 1 - Low Control
B1 GRY 3027 IP Module - Stage 2 - High Control
B2 PPL 3026 IP Module - Stage 2 - Low Control

Inflatable Restraint Sensing and Diagnostic Module

(SDM) (Standard)

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• 15354773
Connector Part Information
• 34-Way F Micro-Pack 100 Series Sealed (YEL)
Pin Wire Color Circuit No. Function
A1 YEL 1139 Ignition 1 Voltage
A2 -- -- Not Used
A3 WHT/BLK 1403 IP Module - High Control
A4 PPL 1807 Class 2 Serial Data (Primary)
A5 PPL 1807 Class 2 Serial Data (Primary)
A6 WHT 347 Steering Wheel Module - High Control
A7 DK GRN 348 Steering Wheel Module - Low Control
A8 DK GRN/WHT 1404 IP Module - LowControl
A9-A14 -- -- Not Used
A15 BLK/WHT 238 Driver Seat Belt Switch - Signal
A16 DK BLU 1363 Driver Seat Belt Switch - Low Reference
A17 -- -- Not Used
A18 BLK/WHT 1751 Ground
B1 DK GRN 2105 Side Impact Module - LF - High Control
B2 BRN 2106 Side Impact Module - LF - Low Control
B3 DK BLU 2104 Side Impact Module - RF - Low Control
B4 GRY 2103 Side Impact Module - RF - High Control
B5 YEL 2161 Side Impact Sensor - Left - Voltage
B6 WHT 2162 Side Impact Sensor - Left - Signal
B7 DK GRN 2164 Side Impact Sensor - Right - Signal
B8 TAN 2163 Side Impact Sensor - Right - Voltage
C1-C8 -- -- Not Used

Inflatable Restraint Sensing and Diagnostic Module

(SDM) (Dual Stage)

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• 15354773
Connector Part Information
• 34-Way F Micro-Pack 100 Series Sealed (YEL)
Pin Wire Color Circuit No. Function
A1 YEL 1139 Ignition 1 Voltage
A2 -- -- Not Used
A3 YEL 3025 IP Module - Stage 1- High Control
A4 PPL 1807 Class 2 Serial Data
A5 PPL 1807 Class 2 Serial Data
A6 TAN 3021 Steering Wheel Module - Stage 1- High Control
A7 BRN 3020 Steering Wheel Module - Stage 1- Low Control
A8 ORN 3024 IP Module - Stage 1- Low Control
A9-A10 -- -- Not Used
A11 YEL 1834 Forward Discriminating Sensor - Signal
A12 GRY 2260 Forward Discriminating Sensor - Low Reference
A13-A14 -- -- Not Used
A15 BLK/WHT 238 Seat Belt Switch - Left
A16 DK BLU 1363 Seat Belt Switch - Left - Low Ref
A17 -- -- Not Used
A18 BLK/WHT 1751 Ground
B1 WHT 3023 Steering Wheel Module - Stage 2- High Control
B2 PNK 3022 Steering Wheel Module - Stage 2- Low Control
B3 PPL 3026 IP Module - Stage 2- Low Control
B4 GRY 3027 IP Module - Stage 2- High Control
B5 YEL 2161 Side Impact Sensor - Left - Voltage
B6 WHT 2162 Side Impact Sensor - Left - Signal
B7 DK GRN 2164 Side Impact Sensor - Right - Signal
B8 TAN 2163 Side Impact Sensor - Left - Voltage
C1 DK GRN 2105 Side Impact Module - Left - High Control
C2 BRN 2106 Side Impact Module - Left - Low Control

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C3 DK BLU 2104 Side Impact Module - Right - Low Control

C4 GRY 2103 Side Impact Module - Right - High Control
C5-C8 -- -- Not Used

Inflatable Restraint Side Impact Module -- LF

• 12077918
Connector Part Information
• 2-Way M Metri-pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A DK GRN 2105 Side Impact Module - Left - High Control
B BRN 2106 Side Impact Module - Left - Low Control

Inflatable Restraint Side Impact Module -- RF

• 12077918
Connector Part Information
• 2-Way M Metri-pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A GRY 2103 Side Impact Module - Right - High Control
B DK BLU 2104 Side Impact Module - Right - Low Control

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Inflatable Restraint Side Impact Sensor (SIS) -- Left

• 15304992
Connector Part Information
• 2-Way Metri-Pack 150 Series (YEL)
Pin Wire Color Circuit No. Function
A WHT 2162 Side Impact Sensor - Left - Signal
B YEL 2161 Side Impact Sensor - Left - Voltage

Inflatable Restraint Side Impact Sensor (SIS) --

Right

• 15304992
Connector Part Information
• 2-Way Metri-Pack 150 Series (YEL)
Pin Wire Color Circuit No. Function
A DK GRN 2164 Side Impact Sensor - Right - Signal
B TAN 2163 Side Impact Sensor - Right - Voltage

Inflatable Restraint Steering Wheel Module Coil

(Standard)

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• 12077923
Connector Part Information
• 2-Way M Metri-pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A WHT 347 Steering Wheel Module - High Control
B DK GRN 348 Steering Wheel Module - Low Control

Inflatable Restraint Steering Wheel Module Coil

(Dual Stage)

• 15336476
Connector Part Information
• 4-Way M Metri-Pack 280 Series (YEL)
Pin Wire Color Circuit No. Function
A1 TAN 3021 Steering Wheel Module - Stage 1 - High Control
A2 BRN 3020 Steering Wheel Module - Stage 1 - Low Control
B1 WHT 3023 Steering Wheel Module - Stage 2 - High Control
B2 PNK 3022 Steering Wheel Module - Stage 2 - Low Control

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Disabling the SIR System

Important: Refer to SIR Service Precautions .

1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
2. Turn the ignition switch to the OFF position.
3. Remove the key from the ignition switch.

Important: With the SIR fuse removed and the ignition switch in the ON position, the AIR
BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR system
malfunction.

4. Remove the SIR fuse from the rear fuse block.

5. Rear fuse block is located under the rear seat.

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6. Remove the driver sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.
7. Remove the Connector Position Assurance (CPA) (1) from the driver yellow connector (3)
located next to steering column (2).
8. Disconnect the driver fontal air bag yellow connector (4) from the vehicle harness yellow
connector (3).

9. Remove the passenger sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges and Console.
10. Remove the Connector Position Assurance (CPA) (4) from the passenger yellow connector (1)
located above the passenger sound insulator.
11. Disconnect the passenger (IP) fontal air bag yellow connector (2) from the vehicle harness
yellow connector (1).

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12. Remove the connector position assurance (CPA) from the driver side air bag yellow
connector (4) located under the driver seat.
13. Disconnect the driver side air bag yellow connector (1) from the vehicle harness yellow
connector (4).
14. Remove the connector position assurance (CPA) from the passenger side air bag yellow
connector (4) located under the passenger seat.
15. Disconnect the passenger side air bag yellow connector (1) from the vehicle harness yellow
connector (4).

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Driver or Passenger Seat Side Inflatable Restraint

Module Replacement
Removal Procedure

Caution: When you are carrying an undeployed inflator module:

• Do not carry the inflator module by the wires or connector on the inflator module
• Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points
away from the surface on which the inflator module rests. When you are storing a steering
column, do not rest the column with the bag opening facing down and the column vertical.
Provide free space for the air bag to expand in case of an accidental deployment. Otherwise,
personal injury may result.

1. Disable the SIR system. Refer to Disabling the SIR System .

2. Move the seat to the full forward position.
3. Remove the rear cover (1) of the seat belt post from the front section (2).

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4. Unzip the seat back cover, exposing the 2 fasteners securing the side impact module to the
seat.

Important: Do not remove the center fastener from side impact module inflator. Removing
the center fastener could cause the side air bag to deploy improperly, or unnecessary air bag
system repairs.

5. Remove the 2 top and bottom fasteners (1) from the side impact inflator module.

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6. Remove the side impact inflator module (1) from the seat (2).
7. Fully deploy the module before disposal. If the module was replaced under warranty, fully
deploy and dispose of the module after the required retention period. Refer to Inflator Module
Handling and Scrapping .
8. Remove the connector position assurance (CPA) (4) from the electrical connector (5) on the
side impact inflator module.
9. Remove the electrical connector (5) from side impact inflator module (1).

Installation Procedure

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Important: After a deployment or replacement replace both retainer fasteners to insure

proper inflator module positioning.

1. Install a new push-in fastener (6) to the side impact inflator module (1).
2. Install a new retaining fastener (3) to the seat (2).
3. Install the electrical connector (5) to the side impact inflator module (1).
4. Install the CPA (4) to the electrical connector (5) on the side impact inflator module.
5. Install the side impact inflator module (1) to the seat (2).

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6. Install the 2 nuts (1) to the side impact inflator module.

Tighten
Tighten the nuts to 9 N·m (80 lb in).

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7. Zip the seat back cover zipper from the top to the bottom, closing the seat back cover.

8. Install the rear cover (1) of the seat belt post to the front section (2).
9. Install the seat to the original position.
10. Enable the SIR system. Refer to Enabling the SIR System .

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Enabling the SIR System

1. Remove the key from the ignition switch.

2. Connect the passenger side air bag yellow connector (1) to vehicle harness yellow
connector (4) located under the passenger seat.
3. Install the connector position assurance (CPA) to the passenger side air bag yellow
connector (4).
4. Connect the driver side air bag yellow connector (1) to vehicle harness yellow connector (4)
located under the driver seat.
5. Install the connector position assurance (CPA) to the driver side air bag yellow connector (4).

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6. Connect the passenger (IP) fontal air bag yellow connector (2) to the vehicle harness yellow
connector (1) located above the passenger sound insulator.
7. Install the connector position assurance (CPA) (4) to the passenger yellow connector (1).
8. Install the passenger sound insulator. Refer to Instrument Panel Insulator Panel Replacement
- Right Side in Instrument Panel, Gauges and Console.

9. Connect the driver fontal air bag yellow connector (4) to the vehicle harness yellow
connector (3) located next to steering column (2).
10. Install the connector position assurance (CPA) (1) to the driver yellow connector (3).
11. Install the driver sound insulator. Refer to Instrument Panel Insulator Panel Replacement -
Left Side in Instrument Panel, Gauges and Console.

12. Rear fuse block is located under the rear seat.

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13. Install the SIR fuse to the rear fuse block.

14. Staying well away from all air bags, turn the ignition switch to the ON position.
14.1. The AIR BAG warning lamp will flash 7 times.
14.2. The AIR BAG warning lamp will then turn OFF.
15. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does not operate as
described. Refer to Diagnostic System Check - SIR .

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Inflatable Restraint Front End Discriminating Sensor

Replacement
Removal Procedure
Caution: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying
power to a sensor:
• Remove any dirt, grease, etc. from the mounting surface.
• Position the sensor horizontally on the mounting surface.
• Point the arrow on the sensor toward the front of the vehicle.
• Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value.
Failure to follow the correct procedure could cause air bag deployment, personal injury, or
unnecessary SIR system repairs.

1. Disable the SIR system. Refer to Disabling the SIR System .

2. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
3. Remove the connector position assurance (CPA) (5) from the inflatable restraint front end
discriminating sensor wiring harness connector (4).
4. Disconnect the inflatable restraint front end discriminating sensor wiring harness
connector (4) from the inflatable restraint front end discriminating sensor (1).

Important: The inflatable restraint front end discriminating sensor mounting fastener (3)
has left handed threads.

5. Through the access hole located in the bottom of the lower tie bar, loosen the inflatable
restraint front end discriminating sensor mounting fastener (3).
6. Remove the inflatable restraint front end discriminating sensor (1) from the lower tie bar by
© 2014 General Motors Corporation. All rights reserved.

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lifting upward and sliding rearward out of the key hole slot (2).

1. Install the inflatable restraint front end discriminating sensor (1) into the key hole slot (2)
located in the lower tie bar.

Tighten
Tighten the fastener (3) to 9 N·m (80 lb in).

2. Connect the inflatable restraint front end discriminating sensor harness wiring connector (4)
to the inflatable restraint front end discriminating sensor (1).
3. Install the connector position assurance (CPA) (5) to the inflatable restraint front end
discriminating sensor wiring harness connector (4).
4. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
5. Enable the SIR system. Refer to Enabling the SIR System .

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Inflatable Restraint Sensing and Diagnostic Module

Replacement
CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or
jolt the SDM. Before applying power to the SDM:
• Remove any dirt, grease, etc. from the mounting surface
• Position the SDM horizontally on the mounting surface
• Point the arrow on the SDM toward the front of the vehicle
• Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value
Failure to follow the correct procedure could cause air bag deployment, personal injury, or
unnecessary SIR system repairs.

Caution: If any water enters the vehicle's interior up to the level of the carpet or higher and soaks
the carpet, the sensing and diagnostic module (SDM) and the SDM harness connector may need to
be replaced. The SDM could be activated when powered, which could cause deployment of the air
bag(s) and result in personal injury. Before attempting these procedures, the SIR system must be
disabled. Refer to Disabling the SIR System.

With the ignition OFF, inspect the SDM mounting area, including the carpet. If any significant
soaking or evidence of significant soaking is detected, you must perform the following tasks:

1. Remove all water.

2. Repair the water damage.
3. Replace the SDM harness connector.
4. Replace the SDM.

Failure to follow these tasks could result in possible air bag deployment, personal injury, or
otherwise unneeded SIR system repairs.

Removal Procedure

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1. Disable the SIR system. Refer to Disabling the SIR System .

2. Move both driver and passenger seat forward and/or to the rear to gain access to console
fasteners.
3. Remove the console. Refer to Front Floor Console Replacement in Instrument Panel, Gages
and Console.
4. When the console is remove the carpet will be pre-slit to provide access to the inflatable
restraint sensing and diagnostic module (SDM).

5. Remove the connector position assurance (CPA) (1) from the SDM wiring harness
connector (2).
6. Push down flex lock button (3) and then move sliding connector locking cover (4) to the open
position.

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7. Remove push-on clip (1) securing SDM wiring harness to console stud.
8. Disconnect the SDM wiring harness connector (3) from the SDM (2).

9. Remove the SDM mounting fasteners (1).

10. Remove the SDM (2) from the console floor (3).

Installation Procedure

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1. Install the SDM (2) to console floor (3).

2. Install the SDM mounting fasteners (1).

Tighten
Tighten fasteners to 9 N·m (80 lb in).

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3. Connect the SDM wiring harness connector (3) to the SDM (2).
4. Install push-on clip (1) securing SDM wiring harness to console stud.

5. Push down flex lock button (3) and then move sliding connector locking cover (4) to the close
position.
6. Install the connector position assurance (CPA) (1) to the SDM wiring harness connector (2).

7. Install the carpet pre-slit to the close position covering the SDM.
8. Install the console. Refer to Front Floor Console Replacement in Instrument Panel, Gages and
Console.
9. Install the driver and passenger seat to the original position.
10. Enable the SIR system. Refer to Enabling the SIR System .

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Important: The AIR BAG indicator may remain ON after the SDM has been replaced.
DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the
indicator remains ON after enabling the SIR system, perform the diagnostic system check
and follow the steps thoroughly to ensure that the SDM is set properly.

11. Program the SDM. Refer to Body Control Module (BCM) Programming/RPO Configuration in
Body Control System.

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Inflatable Restraint Side Impact Module Wiring

Harness Replacement
Removal Procedure
Caution: When you are carrying an undeployed inflator module:
• Do not carry the inflator module by the wires or connector on the inflator module
• Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points away from
the surface on which the inflator module rests. When you are storing a steering column, do not rest
the column with the bag opening facing down and the column vertical. Provide free space for the
air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.

1. Disable the SIR system. Refer to Disabling the SIR System .

2. Removal of passenger or driver inflatable restraint side impact inflator module wiring harness
uses the same procedure.
3. Remove the inflatable restraint side impact inflator module (2) from seat (1). Refer to Driver
and Passenger Seat Side Inflatable Restraint Module Replacement for removal.
4. With seat back cover (3) in the open position the inflatable restraint side impact inflator
module wiring harness (4) will be expose.
5. Remove the retaining clips that fastens side inflator module wiring harness (4) to seat (1).

Installation Procedure

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1. Install new side inflator module wiring harness (4) to seat (1).
2. Install retaining clips that fastens side inflator module wiring harness (4) to seat (1).
3. Install the inflatable restraint side impact inflator module (2) to seat (1). Refer to Driver and
Passenger Seat Side Inflatable Restraint Module Replacement for installation.
4. Enable the SIR system. Refer to Enabling the SIR System .

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Inflatable Restraint Side Impact Sensor Replacement

Removal Procedure
Caution: In order to prevent SIR deployment, personal injury, or unnecessary SIR system repairs,
do not strike the door or the door pillar in the area of the side impact sensor (SIS). Turn OFF the
ignition and remove the key when performing service in the area of the SIS.

1. Disable the SIR system. Refer to Disabling the SIR System .

2. Removal of passenger or driver inflatable restraint side impact sensor (SIS) use the same
procedure.
3. Move the seat to the full forward position.
4. Remove the center pillar trim panel. Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
5. Remove the connector position assurance (CPA) (5) from the inflatable restraint side impact
sensor (SIS) harness connector (4).
6. Disconnect the SIS harness connector (4) from the SIS (2).
7. Remove the SIS mounting fasteners (1).
8. Remove the SIS (2) from the center pillar sheetmetal (3).

Installation Procedure
CAUTION: Be careful when you handle an inflatable restraint side impact sensor (SIS) or inflatable
restraint side impact sensing module (SISM). Do not strike or jolt the SIS or SISM. Before applying
power to the SIS or SISM:
• Remove any dirt, grease, etc. from the mounting surface
• Position the SIS or SISM on the mounting surface
© 2014 General Motors Corporation. All rights reserved.

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• Tighten all of the SIS or SISM fasteners to the specified torque value
Failure to follow the correct procedure could cause air bag deployment, personal injury, or
unnecessary air bag system repairs.

1. Installation of passenger or driver inflatable restraint side impact sensor (SIS) use the same
procedure.
2. Install the SIS (2) to the center pillar sheetmetal (3).

3. Install the SIS mounting fasteners (1).

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

4. Install the SIS harness connector (4) to the SIS (2).

5. Install the connector position assurance (CPA) (5) to the SIS harness connector (4).
6. Install the center pillar trim. Refer to Center Pillar Garnish Molding Replacement in Interior
Trim.
7. Move seat to the original position.
8. Enable the SIR system. Refer to Enabling the SIR System .

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Inflator Module Handling and Scrapping

Live (Undeployed) Inflator Module
Caution: When you are carrying an undeployed inflator module:
• Do not carry the inflator module by the wires or connector on the inflator module
• Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points away from
the surface on which the inflator module rests. When you are storing a steering column, do not rest
the column with the bag opening facing down and the column vertical. Provide free space for the
air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.

Take special care when handling or storing a live (undeployed) inflator module. An inflator module
deployment produces a rapid generation of gas. This may cause the inflator module, or an object in
front of the inflator module, to project through the air in the event of an unlikely deployment.

Dual Stage Inflator Module (If Equipped)

Dual stage inflator modules have two deployment stages. If stage 1 was used to deploy a dual
stage inflator module, stage 2 may still be active. Therefore, a deployed dual stage inflator module
must be treated as an active module. If disposal of a deployed or undeployed dual stage module is
required both deployment loops must be energized to deploy the air bag.

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During the course of a vehicle's useful life, certain situations may arise which will require the
disposal of a live (undeployed) inflator module. Do not dispose a live (undeployed) inflator module
through normal disposal channels until the inflator module has been deployed. The following
information covers the proper procedures for the disposing of a live (undeployed) inflator module.

Do not deploy the inflator module in the following situations:

• After replacement of an inflator module under warranty. The inflator module may need to be
returned undeployed to the manufacturer.
• If the vehicle is the subject of a Product Liability report related to the SIR system and is
subject to a Preliminary Investigation (GM-1241). Do not alter the SIR system in any
manner.
• If the vehicle is involved in a campaign affecting the inflator modules. Follow the instructions
in the Campaign Service Bulletin for proper SIR handling procedures.

Deployment Procedures
The inflator module can be deployed inside or outside of the vehicle. The method used depends
upon the final disposition of the vehicle. Review the following procedures in order to determine
which will work best in a given situation:

Deployment Outside Vehicle (Steering Wheel

Module, IP Module, and Side Impact Module)
Deploy the inflator module outside of the vehicle when the vehicle will be returned to service.
Situations that require deployment outside of the vehicle include the following:

• Using the SIR diagnostics, you determine that the inflator module is malfunctioning.
• The inflator module is cosmetically damaged (scratched or ripped).
• The inflator module pigtail (if equipped) is damaged.
• The inflator module connector is damaged.
• The inflator module connector terminals are damaged.

Deployment and disposal of a malfunctioning inflator module is subject to any required retention
period.

Caution: In order to prevent accidental deployment of the air bag which could cause personal
injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed
inflator module contains substances that could cause severe illness or personal injury if the sealed
container is damaged during disposal. Use the following deployment procedures to safely dispose of
an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a
violation of federal, state, province, or local laws.

Tools Required
• J 38826 SIR Deployment Harness
• J 39401-B Deployment Fixture

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• J 38826-25 Side Impact Module Adapter

• J 38826-75 Steering Wheel Module Adapter (Dual Stage Air Bags)
• J 38826-80 IP Module Adapter (Dual Stage Air Bags)

1. Turn OFF the ignition.

2. Remove the ignition key.
3. Put on safety glasses.
4. Remove the inflator module. Refer to the following:
• If you are removing the steering wheel module, refer to Inflatable Restraint Steering
Wheel Module Replacement .
• If you are removing the IP module, refer to Inflatable Restraint Instrument Panel Module
Replacement .
• If you are removing a side impact module, refer to Driver and Passenger Seat Side
Inflatable Restraint Module Replacement .

5. Place the inflator module with the vinyl trim cover facing up and away from the surface on a
work bench.

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6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the inflator
module or deployment fixture. If possible, use a paved, outdoor location free of activity.
Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient
ventilation.
7. Make sure no loose or flammable objects are in the area.

Important: Dual stage air bags deployments are only used in steering wheel and IP inflator
modules, if the vehicle is equipped. If stage 1 was use to deploy a dual stage inflator module,
stage 2 may still be active. If disposal of a deployed or undeployed dual stage module is
required both deployment loops must be energized to deploy the air bag.

8. If you have a steering wheel inflator module, place the inflator module in the center of the
space.

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9. If you have an IP inflator module, refer to the following instructions:

• Place the J 39401-B SIR deployment fixture (2) in the center of the cleared area.
• Fill the deployment fixture with water or sand.
• Using the proper nuts and bolts, mount the IP module (1) to the deployment fixture (2),
with the vinyl trim facing up.
• Tighten all fasteners that hold the IP module (1) to the deployment fixture (2).

10. If you have a side impact module, refer to the following instructions:
• Place the J 39401-B SIR deployment fixture (3) in the center of the cleared area.
• Fill the deployment fixture with water or sand.
• Using the proper nuts and mount the side impact module (1) to the deployment
fixture (3), with the vinyl trim facing up.
• Adjust and secure the fixture arms (4) to the deployment fixture (3).
• Tighten all fasteners that hold the side impact module (1) to the deployment fixture (3).

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11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed.
12. Short the 2 SIR deployment harness leads (1) together using one banana plug seated into
the other.

Important: Refer to Tools Required list for the correct adapter.

13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1).

14. Extend the SIR deployment harness and adapter to full length from the deployment fixture.

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Important: On the steering wheel dual stage inflator module both connectors must be
attached to the deployment harness adapter. This will ensure that both stage 1 and stage 2
of the deployment loops are energized, regardless of the deployment state.

15. Connect the inflator module to the adapter (2) on the SIR deployment harness (1).
16. Place a 12 V minimum/2 A minimum power source (i.e., vehicle battery) near the shorted
end of the harness.

Important:
• The rapid expansion of gas involved with deploying an inflator module is very loud.
Notify all the people in the immediate area that you intend to deploy the inflator
module.
• When the inflator module deploys, the deployment fixture may jump about 30 cm (1 ft)
vertically. This is a normal reaction of the inflator module due to the force of the rapid
expansion of gas inside the inflator module.
• If you are deploying a dual stage inflator module with stage 1 already deployed, the
fixture may not move and the noise may have been reduced.

17. Clear the area of people.

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18. Separate the 2 banana plugs on the SIR deployment harness.

19. Connect the SIR deployment harness wires to the power source. Inflator module deployment
will occur when contact is made.

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20. Disconnect the SIR deployment harness from the power source after the inflator module
deploys.
21. If the inflator module did not deploy, disconnect the adapter and discontinue the procedure.
Contact the Technical Assistance Group. Otherwise, proceed to the following steps.

CAUTION: After an air bag deploys, the metal surfaces of the inflator module are very hot.
To help avoid a fire or personal injury:
• Allow sufficient time for cooling before touching any metal surface of the inflator
module.
• Do not place the deployed inflator module near any flammable objects.

22. Seat one banana plug into the other in order to short the deployment harness leads.

23. Put on a pair of shop gloves.

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24. Disconnect the pigtail adapter from the inflator module as soon as possible.
25. Inspect the pigtail adapter and the SIR deployment harness. Replace as needed.
26. Dispose of the deployed inflator module through normal refuse channels.
27. Wash hands with a mild soap.

Deployment Inside Vehicle (Vehicle Scrapping

Procedure)
Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the
vehicle for parts. This includes but is not limited to the following situations:

• The vehicle has completed its useful life.

• Irreparable damage occurs to the vehicle in a non-deployment type accident.
• Irreparable damage occurs to the vehicle during a theft.
• The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as
opposed to rebuilding as the same VIN.

CAUTION: When you are deploying an inflator module for disposal, perform the deployment
procedures in the order listed. Failure to follow the procedures in the order listed may result in
personal injury.

1. Turn the ignition switch to the OFF position.

2. Remove the ignition key.
3. Put on safety glasses.
4. Remove all loose objects from the front seats.
5. Disable the SIR system. Refer to Disabling the SIR System .

Caution: A deployed dual stage inflator module will look the same whether one or both
stages were used, always assume a deployed dual stage inflator module has an active stage
2. Improper handling or servicing can activate the inflator module and cause personal injury.

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6. Disconnect the inflatable restraint steering wheel module yellow connector (4) located next to
steering column (2).

Important: If vehicle is equipped with dual stage air bags the steering wheel module and IP
module will each have 4 wires and standard air bags will only have 2 wires. Refer to SIR
Connector End Views for determining high and low circuits.

7. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at
the connector.
8. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

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9. Cut 2 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire.
Use these wires to fabricate the driver deployment harness.
10. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
11. Twist together one end from each of the wires in order to short the wires. Deployment wires
shall remain shorted, and not connected to a power source until you are ready to deploy the
inflator module.

12. Twist together 2 connector wire leads (the high circuits from both stages of the steering
wheel module) to one sets of deployment wires. Refer to SIR Connector End Views in order to
determine the correct circuits.
13. Inspect that the 3 wire connection is secure.

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14. Bend flat the twisted connection.

15. Secure and insulate the 3 wire connection to deployment harness using electrical tape.

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16. Twist together 2 connector wire leads (the low circuits from both stages of the steering wheel
module) to one sets of deployment wires. Refer to SIR Connector End Views in order to
determine the correct circuits.
17. Inspect that the 3 wire connection is secure.

18. Bend flat the twisted connection.

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19. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
20. Connect the deployment harness to the steering wheel module in-line connector.

21. Route the deployment harness out of the driver side of the vehicle.

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22. Disconnect the driver side impact module yellow connector (1) from the vehicle wiring
harness (4) located under the driver seat.

23. Cut the 2 side impact module wires leading to the yellow harness connector, leaving at least
16 cm (6 in) of wire at the connector.
24. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.

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25. Cut 2 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire.
Use these wires to fabricate the deployment harness.
26. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
27. Twist together 1 end from each of the wires in order to short the wires. Deployment wires
shall remain shorted, and not connected to a power source until you are ready to deploy the
side impact module.

28. Twist together 1 connector wire lead to one deployment wire.

29. Inspect that the previous connection is secure.

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30. Bend flat the twisted connection.

31. Secure and insulate the connection using electrical tape.

32. Twist together, bend, and tape the remaining connector wire lead to the remaining
deployment wire.
33. Connect the deployment harness to the side impact module - LF.

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34. Route the deployment harness out of the driver side of the vehicle.

35. Disconnect the IP module yellow harness connector (2) above passenger side sound
insulator.

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Important: If vehicle is equipped with dual stage air bags the IP module will each have
4 wires and standard air bags will only have 2 wires. Refer to SIR Connector End Views for
determining high and low circuits.

36. Cut the yellow harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at
the connector.
37. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.

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38. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand
wire. These wires will be used to fabricate the passenger deployment harness.
39. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
40. Twist together one end from each of the wires in order to short the wires.

41. Twist together two connector wire leads (the high circuits from both stages of the steering
wheel module) to one sets of deployment wires. Refer to SIR Connector End Views in order to
determine the correct circuits.
42. Inspect that the 3 wire connection is secure.

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43. Bend flat the twisted connection.

44. Secure and insulate the 3 wire connection to deployment harness using electrical tape.

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45. Twist together two connector wire leads (the low circuits from both stages of the steering
wheel module) to one sets of deployment wires. Refer to SIR Connector End Views in order to
determine the correct circuits.
46. Inspect that the 3 wire connection is secure.

47. Bend flat the twisted connection.

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48. Secure and insulate the 3 wire connection to deployment harness using electrical tape.
49. Connect the deployment harness to the IP module in-line connector.

50. Route the deployment harness out of the passenger side of the vehicle.

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51. Disconnect the passenger side impact module yellow connector (1) from the vehicle wiring
harness (4) located under the passenger seat.

52. Cut the two side impact module wires leading to the yellow harness connector, leaving at
least 16 cm (6 in) of wire at the connector.
53. Strip 13 mm (0.5 in) of insulation from each of the side impact module connector wire leads.

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54. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand
wire. Use these wires to fabricate the deployment harness.
55. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
56. Twist together one end from each of the wires in order to short the wires. Deployment wires
shall remain shorted, and not connected to a power source until you are ready to deploy the
side air bag module.

57. Twist together one connector wire lead to one deployment wire.
58. Inspect that the previous connection is secure.

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59. Bend flat the twisted connection.

60. Secure and insulate the connection using electrical tape.

61. Twist together, bend, and tape the remaining connector wire lead to the remaining
deployment wire.
62. Connect the deployment harness to the side impact module - RF.

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63. Route the deployment harness out of the passenger side of the vehicle.

64. Completely cover the windshield and front door window openings with a drop cloth.
65. Stretch out all of the deployment harness wires on the left and right side of the vehicle to
their full length.
66. Deploy each deployment loop one at a time.
67. Place a power source, 12 V minimum/2 A minimum (i.e., a vehicle battery) near the shorted
end of the harnesses.
68. Separate the one set of wires and touch the wires ends to the power source in order to
deploy the inflator modules, doing one module at a time.
69. Disconnect the deployment harness from the power source and twist the wire ends together.
70. Continue the same process with the remaining deployment harnesses that are available.
71. Remove the drop cloth from the vehicle.
72. Disconnect all harnesses from the vehicle.
73. Discard the harnesses.

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74. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
75. If one or all of the inflator modules did not deploy, perform the following steps to remove the
undeployed module(s) from the vehicle:
• Inflatable Restraint Steering Wheel Module Replacement
• Inflatable Restraint Instrument Panel Module Replacement
• Driver and Passenger Seat Side Inflatable Restraint Module Replacement
76. Call Technical Assistance Group.

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Instrument Panel Inflatable Restraint Module

Replacement
Removal Procedure

Caution: When you are carrying an undeployed inflator module:

1. Disable the SIR system. Refer to Disabling the SIR System .

2. Remove the right insulator panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gages and Console.
3. Remove the connector position assurance (CPA) (4) from the inflatable restraint I/P module
connector (2).
4. Remove the I/P module yellow connector (2) from the vehicle harness yellow connector (1).
5. Remove the I/P module yellow connector (2) from the instrument panel (I/P) bracket (3).

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6. Remove the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in
Instrument Panel, Gages and Console.
7. Note the I/P module wire harness routing position, to help in re-assembly.
8. Push the I/P module yellow connector (2) back away from the I/P (3).

9. Remove the I/P module mounting fasteners (2).

10. Remove the inflatable restraint module (3) from the I/P (1).Do not damage the module
pigtail (4).

Important: A deployed dual stage inflator module must be energized to ensure that both
stages are no longer active.

11. Fully deploy the module before disposal. If the module was replaced under warranty, fully
deploy and dispose of the module after the required retention period. Refer to Inflator Module

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Handling and Scrapping .

Installation Procedure

1. When installing the inflatable restraint module (3) do not damage the module pigtail (4).
2. Route the I/P module pigtail (4) down through the I/P (1).
3. Install the I/P module (3) to the I/P (1).

4. Install the I/P module mounting fasteners (2).

Tighten
Tighten fasteners to 9 N·m (80 lb in).

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5. Route the I/P module wiring harness (2) in place to secure I/P module yellow connector clip
to I/P (3).
6. Install the I/P upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in
Instrument Panel, Gages and Console.

7. Clip the I/P module yellow connector (2) to I/P bracket (3).
8. Install the I/P module yellow connector (2) to the vehicle harness yellow connector (1).
9. Install the CPA (4) to the I/P module connector (2).
10. Install the right insulator panel. Refer to Instrument Panel Insulator Panel Replacement -
Right Side in Instrument Panel, Gages and Console.
11. Enable the SIR system. Refer to Enabling the SIR System .

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Repairs and Inspections Required After a Collision

Accident With or Without Inflator Module
Deployment - Component Inspections
CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system
requires that any repairs to the vehicle structure return the vehicle structure to the original
production configuration. Not properly repairing the vehicle structure could cause non-deployment
of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than
intended.

CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system
requires that any repairs to the vehicle structure return the vehicle structure to the original
production configuration. Not properly repairing the vehicle structure could cause non-deployment
of the side impact air bag(s) in a side impact collision or deployment of the side impact air bag(s)
for conditions less severe than intended.

After any collision, inspect the following components as indicated. If you detect any damage,
replace the component. If you detect any damage to the mounting points or mounting hardware,
repair the component or replace the hardware as needed.

• The steering column - Perform the steering column accident damage checking procedures.
Refer to Steering Column Accident Damage Inspection - Off Vehicle in Steering.
• The IP knee bolsters and mounting points - Inspect the knee bolsters for bending, twisting,
buckling, or any other type of damage.
• The IP brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of
damage.
• The seat belts - Perform the seat belt operational and functional checks. Refer to Operational
and Functional Checks in Seat Belts.
• The IP cross car beam - Inspect for bending, twisting, buckling, or any other type of damage.
• The IP mounting points and brackets - Inspect for bending, twisting, buckling, or any other
type of damage.
• The seats and seat mounting points - Inspect for bending, twisting, buckling, or any other
type of damage.

Accident With Frontal Air Bag Deployment --

Component Replacement and Inspections
After a collision involving air bag deployment, replace the following components.

• Inflatable restraint IP module

• Inflatable restraint steering wheel module
• Inflatable restraint steering wheel module coil
• Inflatable restraint sensing and diagnostic module (SDM)
© 2014 General Motors Corporation. All rights reserved.

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• Inflatable restraint electronic frontal sensor (EFS) (if equipped with dual stage air bags)

Perform additional inspections on the following components.

• Steering wheel module coil and the coil wiring pigtail - Inspect for melting, scorching, or
other damage due to excessive heat.
• Mounting points or mounting hardware for the IP module, steering wheel module, SDM, and
EFS sensor (if equipped with dual stage air bags) - Inspect for any damage and repair or
replace each component as needed.

Accident With Side Air Bag Deployment --

Component Replacement and Inspections
After a collision involving side air bag deployment, replace the following components.

• Inflatable restraint side impact sensors (SIS) (Left/Right), on the side of the impact.
• Inflatable restraint side impact module (LF/RF), on the side of the impact.
• Inflatable restraint sensing and diagnostic module (SDM).

Perform additional inspections on the following components.

• Mounting points or mounting hardware for the SIS, and side impact module (LF/RF) on the
side of impact - Inspect for any damage and repair or replace each component as needed.
• Mounting points or mounting hardware for the SDM - Inspect for any damage and repair or
replace each component as needed.

Sensor Replacement Guidelines

The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident
damage. The area of accident damage is defined as the portion of the vehicle which is crushed,
bent, or damaged due to a collision. An example of this would be a moderate collision where the
front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the
radiator, replace the SIR sensor.

• Replace the sensor whether or not the air bags have deployed.
• Replace the sensor even if the sensor appears to be undamaged.

Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the
wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to
determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a Diagnostic
Trouble Code (DTC) table and a malfunctioning sensor is indicated, replace the sensor.

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SIR Service Precautions

Caution: When you are performing service on or near the SIR components or the SIR wiring, you
must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct
procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply.
The reserved energy supply provides deployment power for the air bags. Deployment power is
available for as much as 1 minute after disconnecting the vehicle power. Disabling the SIR system
prevents deployment of the air bags from the reserved energy supply.

General Service Instructions

The following are general service instructions which must be followed in order to properly repair
the vehicle and return it to its original integrity:

• Do not expose inflator modules to temperatures above 65°C (150°F).

• Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
• Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.

Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or
greater:

• Inflatable restraint sensing and diagnostic module (SDM)

• Inflatable restraint electronic frontal sensor (EFS)
• Inflatable restraint IP module
• Inflatable restraint steering wheel module
• Inflatable restraint steering wheel module coil
• Inflatable restraint side impact modules
• Inflatable restraint side impact sensors (SIS)

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Steering Wheel Inflatable Restraint Module Coil

Replacement (Vin #14125814 and Less)
Removal Procedure
Caution: When you are carrying an undeployed inflator module:
• Do not carry the inflator module by the wires or connector on the inflator module
• Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points away from
the surface on which the inflator module rests. When you are storing a steering column, do not rest
the column with the bag opening facing down and the column vertical. Provide free space for the
air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.

1. Disable the SIR System. Refer to Disabling the SIR System .

2. Remove inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering
Wheel Module Replacement .
3. Remove the steering wheel nut.
4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment
during installation.
5. Remove the steering wheel. Refer to Steering Wheel Replacement in Steering Wheel and
Column - Tilt.

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6. Grasp the tilt lever.

7. Pull the tilt lever straight out from steering column.
8. Remove the tilt lever assembly.

9. Remove 2 pan head tapping screws (2) from the lower shroud (1).
10. Remove the lower shroud (1).

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11. Remove 1 TORX® head screw (1) from the upper shroud (2).
12. Remove the upper shroud (2).

13. Remove the shroud protector (1) from the lower shroud (2).

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14. Remove the wire harness straps from the steering wheel column wire harness.
15. Remove the retaining ring (3).
16. Remove the inflatable restraint steering wheel module coil (2) from the steering shaft.

Installation Procedure

1. To install the inflatable restraint steering wheel module coil:

• Make sure that the wheels are straight ahead.
• Align the block tooth and the centering mark on the race and upper shaft assembly at the
12 o'clock position.

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Important: Make sure that the SIR coil assembly is centered.

2. A new SIR coil assembly will come pre-centered.

3. If coil assembly centering is required follow the instructions on the notice (1) of the coil
assembly.

4. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam
assembly (2).

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5. Install the wave washer (1) to the upper shaft assembly.

6. Slide the coil assembly (2) onto the race and upper shaft assembly.
7. Remove the centering tab and discard it.
8. Install the retaining ring (3).

9. Install the shroud protector (1) to the lower shroud (2).

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10. Install the upper shroud (2) and secure by using 1 TORX® head screw (1).

Tighten
Tighten the screw to 1.5 N·m (13 lb in).

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11. Install the lower shroud (2) and secure by using 2 pan head tapping screws (1).

Tighten
Tighten the screws to 3.5 N·m (31 lb in).

12. Align the tilt lever into the steering column.

13. Slide the tilt lever handle into the steering column until it locks into position.

14. Feed the wiring through the steering wheel.

15. Align the steering wheel with the mark on the steering shaft.
16. Install nut for the steering wheel.

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Tighten
Tighten the nut to 41 N·m (30 lb ft).

17. Connect wiring to the SIR module.

18. Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering
Wheel Module Replacement .
19. Enable the SIR system. Refer to Enabling the SIR System .

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Steering Wheel Inflatable Restraint Module Coil

Replacement (Vin #14125815 and Greater)
Removal Procedure
Caution: When you are carrying an undeployed inflator module:
• Do not carry the inflator module by the wires or connector on the inflator module
• Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points away from
the surface on which the inflator module rests. When you are storing a steering column, do not rest
the column with the bag opening facing down and the column vertical. Provide free space for the
air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.

1. Disable the SIR System. Refer to Disabling the SIR System .

2. Remove inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering
Wheel Module Replacement .
3. Remove the steering wheel nut.
4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment
during installation.
5. Remove the steering wheel from the steering shaft. Refer to Steering Wheel Replacement in
Steering Wheel and Column - Tilt.

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6. Grasp the tilt lever.

7. Pull the tilt lever straight out from steering column.
8. Remove the tilt lever assembly.

9. Remove 2 pan head tapping screws (2) from the lower shroud (1).
10. Remove the lower shroud (1).

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11. Remove 1 TORX® head screw (1) from the upper shroud (2).
12. Remove the upper shroud (2).

13. Remove the wire harness straps from the steering wheel column wire harness.
14. Remove the retaining ring (3).
15. Remove the inflatable restraint steering wheel module coil (2) from the steering shaft.

Installation Procedure

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1. To install the inflatable restraint steering wheel module coil:

• Ensure that the wheels are straight ahead.
• Align the block tooth and the centering mark on the race and upper shaft assembly at the
12 o'clock position.

Important: If coil assembly centering is required follow the instructions on the notice (1) of
the coil assembly. Refer to Inflatable Restraint Coil Centering - Off Vehicle in Steering Wheel
and Column - Tilt for complete centering procedure.

2. A new SIR coil assembly will come pre-centered. Ensure that the SIR coil assembly is
centered.

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3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam
assembly (2).

4. Install the wave washer (1) to the upper shaft assembly.

5. Slide the coil assembly (2) onto the race and upper shaft assembly.
6. Remove the centering tab and discard.
7. Install the retaining ring (3).

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8. Install the upper shroud (2) and secure by using 1 TORX® head screw (1).

Tighten
Tighten the screw to 1.5 N·m (13 lb in).

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9. Install the lower shroud (2) and secure by using 2 pan head tapping screws (1).

Tighten
Tighten the screws to 3.5 N·m (31 lb in).

10. Align the tilt lever into the steering column.

11. Slide the tilt lever handle into the steering column until it locks into position.

12. Feed the wiring through the steering wheel.

13. Align the steering wheel with the mark on the steering shaft.
14. Install the nut for the steering wheel.

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Tighten
Tighten the nut to 41 N·m (30 lb ft).

15. Connect the wiring to the SIR module.

16. Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering
Wheel Module Replacement .
17. Enable the SIR system. Refer to Enabling the SIR System .

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Steering Wheel Inflatable Restraint Module

Replacement
Tools Required
J 44298 Driver Air Bag Removal Tool

Removal Procedure

Caution: When you are carrying an undeployed inflator module:

1. Disable the SIR system. Refer to Disabling the SIR System .

2. On the back side of steering wheel are 4 openings for removing the steering wheel module.
3. Position the steering wheel so that 2 of the openings are on top.
4. Adjust and install J 44298 into 2 of the holes.
© 2014 General Motors Corporation. All rights reserved.

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Important: Seat the air bag removal toolall the way in to perform properly.

5. Push the handle back towards instrument panel (I/P) releasing the 2 spring loaded fasteners
at the same time.
6. Turn the steering wheel and open J 44298 . Use one of the tool fingers to remove the cruise
control lever cover in order to gain access.
7. Position J 44298 and insert the tool into place around the cruise control lever. Repeat the
same procedure for the other 2 openings.
8. Pull the inflatable restraint module gently away from the steering wheel.

Important: Note the steering wheel module connector (or connectors if equipped with dual
stage air bags) wire routing positions, the redundant control routing positions, and the horn
wire routing positions for the correct re-assembly.

9. Remove the connector position assurance (CPA) (4) and the steering wheel module electrical
connector.
10. Remove the horn grounded lead (2) from the threaded hole in the steering wheel.
11. Rotate the horn contact lead counterclockwise 1/4 turn.
12. Remove the horn contact lead (2) from the steering column cam tower.
13. Remove the steering wheel module (5).

Important: A deployed dual stage inflator module must be energized to ensure that both
stages are no longer active.

14. Fully deploy the module before disposal. If the module was replaced under warranty, fully
deploy and dispose of the module after the required retention period. Refer to Inflator Module
Handling and Scrapping .

Installation Procedure

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1. Connect the horn ground lead (2) into the lower left threaded hole in the steering wheel.
2. Connect the horn contact lead into the steering column cam tower.
3. Rotate the horn contact ¼ turn clockwise to lock.
4. Connect the steering wheel module electrical connector and CPA (4).

Important: If the vehicle is equipped with dual stage air bags, you will find 2 connectors.
Match the right color connector to the right color opening in the module. Route the steering
wheel module wires, the redundant control wires, and the horn wires correctly.

5. Align the steering wheel module fasteners to the steering column fastener holes.
6. Push the steering wheel module firmly into the steering column in order to engage the
fasteners.
7. Enable the SIR system. Refer to Enabling the SIR System .

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Defogger Schematics

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W/DD7 or DD8

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W/UE1

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Stationary Windows Connector End Views

Table 1: Inside Rearview Mirror (wo/UE1)
Table 2: Inside Rearview Mirror (w/UE1)
Table 3: Rear Window Defogger -- Driver
Table 4: Rear Window Defogger -- Passenger

Inside Rearview Mirror (wo/UE1)

• 12124782
Connector Part Information
• 7-Way F Metri - Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
1 BRN 41 Ignition 3 Voltage
2 BLK/WHT 851 Ground
3 LT GRN 24 Backup Lamp Supply Voltage
4-7 -- -- Not Used

Inside Rearview Mirror (w/UE1)

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• 15324871
Connector Part Information
• 16-Way F Metri - Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
1 -- -- Not Used
2 Bare 1705 Drain Wire
3-7 -- -- Not Used
8 BLK/WHT 851 Ground
9 LT GRN 24 Backup Lamp Supply Voltage (w/DD7or DD8)
10 GRY 655 Cellular Telephone Microphone Signal
11 DK GRN/WHT 2514 Keypad Signal
12 LT GRN/BLK 2515 Keypad Supply Voltage
13 BRN 41 Ignition 3 Voltage (w/DD7 or DD8)
14 YEL/BLK 2516 Keypad Green LED Signal
15 BRN/WHT 2517 Keypad Red LED Signal
16 -- -- Not Used

Rear Window Defogger -- Driver

• 12064750
Connector Part Information
• 2-Way M Metri-pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A PPL 293 Rear Defog Element Supply Voltage
B BLK 850 Ground

Rear Window Defogger -- Passenger

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• 12059885
Connector Part Information
• 1-Way M Metri-pack 480 Series (BLK)
Pin Wire Color Circuit No. Function
A BLK 1050 Ground

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Bus Bar/Antenna Terminal Repair

The bus bar/antenna lead terminals can be reattached by soldering, using a solder containing 3
percent silver and a rosin flux paste.

1. Before soldering the bus bar/antenna lead terminal, repair area should be buffed with fine
steel wool.
2. Apply the past-type rosin flux in small quantities to the bus bar/antenna lead terminal repair
area using a brush.

Notice: Use only enough heat to melt the solder. Using excessive heat can damage the rear
window defogger components or the rear window.

3. The soldering iron tip should be coated with solder beforehand. Use only enough heat to melt
the solder and only enough solder to ensure a complete repair.

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Grid Line Repair

Tools Required
• J 25070 Heat Gun - Capable of 260°C (500°F) or equivalent
• Test Lamp
• Rear Window Defogger Repair Kit GM P/N 12346001, Canada P/N 10951643 or equivalent

Removal Procedure
Caution: To avoid personal injury:
• Do not allow the repair material to come in contact with skin or eyes and avoid
breathing vapors.
• Do not use near sparks or open flame.

1. Disconnect the electrical connector.

2. Inspect the rear window grid lines.
3. Ensure that the rear window is at room temperature.
4. Inspect the grid line area that you will repair. Verify that the area is dry and free from
contaminates.
5. Dampen a cloth with isopropyl alcohol. Use the damp cloth in order to wipe the grid line area
clean.

Installation Procedure

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Important:
• Ensure that the grid line repair material is not beyond the expiration date.
• Repair decal or tape must be used in order to control the width of the repair area.
• If the repair decal is used, verify that the die-cut metering slot is the same width as the
grid line.
• Thoroughly stir the grid line repair material until a uniform color appears.
• Verify that there are no air bubbles in the grid line repair material in the repair area.

1. Use a grease pencil in order to mark the grid line break (2) on the outside of the rear window
with a grease pencil.

2. Using GM P/N 12346001 (Canadian P/N 10951643) or equivalent to repair the grid lines.

Apply the grid line repair (2) decal or 2 strips of the tape above and below the repair area.

3. Use the brush (3) in order to spread the grid line repair material (1). Ensure that the repair
material covers all of the areas of the cut out.

Notice: The grid line repair material must be cured with heat. To avoid heat damage to the
interior trim, protect the trim near the repair area where heat is to be applied.

4. Without disturbing the grid line repair material, carefully remove the decal or tape (2).

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Important: Use J 25070 capable of 260°C (500°F) or equivalent . If you do not use a heat
gun, allow at least 24 hours at an ambient temperature of 21-32°C (70-90°F) for complete
curing of the repair materials. Do NOT physically disturb the repair area until after that time.

The grid line will be electrically operative immediately after the repair.

5. Use a heat gun in order to repair the grid line:

• Hold the heat gun nozzle 25 mm (1 in) from the surface.
• Heat the repair area for 2-3 minutes.
6. Connect the electrical connector.
7. Test the grid line operation in order to verify the grid line repair.

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Inside Rearview Mirror Replacement (DD7)

Removal Procedure
Notice: Do not use tools or other objects to pry the mirror mount or the mirror away from
the windshield. Using tools may damage the mirror mount, the mirror or the windshield.

1. Remove the electrical connectors (2) at the rear of the mirror assembly.
2. Twist the mirror to one side and use one hand to support the edge of the mirror against the
windshield. Use the other hand to pull the mirror away from the windshield with a quick jerk.

Installation Procedure

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1. Position the bottom of the mirror base (3) against the windshield at the top of the support.
2. Slide the base onto the support keeping the base parallel to the windshield.
3. As the base starts to engage, apply a force against the base while maintaining a downward
force until it snaps onto the support with an audible click. This operation will require at least
89 Newtons (20 lb) of force.
4. Check to make sure the mirror is securely attached to the support by adjusting the mirror in
a normal up/down and side to side range.

5. Install the electrical connector (2) into the electrical cavity in the back of the mirror (1). An
audible click should be heard to indicate the proper installation of the connector.

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Inside Rearview Mirror Replacement (UE1)

Removal Procedure

1. Disconnect the electrical connector from the back of the mirror.

2. Remove the wire cover.
3. Adjust the mirror to the full upward position.
4. Remove the base trim cover.
5. Loosen the set screw in order to remove the mirror from the button assembly.
6. Slide the mirror assembly in an upward motion in order to remove.
7. Remove the mirror.

Installation Procedure

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1. Position the center bottom of the mirror mount against the windshield at the top of the
support button.
2. Slide the base of the mirror onto the button.

3. Make sure the mirror is firmly seated on the windshield button by pushing down on the base
of the mirror.

Tighten
Tighten the set screw to 1.8 N·m (16 lb in) in order to secure the mirror base to the button.

4. Install the base trim cover.

5. Connect the electrical connector.
6. Reposition the mirror assembly.
7. Install the wire cover.
8. Calibrate the compass.

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Rear Window Defogger Braided Lead Wire

Caution: When working with any type of glass or sheet metal with exposed or rough edges,
wear approved safety glasses and gloves in order to reduce the chance of personal injury.

1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach
the rear defogger bus bar lead wire and/or defogger terminal.
2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was
formed during window manufacture.
3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate
area:
• The rear defogger bus bar lead wire
• The defogger terminal repair area

Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392
(Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification
GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit
will result in poor retention of the window which may allow unrestrained occupants to be
ejected from the vehicle resulting in personal injury.

Important: Do not hold the tool in one spot or operate the tool on the window for longer
than 30-40 seconds.

If the window becomes hot to the touch, allow the window to air cool before proceeding
further. Cooling with water may crack the heated window.

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4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only
enough solder to ensure a complete repair.
5. Apply the solder to the feed bus bar or the ground bus bar.

Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder.

6. Apply a small amount of flux to the appropriate areas:

• The underside of the rear defogger bus bar lead wire
• The defogger terminal
7. Align the spots with the flux to the appropriate areas:
• The underside of the rear defogger bus bar lead wire
• The defogger terminal
8. Coat the tip of the soldering iron with solder.
9. Solder the appropriate areas:
• The underside of the rear defogger bus bar lead wire
• The defogger terminal
10. Draw the iron across the fluxed spot. Thinly coat the spot with solder.
11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar.
12. Use pliers in order to hold the appropriate component:
• The rear defogger bus bar lead wire
• The defogger terminal
13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses
together:
• The top of the rear defogger bus bar lead wire
• The defogger terminal

Important: Do not remove the holding force until the solder has solidified.

14. Remove the excess flux with the solvent.

15. Connect the electrical connector.

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Rear Window Replacement

Tools Required
• J 24402-A Glass Sealant (Cold Knife) Remover
• J 39032 Stationary Glass Removal Tool
• Urethane Adhesive Kit GM P/N 12346392 or Equivalent
• Isopropyl Alcohol or Equivalent
• Cartridge-type Caulking Gun
• Commercial-type Utility Knife
• Razor Blade Scraper
• Suction Cups
• Plastic Paddle

Removal Procedure
Important: Before cutting out a stationary window, apply a double layer of masking tape
around the perimeter of the painted surfaces and inner trim of the window.

1. Open the rear compartment lid in order to access the reveal molding.

2. Remove the rear window reveal molding (1).

3. Remove the upper interior quarter trim. Refer to Rear Quarter Upper Trim Panel Replacement
in Interior Trim.

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4. Disconnect the rear window electrical connectors

5. Disconnect the OnStar® antenna. Refer to Mobile Telephone Antenna Replacement in Cellular
Communication.
6. Disconnect the antenna connection from the rear window.

Caution: When working with any type of glass or sheet metal with exposed or rough edges,
wear approved safety glasses and gloves in order to reduce the chance of personal injury.

7. Use safety glasses and gloves.

Important: Keep the cutting edge of the tool against the rear window. This will allow the
urethane adhesive to be separated from the rear window. Leave a base of urethane on the
pinchweld flange. The only suitable lubrication is clear water.

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8. Use the J 24402-A or J 39032 in order to cut the rear window from the pinchweld flange. Do
this from inside the vehicle in order to protect the outer paint surface.

9. With the aid of an assistant, use the suction cups in order to lift the rear window from the
opening.

Installation Procedure
1. Verify all primers and urethane adhesive are within expiration dates.

2. Inspect the following components for the causes of a broken rear window:
• The flange of the rear window opening
• The rear window reveal molding
3. Inspect for any of the following conditions in order to help prevent future breakage of the
rear window:
• High weld
• Solder spots
• Hardened spot weld sealer
• Any other obstruction or irregularity in the pinchweld flange

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or

replacements are necessary, refinish the pinchweld flange in order to present a clean primer
only surface. If paint repairs are required, mask the flange bonding area prior to the
application of the color coat in order to provide a clean primer only surface. Materials such as
BASF DE17®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP 70, and Martin-
Semour 5120 and 5130 products are approved for this application.

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4. After repairing the opening as indicated, perform the following steps:

5. Inspect the condition of the rear window opening and the urethane adhesive bead in order to
determine which installation method you will use. Refer to Short Method Description or
Extended Method Description for the guidelines.
6. After repairing the opening as indicated, shake the pinchweld primer (black #3) for at least 1
minute.

Caution: Failure to prep the area prior to the application of primer may cause insufficient
bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow
unrestrained occupants to be ejected from the vehicle resulting in personal injury.

7. Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding
area on the body.
8. Allow the primer to dry for approximately 10 minutes. Ensure that all nicks and scratches are
covered.

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9. If the original reveal molding is damaged it must be replaced.

10. Install the new rear window reveal molding (1) to the rear window.
11. Start from the center and hand press the rear window reveal molding (1) onto the rear
window (2).

12. With the aid of an assistant, dry fit the rear window in the opening in order to determine the
correct way to position the rear window in the opening.
13. Use masking tape (1, 3) in order to mark the location of the stationary window in the
opening.
14. Slit the masking tape (1, 3) at the edges of the rear window.
15. With the aid of an assistant, remove the rear window from the opening.
16. Place the rear window inside up on a clean, protected surface.
17. If the original rear window is being reused, remove all but approximately 2 mm (3/64 in) of
the existing urethane adhesive from the rear window surface, using a utility knife or razor
blade scraper.

Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of
urethane adhesive .

18. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the
existing bead of adhesive from the pinchweld flange.
19. Clean around the edge of the inside surface of the rear window with a 50/50 mixture of
isopropyl alcohol and water by volume on a dampened, lint free cloth.

Important: Do not apply the (black #3) primer to the existing bead of the urethane
adhesive. Apply the primer only to nicks, scratches or the primed surfaces.

20. Shake the pinchweld primer (black #3) for at least 1 minute.
21. Use a new dauber to apply the primer to the surface of the pinchweld flange.
22. Allow the pinchweld primer to dry for approximately 10 minutes.
23. If the extended method is being performed, do the following:

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Important: Use care when applying the prep (clear #1) to the window. This primer dries
almost instantly and may stain the viewing area of the rear window if not applied evenly.

24. Use a new dauber, to apply the stationary window prep (clear #1) to an area approximately
10-16 mm (3/8-5/8 in) around the entire perimeter of the rear glass inner surface.

The glass must be installed within 8 hours after applying the primer to the glass.

25. Apply the rear window prep (clear #1) to the same area of the glass.
26. Wipe the primed window area immediately with a lint free cloth.
27. Shake the glass primer (black #2) for at least 1 minute.
28. Shake the rear window primer (black #2) for at least 1 minute.

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29. Use a new dauber, in order to apply the rear window primer (black #2) to the areas of the
rear window (1) to which prep (clear #1) was applied.
30. Allow the primer to dry for approximately 10 minutes.

31. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of
6.0 mm (1/4 in).
32. If using the extended method, cut the applicator nozzle in order to provide a bead 10.5 mm
(0.14 in) wide and 10.5 mm (0.14 in) high.

33. Using a cartridge-type caulking gun, apply a smooth continuous bead of new urethane
adhesive around the edge of the rear window where the primer was applied.
34. When using the short method, apply the urethane adhesive to the existing bead of urethane
adhesive on the body.

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35. When using the extended method, use the edge of the rear window or the inside edge of the
reveal molding as a guide for the nozzle in order to apply the urethane adhesive to the inner
surface of the rear window.

36. With the aid of an assistant, install the rear window into the opening.
37. Align the masking tape (1, 3) on the rear window (2) and on the body.
38. Press the rear window firmly into place in order to wet-out and seat the urethane adhesive.
39. Tape the rear window in 2 places to the body in order to minimize movement until the
urethane adhesive cures.

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40. Clean any excess urethane adhesive from the body.

Important: Do not direct a hard stream of high pressure water at the fresh urethane
adhesive.

41. Use a soft spray of warm water in order to immediately water test the rear window.
42. Inspect the rear window for leaks.
43. If any leaks are found, use a plastic paddle in order to apply extra urethane at the leak point.
44. Retest the rear window for leaks.

Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be

ejected from the vehicle resulting in personal injury.
• For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C

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(70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours
for the complete curing of the urethane adhesive.
• For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour .
Do NOT physically disturb the repair area until after these minimum times have elapsed.

45. The following conditions must be maintained to properly cure the urethane.
45.1. Partially lower a door rear window in order to prevent pressure buildups when closing
doors before the urethane adhesive cures.
45.2. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above
curing times.
45.3. Do not use compressed air in order to dry the urethane adhesive.

46. Connect the rear window electrical connectors.

47. Connect the OnStar® antenna. Refer to Mobile Telephone Antenna Replacement in Cellular
Communication.
48. Connect the antenna connection to the rear window.
49. Install the rear upper interior quarter trim. Refer to Rear Quarter Upper Trim Panel
Replacement in Interior Trim.
50. Remove the masking tape from the area around the window in order to protect the painted
surfaces from damage and to protect the headliner.
51. Close the rear compartment lid.

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Rearview Mirror Support Installation

Special Tools
Safety Razor or Utility Knife

1. Determine the location of the mirror mounting base by marking the outside of the windshield
with a marking pencil where the base was previously located. If it is not clear where the base
was mounted, use the following steps to determine where the base should be installed:

1.1. Using a measuring tape, measure the distance between the windshield pillars from the
base of the shade line .
1.2. Using a marking pencil, halfway between the windshield pillars, draw a centerline (1)
on the windshield from the roof panel to the windshield base.
1.3. Draw a perpendicular line intersecting the centerline (2) at that location.

The top center of the mirror mounting base will be at the intersection of these lines.

2. Scrape the inside windshield thoroughly with a safety razor or utility knife in order to remove
all old adhesive.
3. If reinstalling the original mounting base, place the mirror mounting base in a suitable
holding device, such as a vise.
4. Clean the mirror mounting base thoroughly with a safety razor or utility knife in order to
remove all old adhesive.
5. Clean the inside windshield and the mounting surface of the mirror mounting base thoroughly
with a clean cloth saturated with naphtha or a 50/50 mixture (by volume) of clean water and
isopropyl alcohol.

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6. Use Inside Mirror Adhesive Kit GM P/N 89021329 (Canadian P/N 993362), or equivalent, to
apply a small amount of activator to the mounting surface of the mirror mounting base.
7. Apply a small amount of activator to the windshield where the mounting base is to be
installed.
8. Allow the activator to dry 5 minutes.

Important: Do not touch the mounting surface of the mirror mounting base or the window.

9. Apply 1 drop of adhesive to the center of the mirror mounting base.

10. Immediately apply the mounting base to the windshield, ensuring that the mounting base
aligns correctly to the marks made on the outside of the windshield.
11. Hold the mounting base firmly in place for 1 minute.
12. Allow the adhesive to set for 15 minutes.

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13. Install the mirror to the mirror mounting base and fasten, if necessary.
14. Connect the electrical connector and install the wire cover, if equipped.

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Window Polishing
Minor Scratch and Abrasion Removal
Remove or reduce any minor scratches and abrasions by following the procedure below. Use care
in order to prevent distortions of vision. Double vision may result if you attempt to remove deep
scratches. Do not attempt to remove any deep scratches near the driver's line of vision. If deep
scratches are present, replace the window.

The polishing procedure that follows was developed using a cerium oxide compound. Follow the
manufacturer's instructions if any other materials are used. The polishing procedure should not be
used on deep tinted windows. The coating on the windows could be damaged.

Recommended Equipment
• l A low speed (600-1,300 RPM) rotary polisher
• l A wool felt, rotary polishing pad 76 mm (3 in) the diameter and 51 mm (2 in) thick
• l Powdered cerium oxide mixed with water, this is the abrasive compound
• l A wide mouth container in order to hold the abrasive compound

Polishing Procedure
1. Mix at least 44 ml (1.5 oz) of cerium oxide with enough water in order to obtain a creamy
consistency.
• If the mixture is too thick, the mixture will cake on the felt pad more quickly.
• If the mixture is too runny, more polishing time will be needed.
2. Draw a circle around the scratches on the opposite side of the window in order to serve as a
guide for locating the scratch while polishing.
3. Cover the surrounding area with masking paper in order to catch the drippings or any
splattered polish.

Important: Do not submerge the pad or allow the pad to stay in the mixture, as the bond
may loosen between the pad and the metal plate.

4. Dip the felt pad, attached to the polisher, into the mixture.

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5. Note the following suggestions while polishing the scratched area:

• Stir the mixture as often as needed in order to maintain the creamy consistency of the
compound.
• Use moderate but steady pressure.
• Hold the pad flat against the window.
• Use a feathering-out motion.
• Dip the pad into the mixture every 15 seconds in order to ensure that the wheel and the
window are always wet during the polishing operation. A dry pad causes excessive heat to
develop.
• Keep the pad free of dirt and other foreign substances.
6. After removing the scratch, wipe the area clean of any polish.
7. Clean the polishing pad.

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Windshield Replacement
Tools Required
• J 24402-A Glass Sealant (Cold Knife) Remover
• J 39032 Stationary Glass Removal Tool
• Urethane Adhesive Kit GM P/N 12346392 or Equivalent
• Isopropyl Alcohol or Equivalent
• Cartridge-type Caulking Gun
• Commercial-type Utility Knife
• Razor Blade Scraper
• Suction Cups
• Plastic Paddle

Removal Procedure

Important: Before cutting out a stationary window, apply a double layer of masking tape
around the perimeter of the painted surfaces and inner trim of the window.

1. Open the hood.

2. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in
Wipers/Washer Systems.
3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
4. Disconnect the antenna lead. Refer to Antenna Cable Replacement .
© 2014 General Motors Corporation. All rights reserved.

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5. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .

Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger
compartment and cause personal injury.

6. Cover the defroster grille outlets as needed.

Caution: When working with any type of glass or sheet metal with exposed or rough edges,
wear approved safety glasses and gloves in order to reduce the chance of personal injury.

7. Use safety glasses and gloves.

Important: The windshield reveal molding fills the cavities between the body and windshield
and can not be reused if stretched or damaged.

8. Remove the windshield reveal molding from the windshield.

Grasp the lower corner of the windshield reveal molding by hand and slowly pull the reveal
molding away from the windshield.

9. If the windshield reveal molding will not release, use a utility knife in order to cut around the
windshield in order to remove the windshield reveal molding.

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10. Remove the lower windshield supports (1) from the cowl panel (2).

Important: Keep the cutting edge of the tool against the windshield. This will allow the
urethane adhesive to be separated from the windshield. Leave a base of urethane on the
pinchweld flange. The only suitable lubrication is clear water.

11. Use the J 24402-A or J 39032 tool in order to remove the windshield.

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12. Remove the windshield (1) from the vehicle with the aid of an assistant.

Installation Procedure

1. Install the lower window supports (1) to the cowl panel, if equipped.

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2. If the original window reveal molding (1) is damaged it must be replaced.

Install the window reveal molding. Refer to Windshield Reveal Molding Replacement .

3. Replace the acoustic strip if damaged when removing.

4. With the aid of an assistant, dry fit the window (1) in the opening in order to determine the
correct way to position the window in the opening.

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5. Use masking tape (1) in order to mark the location of the window (2) in the opening.
6. Slit the masking tape at the top edge and sides of the window.

7. With the aid of assistant remove the window (1) from the opening.
8. Place the window inside up on a clean, protected surface.
9. Inspect for any of the following problems in order to help prevent future breakage of the
window:
10. Inspect the following components for the causes of a broken window:
• The flange of the window opening
• The window reveal molding
11. Inspect for any of the following problems in order to help prevent future breakage of the
window:
• High weld

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• Solder spots
• Hardened spot weld sealer
• Any other obstruction or irregularity in the pinchweld flange.

Important: If corrosion of the pinchweld flange is present, or if sheet metal repairs or

replacements are required, the pinchweld flange must be refinished in order to restore the
bonding area strength. If paint repairs are required, mask the flange bonding area prior to
applying the color coat in order to provide a clean primer only surface. Materials such as
BASF DE17®, DuPont 2610®, Sherwin-Williams PSE 4600 and NP70® and Martin-
Semour 5120 and 5130® products are approved for this application.

12. After repairing the opening do the following.

13. Inspect the condition of the window opening and the urethane adhesive bead to determine
which installation method should be used. Refer to Short Method Description or Extended
Method Description for guidelines.
14. Remove no more of the urethane adhesive from the pinchweld than necessary in order to
maintain the original shape. This will ensure the proper clearance between the window and
the pinchweld flange.

Important: Do not remove all traces of the adhesive. Remove all mounds or loose pieces of
urethane adhesive.

15. If the original window is being reused remove all but a thin film of the existing urethane
adhesive from the window surface by using a clean utility knife or razor blade scraper.
16. If the extended method is being used remove all but approximately 2 mm (3/64 in) of the
existing bead of urethane adhesive from the pinchweld flange.
17. After repairing the opening, remove all traces of broken glass from the outer cowl panel,
seats, floor and defroster ducts.
18. Clean around the edge of the inside surface of the window with a 50/50 mixture of isopropyl
alcohol and water by volume on a dampened lint free cloth.

19. Verify all primers and urethane adhesive are within expiration dates.

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Important: Do not apply the (black #3 primer to the existing bead of the urethane
adhesive. Apply only to nicks, scratches or the primed surfaces.

20. Shake the pinchweld primer (black #3) for at least 1 minute.
21. Use a new dauber to apply the pinchweld primer (black #3) to the surface (1) of the bonding
area on the body only.
22. Allow the primer to dry for approximately 10 minutes.

23. Install the spacers and the VIN plate filler strip, if equipped.

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Important: Use care when applying prep (clear #1) on the window. This primer dries almost
instantly, and may stain the viewing area of the window if not applied evenly.

24. Use a new dauber in order to apply glass prep (clear #1) to the area approximately 10-
16 mm (3/8-5/8 in) around the entire perimeter of the window inner surface.

25. Apply a second coat of the glass prep number (clear #1) to the same area of the glass.

Wipe the glass primed area immediately with a clean lint free cloth.

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26. Shake the glass primer (black #2) for at least 1 minute.
26.1. Use a new dauber in order to apply the glass primer (black #2) to the same areas (2)
that glass prep (clear #1) was applied.
26.2. The glass primer (black #2) is good up to 8 hours after applying it to the glass. The
primed surface of the glass must be kept clean.
26.3. Allow the glass primer to dry for approximately 10 minutes.

27. If using the short method, cut the tip of the applicator nozzle in order to provide a bead of
6.0 mm (1/4 in).
28. If using the extended method, cut the applicator nozzle in order to provide a bead of
12.7 mm (1/2 in) wide and 12.7 mm (1/2 in) high.

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29. Use a cartridge type caulking gun to apply a smooth, continuous bead of urethane adhesive.
30. When using the short method, apply the urethane adhesive to the existing bead of urethane
adhesive on the body.

31. When using the extended method, use the edge of the windshield window or the inside edge
of the reveal molding as a guide for the nozzle in order to apply the urethane adhesive (1) to
the inner surface of the windshield window (3).

If applying urethane adhesive to the inside edge of the windshield reveal molding (1) use the
windshield reveal molding as a guide for the nozzle.

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32. Use suction cups, along with the aid of an assistant to install the windshield into the opening.

33. Place the windshield on the lower supports (1).

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34. Align the masking tape (1, 2) on the windshield (3) and the body.

35. Press the windshield firmly into place.

36. Tape the windshield to the body in order to minimize movement until the urethane adhesive
cures.

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37. Clean any excess urethane adhesive from the body.

Important: Do not direct a hard stream of high pressure water to the freshly applied
urethane adhesive.

38. Use a soft spray of warm water in order to immediately water test the windshield window.
39. Inspect the windshield for leaks.
40. If any leaks are found, use a plastic paddle in order to apply extra urethane adhesive at the
leak point.
41. Retest the windshield for leaks.

Caution: Insufficient curing of urethane adhesive may allow unrestrained occupants to be

ejected from the vehicle resulting in personal injury.

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• For the moisture-curing type of urethane adhesive, allow a minimum of 6 hours at 21°C
(70°F) or greater and with at least 30 percent relative humidity. Allow at least 24 hours
for the complete curing of the urethane adhesive.
• For the chemical-curing type of urethane adhesive, allow a minimum of 1 hour .
Do NOT physically disturb the repair area until after these minimum times have elapsed.

42. The following conditions must be maintained to properly cure the urethane.
42.1. Partially lower a door window in order to prevent pressure buildups when closing
doors before the urethane adhesive cures.
42.2. Do not drive the vehicle until the urethane adhesive is cured. Refer to the above
curing times.
42.3. Do not use compressed air in order to dry the urethane adhesive.
43. Connect the antenna lead. Refer to Antenna Cable Replacement .
44. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement .
45. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement in Body Front End.
46. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in
Wipers/Washer System.
47. Remove the masking tape from the area around the window in order to protect the painted
surfaces from damage and to protect the headliner.
48. Close the hood.

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Windshield Reveal Molding Replacement

Removal Procedure

Important: These moldings require the removal of the window for proper installation.

1. Remove the windshield. Refer to Windshield Replacement .

2. Remove the reveal molding.

Installation Procedure

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1. Use your hand in order to press the reveal molding onto the windshield or rear window.

Install the reveal molding as follows:

1.1. Locate the molding corners to the locator line at the windshield corners.
1.2. Install the moulding starting from the corners working toward the center.
1.3. Roll the moulding to the glass starting from the corners using the roller specified.
2. Install the windshield. Refer to Windshield Replacement .

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Fastener Tightening Specifications

Specification
Application Metric English
Column Support Bolts 27 N·m 20 lb ft
Cable Support Bracket Screws 10 N·m 89 lb in
Intermediate Shaft Pinch Bolt 47 N·m 35 lb ft
Intermediate Shaft Seal Screw 2 N·m 21 lb in
Multi-Function Switch Screws 7 N·m 62 lb in
Steering Column Trim Cover Lower 3.5 N·m 31 lb in
Steering Column Trim Cover Upper 1.5 N·m 13 lb in
Steering Wheel Mass Damper 3 N·m 27 lb in
Steering Wheel Nut 41 N·m 30 lb ft

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Steering Column Disassembled View (Aurora)

Tilt Steering Column, Floor Shift

(1) Upper Trim Cover

(2) Lower Trim Cover
(3) Steering Column Closeout Trim Cover
(4) Flanged Prevailing Torque Nut
(5) Retaining Ring
(6) Inflatable Restraint Steering Wheel Module Coil
(7) Wave Washer
(8) Bearing Retainer
(9) Cam Orientation Plate
(10) Turn Signal Cancel Cam Assembly
© 2014 General Motors Corporation. All rights reserved.

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(11) Upper Bearing Spring

(12) Upper Bearing Inner Race Seat
(13) Inner Race
(14) Turn Signal Switch Housing
(15) Windshield Wiper and Washer Switch Assembly
(16) Steering Column Tilt Head Assembly
(17) Wire Harness Strap
(18) Spring Guide
(19) Tilt Spring
(20) Release Lever Pin
(21) Pan Head Tapping Screws
(22) Wire Harness Straps
(23) Pan Head Tapping Screws
(24) Turn Signal and Multifunction Switch Assembly
(25) Wire Harness Straps
(26) Axial Position Assurance Connector
(27) Race and Upper Shaft Assembly
(28) Centering Sphere
(29) Joint Preload Spring
(30) Lower Steering Shaft Assembly
(31) Pivot Pin
(31) Pivot Pin
(32) Wire Restraint Clip
(33) Steering Column Support Assembly
(34) Dual Triangle Sensor Assembly
(35) Sensor Locator
(36) Boot Seal
(37) Boot
(38) Bolt Retainer
(39) Bolt and Retainer Assembly
(40) Intermediate Steering Shaft Assembly

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Steering Column Disassembled View (Prime Aurora)

Tilt Steering Column, Floor Shift

(1) Upper Trim Cover

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(11) Upper Bearing Spring

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Inflatable Restraint Coil Centering - Off Vehicle

(Column Shift And Floor Shift)

Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil
assembly may damage the unit, causing an inflatable restraint malfunction.

1. Verify the following before centering the inflatable restraint steering wheel module coil:
• 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.

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2. If the front (5) of the inflatable restraint steering wheel module coil has a centering
window (4), and on the back side (2) a spring service lock (1), perform the following steps:
2.1. Hold the inflatable restraint steering wheel module coil 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, counterclockwise, until the centering window appears yellow
and both arrows (3) line up.
2.4. Release spring service lock between the locking tab. The inflatable restraint steering
wheel module coil is now centered.
2.5. Align the centered inflatable restraint steering wheel module coil with the horn tower
and slide onto the steering shaft assembly.

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3. If the front (4) of the inflatable restraint steering wheel module coil has a centering
window (3) and no spring service lock on the back side (1), perform the following steps:
3.1. Hold the inflatable restraint steering wheel module coil with the face up.
3.2. Rotate the coil hub clockwise until the coil ribbon stops.
3.3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow
and both arrows (2) line up. This is the CENTER position.
3.4. While holding the coil hub in the CENTER position, align the inflatable restraint steering
wheel module coil with the horn tower and slide onto the steering shaft assembly.

4. If no centering window is present on the front side (3) of the inflatable restraint steering
wheel module coil, but a spring service lock (1) is on the back side (2), perform the following
steps:
4.1. Hold the inflatable restraint steering wheel module coil with the back side up.
4.2. While depressing the spring service lock, rotate the coil hub in the direction of the
arrow (4) until the coil ribbon stops.
4.3. Still pressing the spring service lock, rotate the coil hub in the opposite direction
2 ½ revolutions.
4.4. Release the spring service lock between locking tabs. The inflatable restraint steering
wheel module coil is now centered.
4.5. Align the centered inflatable restraint steering wheel module coil with the horn tower
and slide onto the steering shaft assembly.

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5. For no centering window on the front side (2) of the inflatable restraint steering wheel
module coil and no spring service lock on the back side (1), perform the following steps:
5.1. Hold the inflatable restraint steering wheel module coil with the face up.
5.2. Rotate the coil hub in the direction of the arrow until the coil ribbon stops.
5.3. Rotate the coil hub, slowly, counterclockwise, for 2 ½ revolutions. This is the CENTER
position.
5.4. While maintaining the coil hub in the CENTER position, align the centered inflatable
restraint steering wheel module coil with the horn tower and slide onto the steering
shaft assembly.

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Inflatable Restraint Steering Wheel Module Coil

Assemble - Off Vehicle

1. Install the wave washer (1).

Important: Improper alignment of the inflatable restraint steering wheel module coil may
damage unit causing an inflatable restraint malfunction.

on2014
the General
steering shaft
Motors assemblyAll(1)
Corporation. to the
rights 12 o'clock position.
reserved.

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Important: A new inflatable restraint steering wheel module coil is pre-centered. Do not
remove the centering tab from the new inflatable restraint steering wheel module coil until
the installation is complete.

3. If installing the existing inflatable restraint steering wheel module coil, it must be centered
first. Refer to Inflatable Restraint Coil Centering - Off Vehicle .
4. Align the inflatable restraint steering wheel module coil (2) with the horn tower sticking
through the shaft lock shield assembly (1).
5. Slide the inflatable restraint steering wheel module coil (2) onto the steering shaft assembly.
6. Remove and discard the centering tab from the new inflatable restraint steering wheel
module coil (2).

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Important: Seat the retaining ring (1) securely on the groove of the race and upper shaft
assembly (2).

7. Install the retaining ring (1) using snap ring pliers.

8. Install the black inflatable restraint steering wheel module coil connector to the fused jumper
assembly connector.

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

9. Install the wire harness straps.

10. Install the wire harness assembly into the wire restraint clip (1).

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11. Install the upper and lower trim covers. Refer to Steering Column Trim Covers - Assemble -
Off Vehicle .
12. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Inflatable Restraint Steering Wheel Module Coil

Disassemble - Off Vehicle

Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.

Important: Before performing the following procedures, check the fused jumper assembly
for burned 2 amp fuses.

2. Remove the upper and lower trim covers. Refer to Steering Column Trim Covers -
Disassemble - Off Vehicle .
3. Remove the wire harness assembly from the wire restraint clip (1).
4. Remove the wire harness straps.

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5. Remove the black inflatable restraint steering wheel module coil connector from the fused
jumper assembly connector.

6. Remove the retaining ring (1) using snap ring pliers.

7. Remove the inflatable restraint steering wheel module coil (2).
8. Remove the wave washer (3).

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Intermediate Steering Shaft Replacement

Removal Procedure
1. Remove the Steering column. Refer to Steering Column Replacement .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.

4. Remove the pinch bolt at the power steering gear stub shaft.
5. Remove the intermediate shaft from the power steering gear stub shaft.
6. Remove the intermediate steering shaft.

Installation Procedure

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1. Install the intermediate shaft to the power steering gear stub shaft.

2. Install the pinch bolt to the power steering gear stub shaft.

Tighten
Tighten the power steering gear pinch bolt to 47 N·m (35 lb ft).

3. Install the left front tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Lower the vehicle.
5. Install the steering column. Refer to Steering Column Replacement .

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Multifunction Turn Signal Lever Replacement - On

Vehicle
Removal Procedure

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges,
and Console.
3. Remove the steering wheel. Refer to Steering Wheel Replacement .
4. Remove the tilt lever. Refer to Tilt Lever Replacement - On Vehicle .
5. Remove the lower screws from the lower shroud.

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6. Remove the lower shroud.

• Tilt the shroud down and slide back to disengage the locking tabs.
• Remove the shroud protector.

7. Remove the screws from the upper shroud.

8. Remove the upper shroud.

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9. Remove the fasteners from the multi-function switch.

10. Disconnect the multi-function switch electrical connections.
11. Remove the multi-function switch.

Installation Procedure

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1. Install the multi-function switch and the fasteners.

Tighten
Tighten the fasteners to 7 N·m (62 lb in).

2. Route the electrical harness and connect electrical connections.

3. Install the upper shroud and install the fasteners.

Tighten
Tighten the fasteners to 7 N·m (62 lb in).

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4. Install the lower shroud.

• Ensure that the slots on the lower shroud engage with the tabs on the upper shroud.
• Tilt the lower shroud up and snap the shrouds together.

5. Install the 2 fasteners.

Tighten
Tighten the fastener to 7 N·m (62 lb in).

6. Install steering wheel. Refer to Steering Wheel Replacement .

7. Install tilt lever. Refer to Tilt Lever Replacement - On Vehicle .
8. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Pane, Gauges, and
Console.
9. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Steering Column Accident Damage Inspection - Off

Vehicle
Inspection Procedure
•

l 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 misaligned steering column.
• l 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.
• l 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.
•

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l Check for jacket assembly collapse by measuring the distance from the lower edge of the
upper jacket to a defined point on the lower jacket. Replace the jacket assembly if the
measured dimensions are not within specifications.
•

l Check for tab (1) breakage on the bearing and adapter assembly.
•

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l Visually inspect the steering shaft for sheared injected plastic (1). If the steering shaft
shows sheared plastic, replace the steering shaft.
• l 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).

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Steering Column Replacement

Tools Required
J 42640 Steering Column Anti Rotation Pin

Removal Procedure
Notice: The wheels of the vehicle must be straight ahead and the steering column in the
LOCK position before disconnecting the steering column or intermediate shaft from the
steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which
may cause damage to the coil assembly.

Notice: Once the steering column is removed from the car, the column is extremely
susceptible to damage. Dropping the column on its end could collapse the steering shaft or
loosen the plastic injections which maintain column rigidity. Leaning on the column could
cause the jacket to bend or deform. Any of the above damage could impair the column's
collapsible design. If it is necessary to remove the steering wheel, use only the specified
steering wheel puller. Under no conditions should the end of the shaft be hammered upon as
hammering could loosen plastic injections which maintain column rigidity.

Notice: The steering column should never be supported only by the lower support bracket.
Damage to the lower support could result.

1. Disconnect the negative battery cable.

2. Disable the SIR system. Refer to Disabling the SIR System in SIR.

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3. Insert J 42640 into the steering column access hole in order to lock the steering column. This
will maintain the correct orientation.
4. Remove the steering wheel. Refer to Steering Wheel Replacement .
5. Remove the steering column bracket. Refer to Steering Column Bracket Replacement in
Instrument Panel, Gages and Console.

6. Disconnect the steering column wiring harness connector from the main body wiring harness.
7. Position the seal as needed
8. Remove the pinch bolt (2) from the upper intermediate shaft.

Important: Stabilize the studs in order to remove the nuts securing the steering column to
the instrument panel.

9. Support the column.

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10. Position a 13-mm crowfoot wrench onto one of the nuts which secures the steering column to
the I/P.
11. While holding the stud in position with a #7 inverted TORX® socket, remove the nut.
12. Repeat the above steps for each nut.

Important: Discard the clips at the upper steering column support, if equipped. These clips
are for assembly plant usage only.

13. Remove the steering column from the vehicle.

Installation Procedure
1. Position the steering column through the seal and onto the intermediate steering shaft.

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2. Support the column. Install the nuts on the support bracket studs.

3. Install the pinch bolt (2) to the upper intermediate shaft.

Tighten
• Tighten the bolt to 47 N·m (35 lb ft).
• Tighten the nuts to 27 N·m (20 lb ft).
4. Move the intermediate steering shaft seal into position.
5. Connect the steering column wiring harness connector to the main body wiring harness.
6. Install the steering column bracket. Refer to Steering Column Bracket Replacement in
Instrument Panel, Gages, and Console.
7. Install the steering wheel. Refer to Steering Wheel Replacement .
8. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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9. Remove J 42640 from the steering column.

10. Connect the negative battery cable.
11. Inspect the steering for proper operation.

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Steering Column Tilt Spring Replacement

Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the steering wheel. Refer to Steering Wheel Replacement .
3. Remove the knee bolster. Refer to Knee Bolster Replacement .
4. Remove the steering column trim covers. Refer to Steering Column Trim Covers Replacement
- On Vehicle .

5. Use the tilt lever to tilt the column in the UP position.

6. Remove the tilt spring (1).

Installation Procedure

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1. Lubricate tilt spring guide with synthetic grease.

2. Install the tilt spring guide into the tilt spring.

3. Install the tilt spring (1).

4. Install the steering column trim covers. Refer to Steering Column Trim Covers Replacement -
On Vehicle .
5. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and
Console.
6. Install the steering wheel. Refer to Steering Wheel Replacement .
7. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Steering Column Trim Covers - Assemble - Off Vehicle

Tools Required
J 41352 Modular Column Holding Fixture

1. If necessary, install the closeout trim cover (2) onto the upper trim cover (1).

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2. Install the upper trim cover (1) with the closeout trim cover (2) and secure by using
1 TORX® head screw (3).

Tighten
Tighten the screw to 1.5 N·m (13 lb in).

3. Install the lower trim cover (1).

4. Connect the lower trim cover (1) to the closeout trim cover.
5. Install 2 pan head tapping screws (2).

Tighten
Tighten the screws to 3.5 N·m (31 lb in).

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6. Remove 2 screws from the top piece of J 41352 .

7. Take the column out from J 41352 .
8. Remove the bottom piece of J 41352 from the vise.

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

9. Remove the steering column and J 41352 from the vise.

10. Install the steering column into the vehicle. Refer to Steering Column Replacement .
11. Install the steering wheel onto the steering column. Refer to Steering Wheel Replacement .
12. Install the tilt lever. Refer to Tilt Lever Replacement - On Vehicle .
13. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Steering Column Trim Covers - Disassemble - Off

Vehicle
Tools Required
J 41352 Modular Column Holding Fixture

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.

Important: Place the steering column in the center position.

2. Remove the tilt lever from the upper trim cover. Refer to Tilt Lever Replacement - On
Vehicle .
3. Remove the steering © wheel
2014 from the
General steering
Motors column.
Corporation. Referreserved.
All rights to Steering Wheel Replacement .

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4. Remove the steering column from the vehicle. Refer to Steering Column Replacement .
5. Check the steering column for accident damage. Refer to Steering Column Accident Damage
Inspection - Off Vehicle .
6. Place the bottom of J 41352 into a vise.
7. Set the steering column in the bottom of J 41352 .
8. Place the top piece of J 41352 onto the column and secure with 2 screws.

9. Gently remove the closeout trim cover from the lower trim cover (1).
10. Remove 2 pan head tapping screws (2) from the lower trim cover (1).
11. Remove the lower trim cover (1).

12. Remove 1 TORX® head screw (3) from the upper trim cover (1).
13. Remove the upper trim cover (1) with the closeout trim cover (2).

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14. If necessary, remove the closeout trim cover (2) from the upper trim cover (1).

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Steering Column Trim Covers Replacement - On Vehicle

Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.

4. Remove the tilt lever.

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5. Remove the lower steering column trim cover retaining screws.

6. Disconnect the closeout shroud from the lower steering column trim cover.

7. Remove the upper steering column trim cover (1) retaining screw (3).
8. Disconnect the closeout shroud (2) from the upper steering column trim cover (1).

Installation Procedure

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1. Connect the closeout shroud to the upper steering column trim cover.

2. Install the upper steering column trim cover retaining screw.

Tighten
Tighten the upper steering column trim cover retaining screw to 1.5 N·m (13 lb in).

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3. Connect the closeout shroud to the lower steering column trim cover.
4. Install the lower steering column trim cover retaining screws.

Tighten
Tighten the lower steering column trim cover retaining screws to 3.5 N·m (31 lb in).

5. Install the tilt lever.

6. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and
Console.
7. Install the steering wheel. Refer to Steering Wheel Replacement .
8. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Steering Shaft, Lower Bearing, and Jacket - Assemble -

Off Vehicle

1. Apply lithium grease to the race and upper shaft assembly.

2. Align the marks on the race and upper shaft assembly with the marks you made from the
disassemble procedure to the lower shaft assembly
3. Install the lower shaft assembly to the race and upper shaft assembly.

4. Install the cable support bracket.

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5. Lubricate the 3 flat head screws with LOCTITE®.

Install the 3 flat head screws.

Tighten
Tighten the screws to 10 N·m (89 lb in).

6. Install the dual triangle sensor assembly.

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7. Perform the following steps:

7.1. Install the boot seal (1)
7.2. Install the sensor retainer (2)
7.3. Install the steering shaft seal (3)
7.4. Install the boot (4)

8. Install the steering shaft assembly (2) into the steering column tilt head assembly (1).

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9. Install the tilt head assembly (1) and the lower steering shaft (3) into the steering column
support assembly (2).

Important: Replace the steering column support assembly if the steering column support
assembly has been staked 3 times.

10. Lubricate the pivot pins with synthetic grease.

Install the 2 pivot pins onto the steering column support assembly. Stake the pins in
3 places.

11. Install the tilt spring assembly only. Refer to Tilt Spring - Assemble - Off Vehicle .

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Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

12. Install the turn signal and multifunction switch assembly only. Refer to Turn Signal and
Multifunction Switch Assembly - Assemble - Off Vehicle .
13. Install the turn signal switch housing. Refer to Turn Signal Switch Housing - Assemble - Off
Vehicle .
14. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Steering Shaft, Lower Bearing, and Jacket -

Disassemble - Off Vehicle
Tools Required
J 21854-01 Pivot Pin Remover

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the turn signal switch housing. Refer to Turn Signal Switch Housing - Disassemble -
Off Vehicle .
3. Remove the turn signal and multifunction switch assembly only. Refer to Turn Signal and
Multifunction Switch Assembly - Disassemble - Off Vehicle .
4. Remove the tilt spring only. Refer to Tilt Spring - Disassemble - Off Vehicle .
5. Remove 2 pivot pins (1) from the steering column support assembly using J 21854-01 .
© 2014 General Motors Corporation. All rights reserved.

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6. Remove the dual triangle sensor assembly.

7. Perform the following steps:

7.1. Remove the boot (4).
7.2. Remove the steering shaft seal (3).
7.3. Remove the sensor retainer (2).
7.4. Remove the boot seal (1).

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8. Remove the 3 flat head screws.

9. Remove the cable support bracket.

10. Remove the tilt head assembly (1) from the steering column support assembly (2) with the
lower steering shaft (3) still attached.

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11. Remove the tilt head assembly (1) from the steering shaft assembly (2).

Important: Mark the race and upper shaft (1) and the lower steering shaft (2) to ensure
proper assembly. Failure to assemble properly will cause the steering wheel to be turned
180 degrees.

12. Tilt the upper shaft assembly 90 degrees to the steering shaft assembly and disengage.

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Steering Wheel Replacement

Tools Required
• J 42578 Steering Wheel Puller Legs
• J 1859-A Steering Wheel Puller

Removal Procedure
1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the Inflatable Restraint Steering Wheel Module. Refer to Inflatable Restraint Steering
Wheel Module Replacement in SIR.

3. Remove the steering wheel mass damper retaining screws.

4. Remove the mass damper from the steering wheel.
5. Remove the steering wheel retaining nut.
6. Note the mark on the steering shaft and the steering wheel in order to ensure proper
alignment during installation.

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7. Use the J 42578 and the J 1859-A in order to remove the steering wheel .
8. Remove the J 42578 and the J 1859-A from the steering wheel.

Installation Procedure

1. Route the wiring through the steering wheel.

2. Align the mark on the steering wheel with the mark on the shaft.
3. Install the steering wheel.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners

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4. Install the steering wheel retaining nut.

Tighten
Tighten the steering wheel retaining nut to 41 N·m (30 lb ft).

5. Install the mass damper.

6. Install the mass damper retaining screw.

Tighten
Tighten the mass damper retaining screws to 3 N·m (27 lb in).

7. Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering
Wheel Module Replacement in SIR.
8. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Tilt Lever Replacement - On Vehicle

Removal Procedure

1. Grasp the tilt lever.

2. Pull the tilt lever straight out from steering column.

Installation Procedure

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1. Align the tilt lever into the steering column.

2. Slide the tilt lever handle into the steering column until it locks into position.

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Tilt Spring - Assemble - Off Vehicle

1. Lubricate spring guide with synthetic grease. Install the spring guide into the tilt spring.

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.
© 2014 General Motors Corporation. All rights reserved.

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2. Install the tilt spring (1).

2.1. Install the tilt spring (1) to the post on the steering column support assembly (2).
2.2. Secure the tilt spring (1).
3. Install the upper and lower trim covers. Refer to Steering Column Trim Covers - Assemble -
Off Vehicle .
4. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Tilt Spring - Disassemble - Off Vehicle

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the upper and lower trim covers. Refer to Steering Column Trim Covers -
Disassemble - Off Vehicle .
3. Use the tilt lever to tilt the column in the UP position.

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4. Remove the tilt spring (1).

4.1. Pry the tilt spring up until a bulge occurs and most of the tilt spring tension is
removed.
4.2. Secure the tilt spring and continue prying until the tilt spring disengages from the post
on the steering column support assembly (2) and the steering column tilt head
assembly (3).

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5. Remove the spring guide from the tilt spring.

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Turn Signal and Multifunction Switch Assembly -

Assemble - Off Vehicle

Important: The electrical contact on the turn signal and multifunction switch assembly must
rest on the turn signal cancel cam assembly.

1. Install the turn signal and multifunction switch assembly.

2. Secure by using 2 pan head tapping screws.

Tighten
Tighten the screws to 7 N·m (62 lb in).

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3. Reconnect the connectors of the turn signal and multifunction switch assembly.

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

4. Install the wire harness straps.

5. Install the wire harness assembly into the wire restraint clip (1).
6. Install the upper and lower trim covers. Refer to Steering Column Trim Covers - Assemble -
Off Vehicle .
7. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Turn Signal and Multifunction Switch Assembly -

Disassemble - Off Vehicle

Remove the wire harness assembly from the wire restraint clip (1).

4. Disconnect the connectors of the turn signal and multifunction switch assembly.

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5. Remove 2 pan head tapping screws from the turn signal and multifunction switch assembly.
6. Remove the turn signal and multifunction switch assembly.

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Turn Signal Cancel Cam and Upper Bearing Inner Race -

Assemble - Off Vehicle
Tools Required
• J 23653-SIR Steering Column Lock Plate Compressor
• J 42137 Steering Column Lock Plate Compressor Adapter

1. Install the inner race (4).

2. Install the upper bearing inner race seat (3).
3. Install the upper bearing spring (2).
4. Lubricate the turn signal cancel cam assembly (1).

Important: The electrical contact of the turn signal and multifunction switch assembly must
rest on the turn signal cancel cam assembly.

5. Install the turn signal cancel cam assembly (1).

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6. Install the shaft lock shield assembly.

7. Install the new bearing retainer (1) using J 23653-SIR and J 42137 .

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

8. Install the inflatable restraint steering wheel module coil. Refer to Inflatable Restraint
Steering Wheel Module Coil Assemble - Off Vehicle .
9. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Turn Signal Cancel Cam and Upper Bearing Inner Race -

Disassemble - Off Vehicle
Tools Required
• J 23653-SIR Steering Column Lock Plate Compressor
• J 42137 Steering Column Lock Plate Adapter Compressor Adapter

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.

Important: Do not remove the wire harness straps unless necessary.

2014 General Motors wheel module
Corporation. All rights Refer to Inflatable Restraint
coil. reserved.

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Steering Wheel Module Coil Disassemble - Off Vehicle .

3. Remove and dispose of the bearing retainer (1) using J 23653-SIR and J 42137 .

4. Remove the shaft lock shield assembly (1).

5. Remove the turn signal cancel cam assembly (2).
6. Remove the upper bearing spring (3).
7. Remove the upper bearing inner race seat (4).
8. Remove the inner race (5).

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Turn Signal Switch Housing - Assemble - Off Vehicle

(Aurora)

1. Install the turn signal switch housing (2) to the steering column tilt head assembly.

2. Install the 2 pan head tapping screws (1).

Tighten
Tighten the screws to 7 N·m (62 lb in).

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3. Slide the windshield wiper and washer switch assembly into the turn signal switch housing
until the tabs lock in place.

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module coil. This may result in a malfunction of the coil, which may cause
personal injury.

4. If necessary, connect the windshield wiper and washer switch assembly connector.
5. Install the upper tilt head components. Refer to Turn Signal Cancel Cam and Upper Bearing
Inner Race - Assemble - Off Vehicle .
6. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Turn Signal Switch Housing - Assemble - Off Vehicle

(Prime Aurora)

Important: The switch mounting bracket must be pressed firmly against the steering
column tilt head in order for the screws from the turn signal and multifunction switch
assembly screws to line up.

1. Slide the turn signal switch housing onto the steering column shaft assembly.
2. Install the windshield wiper and washer switch, if needed.
3. Install the turn signal and multifunction switch assembly only. Refer to Turn Signal and
Multifunction Switch Assembly - Assemble - Off Vehicle .
4. Install the steering column tilt head components. Refer to Turn Signal Cancel Cam and Upper
Bearing Inner Race - Assemble - Off Vehicle .
5. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Turn Signal Switch Housing - Disassemble - Off Vehicle

(Aurora)

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the upper tilt head components. Refer to Turn Signal Cancel Cam and Upper Bearing
Inner Race - Disassemble - Off Vehicle .
3. If necessary, disconnect the connector from the windshield wiper and washer switch
assembly.
4. Remove the windshield wiper and washer switch assembly in the following way:
4.1. Press on the locking tabs of the windshield wiper and washer switch assembly.
4.2. Pull the windshield wiper and washer switch assembly out of the turn signal switch
housing.

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5. Remove the 2 pan head tapping screws (1).

6. Remove the turn signal switch housing (2).

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Turn Signal Switch Housing - Disassemble - Off Vehicle

(Prime Aurora)

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the steering column tilt head housing components. Refer to Turn Signal Cancel Cam
and Upper Bearing Inner Race - Disassemble - Off Vehicle .
3. Remove the turn signal and multifunction switch assembly only. Refer to Turn Signal and
Multifunction Switch Assembly - Disassemble - Off Vehicle .
4. Remove the windshield wiper and washer switch if needed.
5. Slide the turn signal switch housing off of the steering column shaft assembly.

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Windshield Wiper and Washer Switch Assembly -

Assemble - Off Vehicle

1. Slide the windshield wiper and washer switch assembly into the turn signal switch housing so
that the locking tabs snap into place.
2. Connect the windshield wiper and washer switch assembly connector.

Caution: Improper routing of the wire harness assembly may damage the inflatable restraint
steering wheel module
© coil. This may
2014 General result
Motors in a malfunction
Corporation. of the coil, which may cause
All rights reserved.

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personal injury.

3. Install the wire harness straps.

4. Install the wire harness assembly into the wire restraint clip (1).
5. Install the upper and lower trim covers. Refer to Steering Column Trim Covers - Assemble -
Off Vehicle .
6. Enable the inflatable restraint steering wheel module. Refer to Enabling the SIR System in
SIR.

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Windshield Wiper and Washer Switch Assembly -

Disassemble - Off Vehicle

1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the upper and lower trim covers. Refer to Steering Column Trim Covers -
Disassemble - Off Vehicle .
3. Remove the wire harness assembly from the wire restraint clip (1).
4. Remove the wire harness straps.

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5. Disconnect the windshield wiper and washer switch assembly connector.

6. Remove the windshield wiper and washer switch assembly in the following way:
6.1. Press on the locking tabs of the windshield wiper and washer switch assembly.
6.2. Pull the windshield wiper and washer switch assembly out of the turn signal switch
housing.

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Windshield Wiper and Washer Switch Replacement - On

Vehicle
Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
• Air bag deployment
• Personal injury
• Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
• Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
• If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the steering column bracket. Refer to Steering Column Bracket Replacement in
Instrument Panel, Gages, and Console.
3. Remove the steering column trim covers. Refer to Steering Column Trim Covers Replacement
- On Vehicle .

4. Remove the wire harness assembly from the wire restraint clips (1).
5. Disconnect the wire connector.

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6. Disconnect the windshield wiper and washer switch assembly.

7. Remove the windshield wiper and washer switch assembly in the following manner.
• Press on the locking tabs of the windshield wiper and washer switch assembly.
• Pull the windshield wiper and washer switch assembly out of the switch mounting bracket.

Installation Procedure

1. Install the windshield wiper and washer switch assembly into the switch mounting bracket so
that the locking tabs snap into place.
2. Connect the wire harness assembly.

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3. Install new wire harness straps.

4. Install the wire harness assembly into the wire restraint clips (1).
5. Install the steering column trim covers. Refer to Steering Column Trim Covers Replacement -
On Vehicle .
6. Install the steering column bracket. Refer to Steering Column Bracket Replacement in
Instrument Panel, Gages, and Console.
7. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Tire Pressure Monitor Procedure

Important: There are 2 ways to reset the Tire Pressure Monitor (TPM) system. The system
requires up to 30 minutes of straight line driving in each of the 3 speed ranges to complete the
calibration process, for further information, refer to Tire Pressure Monitor Description and
Operation . If the TPM system does not reset using the Driver Information Center (DIC) procedure,
refer to Driver Information Center (DIC) Switch Inoperative in Instrument Panel, Gages, and
Console. If DTC C1245 remains current, refer to Diagnostic System Check - Tire Pressure
Monitoring .

Using the DIC

1. Set all tire pressures to the manufacturer's recommended specifications.
2. Turn ON the ignition, with the engine OFF.
3. Press the SELECT right arrow button until GAGE is displayed.
4. Press the SELECT down arrow button until TIRE PRESSURE is displayed.
5. Press and hold the RESET button until TIRE PRESSURE RESET is displayed.
6. Release the RESET button, TIRE PRESSURE NORMAL is displayed.
7. Use the scan tool in order to clear the TPM DTC.

Using the Scan Tool

1. Set all tire pressures to the manufacturer's recommended specifications.
2. Install the scan tool.
3. Turn ON the ignition, with the engine OFF.
4. With the scan tool, select Special Functions.
5. Select Tire Pressure Reset.
6. Press the Reset soft key, TIRE PRESSURE NORMAL is displayed on the DIC.
7. Use the scan tool in order to clear the TPM DTC.

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| Aurora (VIN G) Service Manual | Suspension | Tire Pressure Monitoring |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 632643

Tire Pressure Monitoring System Schematics

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Steering Assist Component Views

Engine Compartment, Near the Power Steering Gear

(1) Variable Effort Steering Actuator

(2) Variable Effort Steering Actuator Pigtail Connector
(3) Power Steering Gear

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Steering Assist Connector End Views

Variable Effort Steering Actuator

Connector Part • 12052635

Information • 2-Way F Metric Pack 150 Series (BLK)
Circuit
Pin Wire Color No. Function
Variable Effort Steering Actuator High Effort
A GRY 1787
Control
Variable Effort Steering Actuator Low Effort
B WHT 345
Control

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| Aurora (VIN G) Service Manual | Steering | Variable Effort Steering |

2001 Oldsmobile Aurora
Schematic and Routing Diagrams | Document ID: 520980

Steering Assist Schematics (w/NV8)

Steering Controls Schematics (w/NV8)

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Steering Wheel Position Sensor Centering

Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations below
BEFORE removing the sensor from the steering column. Once you have identified the steering
wheel position sensor, follow the instructions listed in the removal procedure.

1. Verify the type of steering wheel position sensor.

2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the
right.

Important: If reusing the existing sensor, you do not have to align the sensor before
removal. Centering is not required when it is time to reinstall.

3. Remove the connector from the sensor.

4. Remove the sensor (1) from the adapter and bearing assembly.
5. To install the sensor, proceed to step 1 in the installation section.

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6. From the technicians point of view, the FRONT of the sensor will have:
• foam ring (2)
• pin hole (1) for centering pin (note location of pin hole)
• flush rotor flange cuff (4)

Important: If reusing the existing sensor, you must make an alignment mark on the rotor
flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when
installing the sensor. A new sensor will be required if misaligned.

7. Make an alignment mark on the flush rotor flange cuff (3).

8. Remove the connector from the sensor.
9. Remove the sensor from the adapter and bearing assembly.
10. To install the sensor, proceed to step 5 in the installation section.

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11. From the technicians point of view, the FRONT of the sensor will have:
• raised rotor flange cuff (3)
• alignment mark (2) on rotor flange cuff (3) for installation
• pin hole (1) for centering pin (note location of pin hole)
12. Remove the connector from the sensor.
13. Remove the sensor from the adapter and bearing assembly.
14. To install the sensor, proceed to step 9 in the installation section.

15. From the technicians point of view, the FRONT of the sensor will have:
• raised rotor flange cuff (3)
• alignment mark (2) on rotor flange cuff (3) for installation
• pin hole (1) for centering pin (note location of pin hole)
• sensor clip in FRONT of the sensor
16. Remove the connector from the sensor.
17. Remove the sensor clip from the sensor.
18. Remove the sensor from the adapter and bearing assembly.
19. To install the sensor, proceed to step 13 in the installation section.

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20. From the technicians point of view, the FRONT of the sensor will have:
• flush rotor flange cuff (3)
• pin hole (1) for centering pin (note location of pin hole)
• alignment mark (2) on flush rotor flange cuff (3) for installation
21. Remove the connector from the sensor.
22. Remove the sensor from the adapter and bearing assembly.
23. To install the sensor, proceed to step 17 in the installation section.

24. From the technicians point of view, the FRONT of the sensor will have:
• flush rotor flange cuff (4)
• pin hole (2) for centering pin (note location of pin hole)
• alignment mark (3) on flush rotor flange cuff (4) for installation

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• foam ring (1)

25. Remove the connector from the sensor.
26. Remove the sensor from the adapter and bearing assembly.
27. To install the sensor, proceed to step 21 in the installation section.

Installation Procedure

Important: If reusing the existing sensor, no centering of the sensor is required.

1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the
pin until the sensor is seated.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your
right.

From the technicians point of view, the BACK of the sensor (2) connector will be on your left.

3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
4. Install the connector to the sensor.

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5. From the technicians point of view, the FRONT of the sensor will have:
• foam ring (4)
• pin hole (7) for centering pin (note location of pin hole)
• flushed rotor flange cuff (6)
• alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
• double D flats (1)
• foam ring (3)
• alignment tab (2) for installing into the adapter and bearing assembly.
• view of the inside of the connector

Important: If reusing the existing sensor, you must align the marks on the flush rotor
flange cuff before installation. The alignment mark must stay aligned until the sensor is
seated into the adapter and bearing assembly.

If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the
pin until the sensor is seated. If the new sensor did not come with a pin installed, you must
reorder a new sensor.

7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
8. Install the connector to the sensor.

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9. From the technicians point of view, the FRONT of the sensor will have:
• pin hole (3) for centering pin (note location of pin hole)
• raised rotor flange cuff (5)
• alignment mark (4) for installation
10. From the technicians point of view, the BACK of the sensor will have:
• double D flats (1)
• alignment tab (2) for installing into the adapter and bearing assembly.

Important: If reusing the existing sensor, you must align the marks on the raised rotor
flange cuff before installation. The alignment mark must stay aligned until the sensor is
seated into the adapter and bearing assembly.

11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
12. Install the connector to the sensor.

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13. From the technicians point of view, the FRONT of the sensor will have:
• pin hole (2) for centering pin (note location of pin hole)
• raised rotor flange cuff (4)
• alignment mark (3) for installation
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D flats.

15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
16. Install the connector to the sensor.

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17. From the technicians point of view, the FRONT of the sensor will have:
• pin hole (2) for centering pin (note location of pin hole)
• flush rotor flange cuff (4)
• alignment mark (3) for installation
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D flats.

19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
20. Install the connector to the sensor.

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21. From the technicians point of view, the FRONT of the sensor will have:
• pin hole (3) for centering pin (note location of pin hole)
• flush rotor flange cuff (5)
• alignment mark (4) for installation
• foam ring (6)
22. From the technicians point of view, the BACK of the sensor will have:
• double D flats (1)
• alignment tab (2) for installing into the adapter and bearing assembly.

23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
24. Install the connector to the sensor.

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Steering Wheel Position Sensor or Steering Shaft Lower

Bearing Replacement
Removal Procedure

1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the steering column from the vehicle. Refer to Steering Wheel Replacement .
3. Remove the following from the steering shaft:
3.1. boot (4)
3.2. steering shaft seal (3)
3.3. sensor retainer (2)
3.4. boot seal (1)

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4. Remove the steering wheel position sensor. Refer to Steering Wheel Position Sensor
Centering .

Installation Procedure

1. Install the steering wheel position sensor. Refer to Steering Wheel Position Sensor
Centering .

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2. Install the following onto the steering shaft:

2.1. boot seal (1)
2.2. sensor retainer (2)
2.3. steering shaft seal (3)
2.4. boot (4)
3. Install the steering column to the vehicle. Refer to Steering Wheel Replacement .
4. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Variable Effort Steering Programming

The variable power steering system has 3 response modes. Use a scan tool and the following table
in order to select the Variable Power Steering response mode per customer request.

Action Scan Tool Display

1. Install a scan tool. • DRP/ABS/TCS/TIM/VSES (If equipped.)
2. Input vehicle information and
• Magna Steer
select Chassis.
• Rear Integration Module
Select Magna Steer. • Diagnostics
• Recalibration
Select Recalibration. Magna Steer Recalibration Procedure - Be sure Ignition
is ON Engine OFF

Press [ENTER] to Start

Press [ENTER]. Is VIN Correct?
Select YES. Does vehicle have Magna Steer RPO # NV8 ?
Select YES. Recal with the FACTORY STANDARD calibration
Select NO. Select Calibration

• More Firm
• Factory Calibration
• Less Firm
Select the desired response mode. Magna Steer Recalibration Procedure is complete

Press [EXIT] to Return to Menu.

Exit the scan tool. Reprogramming is complete.

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Fastener Tightening Specifications

Specification
Application Metric English
Adjustment Link Cam Nut 91 N·m 67 lb ft
Strut to Body Attaching Nut 47 N·m 35 lb ft
Strut to Knuckle Nut 147 N·m 108 lb ft
Tie Rod (Front) Lock Nut 64 N·m 47 lb ft

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Wheel Alignment Specifications (Vin #14103349 and

Less)
Operation Service Allowable Service Preferred
Front
l Caster 5.5-6.5 6
l Cross Caster -0.5 to +0.5 0
l Camber -0.7 to +0.3 -0.2
l Cross Camber -0.5 to +0.5 0
l Sum Toe 0-0.4 0.2
l Steering Wheel Angle +3 to -3 0
Rear
l Camber -0.8 to +0.2 -0.3
l Cross Camber -0.75 to +0.75 0
l Sum Toe 0-0.4 0.2
l Thrust Angle -0.1 to +0.1 0

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Wheel Alignment Specifications (Vin # 14103350 and

Greater)
Operation Service Allowable Service Preferred
Front
l Caster 4.5-5.5 5
l Cross Caster -0.5 to +0.5 0
l Camber -0.7 to +0.3 -0.2
l Cross Camber -0.5 to +0.5 0
l Sum Toe 0-0.4 0.2
l Steering Wheel Angle +3 to -3 0
Rear
l Camber -0.8 to +0.2 -0.3
l Cross Camber -0.75 to +0.75 0
l Sum Toe 0-0.4 0.2
l Thrust Angle -0.1 to +0.1 0

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Front Camber Adjustment

Tools Required
J 39601 Camber Adjustment Tool

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

Important: Do not allow the bolts to turn. This will ruin the serrated shoulder.

3. Remove the nut and tap the upper and lower bolt from the strut and knuckle.
4. Separate the strut from the knuckle.

Important: It is necessary to grind the lower bolt hole on the strut to achieve proper
camber setting.

If camber specification is not achieved by this procedure check for bent or worn parts.

5. Using a round file or a die grinder file the inner metal plate to the outside plates diameter.
6. File excess metal to make the slotted holes.
7. Paint the exposed metal with rust preventive paint or primer.
8. Replace the strut to the knuckle.
9. Install both the upper and lower bolts.
10. Do not tighten at this time (leave loose).
11. Install the J 39601 to the bottom strut bolt.

Notice: Refer to Fastener Notice in the Preface section.

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12. Using the J 39601 , set the camber. Refer to Wheel Alignment Specifications .

Tighten
Tighten the upper strut to knuckle nut to 147 N·m (108 lb ft).

13. Remove the J 39601 .

Tighten
Tighten the lower strut to knuckle nut to 147 N·m (108 lb ft).

14. Replace the tire and wheel. Refer to Tire and Wheel Removal and Installation .
15. Lower the vehicle.
16. Perform a wheel alignment. Refer to Wheel Alignment Specifications .

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Front Caster Adjustment

Use the following procedure in order to prepare the top strut mounting holes:

1. Remove the top 3 fasteners from the strut tower.

2. Lift the front of the vehicle by the body in order to separate the strut from the inner
wheelhouse. Refer to Lifting and Jacking the Vehicle .

3. Pop out the 2 guide pins.

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5. Paint the exposed metal using rust preventative paint or primer.

6. Lower the front of the vehicle.
7. Install the strut attaching fasteners.

Do not tighten the fasteners at this time.

8. Move the top of the strut forward or rearward in order to adjust the caster. A 1 mm
(0.040 in) position change at the tower is about equal to a 0.1 degree change in the caster.
Refer to Wheel Alignment Specifications .

Tighten
Tighten the strut fasteners to 47 N·m (35 lb ft).

9. Perform a complete wheel alignment.

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Rear Toe Adjustment

Important: Complete the left and right rear toe adjustments separately, per wheel. Use the
following procedure.

1. Loosen the inner adjustment link cam nut.

2. In order to adjust the toe, rotate the cam bolt. Refer to Fastener Tightening Specifications .

Tighten
Tighten the cam nut (2) to 91 N·m (67 lb ft).

3. Recheck the toe setting after tightening.

4. Readjust the toe setting if necessary. Refer to Wheel Alignment Specifications .

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Wheel Alignment - Steering Wheel Angle and/or Front

Toe Adjustment

1. Loosen the lock nuts on the tie rod.

Notice: Care must be taken that the boots are not twisted when rotating the inner tie rods,
or damage to the boots may result.

2. Rotate the inner tie rod to adjust the toe. Refer to Wheel Alignment Specifications .

Tighten
Tighten the lock nuts to 64 N·m (47 lb ft).

3. Adjust the boots as needed in order to prevent damage.

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Wheel Alignment Measurement

Steering and vibration complaints are not always the result of improper alignment. One possible
cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly
manufactured tires. Lead is the vehicle deviation from a straight path on a level road without
pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in
order to determine if the vehicle has a tire lead problem.

Before performing any adjustment affecting wheel alignment, perform the following inspections and
adjustments in order to ensure correct alignment readings:

• Inspect the tires for the proper inflation and irregular tire wear. Refer to Tire Inflation
Pressure Specifications in Maintenance and Lubrication and Tire Diagnosis - Irregular or
Premature Wear in Tires and Wheels.
• Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications
in Vibration Diagnosis and Correction.
• Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings
Diagnosis in Suspension General Diagnosis.
• Inspect the ball joints and tie rod ends for looseness or wear.
• Inspect the control arms and stabilizer shaft for looseness or wear.
• Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening
Specifications in Power Steering System.
• Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to
Suspension Strut and Shock Absorber Testing - On Vehicle in Suspension General Diagnosis.
• Inspect the vehicle trim height. Refer to Trim Height Inspection in Suspension General
Diagnosis.
• Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or
suspension components.
• Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating
load added.

Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the
vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration
also to the condition of the equipment being used for the alignment. Follow the equipment
manufacturer's instructions.

Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the
setting exceeds the service allowable specifications, correct the alignment to the service preferred
specifications. Refer to Wheel Alignment Specifications .

Perform the following steps in order to measure the front and rear alignment angles:

1. Install the alignment equipment according to the manufacturer's instructions.

2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment.
3. Measure the alignment angles and record the readings.

Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the
rear wheel alignment ©angles first inMotors
2014 General orderCorporation.
to obtain All
proper
rights front alignment angles.
reserved.

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4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment

Specifications .

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Fastener Tightening Specifications

Specification
Application Metric English
Drive Axle Nut 160 N·m 118 lb ft
Inner Joint Large Seal Clamp 176 N·m 130 lb ft
Outer Joint Large Seal Clamp 176 N·m 130 lb ft

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Wheel Drive Shafts Disassembled Views (Halfshaft)

Free-Motion Design-Front Wheel Halfshaft

(1) Retainer and Housing Assembly

(2) Shaft Retaining Ring
(3) Tripot Joint Spider
(4) Spacer Ring
(5) Boot Retaining Clamp
(6) Trilobal Tripot Bushing
(7) Halfshaft Inboard Boot
(8) Boot Retaining Clamp
(9) Halfshaft Bar
(10) Boot Retaining Clamp © 2014 General Motors Corporation. All rights reserved.

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(11) Halfshaft Outboard Boot

(12) Boot Retaining Clamp
(13) Race Retaining Ring
(14) Chrome Alloy Ball
(15) CV Joint Inner Race
(16) CV Joint Cage
(17) CV Joint Outer Race

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Wheel Drive Shafts Disassembled Views (Wheel Drive

Shaft)

(1) Retaining Ring

(2) Retainer and Housing Assembly
(3) Spacer Ring
(4) Tripot Spider Assembly
(5) Spacer Ring
(6) Seal Retaining Clamp
(7) Tripot Trilobal Bushing
(8) Inboard Seal
(9) Swage Ring
(10) Halfshaft Bar
(11) Swage Ring © 2014 General Motors Corporation. All rights reserved.

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(12) Outboard Seal

(13) Seal Retaining Clamp
(14) Race Retaining Ring
(15) Chrome Alloy Balls
(16) CV Joint Inner Race
(17) CV Joint Cage
(18) CV Joint Outer Race

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Wheel Drive Shaft Inner Joint and Boot Replacement

(Inboard Assembly)
Tools Required
• J 35910 Earred Clamp Tool
• J 41048 Small Swage Tool
• J 8059 Snap Ring Pliers

Disassembly Procedure

Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing
surface (the tripot male/female shank of the joint) should be inspected for corrosion. If
corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a
rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be
used to clean off any remaining debris and the joint wiped dry before installation. Corrosion
on the joint sealing surface may damage the transmission seals and cause a fluid leak.

1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot
housing (1).
2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.

Notice: Do not cut through the wheel drive shaft inboard or outboard boot during service.
Cutting through the boot may damage the sealing surface of the housing and the tripot or
the constant velocity ©
joint
2014bushing. Damage
General Motors to the sealing
Corporation. reserved. may lead to water and dirt
All rights surface

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intrusion and premature wear of the constant velocity joint.

4. Separate the halfshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
5. Slide the boot (4) away from the joint along the halfshaft bar.
6. Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar.
7. Remove the trilobal tripot bushing (3) from the housing (1).

8. Spread spacer ring (2) with the J 8059 .

9. Slide the spacer ring and tripot joint spider back on halfshaft bar (1).

10. Remove the halfshaft bar retaining ring from the groove (5) on the halfshaft bar.
11. Slide tripot joint spider assembly (2) off of the halfshaft bar.
12. Clean the following items with cleaning solvent:
• The tripot balls
• The needle rollers

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• The housing
13. Remove all traces of old grease and any contaminates. Dry all parts.

14. Inspect the following parts for damage or wear:

• The halfshaft inboard boot (4)
• The tripot joint spider assembly (2)
• The housing (1)
• The trilobal tripot bushing (3)
• The needle rollers

Assembly Procedure

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1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Slide the joint
boot (1) and the small boot clamp (2) onto the halfshaft bar.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar.

3. Mount J 41048 in a vise and proceed as follows:

3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048 .
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J 41048 .
3.4. Before proceeding, ensure there are no pinch points on the halfshaft inboard boot. This
could cause damage to the halfshaft inboard boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.

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4. Align the following items:

• The halfshaft inboard boot (1)
• The housing
• The swage ring (2)

Tighten
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate
between each bolt until both sides are bottomed.

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5. Install the spacer ring (2) on the halfshaft bar (1) in groove using J 8059 .

Important: Ensure that the counterbored face of the tripot joint spider (2) faces toward the
end of the halfshaft bar (4).

6. Slide the tripot joint spider assembly (2) toward the spacer ring (1) as far as it will go on the
halfshaft bar (4).
7. Install the halfshaft bar retaining ring in the groove of the halfshaft bar.

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Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

8. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use
the remainder of the grease to repack the housing.
9. Install the trilobal tripot bushing (3) to housing.
10. Position the larger new boot retaining clamp (2) on the halfshaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.

12. Slide the large diameter of the halfshaft inboard boot (2), with the larger clamp (3) in place,
over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.

Important: The halfshaft inboard boot must not be dimpled, stretched out or out of shape in
any way. If the halfshaft inboard boot is not shaped correctly, carefully insert a thin flat blunt

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tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order
to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the
tool.

13. Position the joint assembly at the proper vehicle dimension.

14. Align the following items while latching:

• The halfshaft inboard boot (3)
• The tripot housing (1)
• The large boot retaining clamp (2)

Tighten
Crimp the boot retaining clamp (2) with J 35910 to 176 N·m (130 lb ft). Add the breaker
bar (5) and the torque wrench (4) to the J 35910 if necessary.

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Wheel Drive Shaft Inner Joint and Boot Replacement

(Inner Joint Assembly)
Tools Required
• J 35910 Earred Clamp Tool
• J 41048 Small Swage Tool
• J 8059 Snap Ring Pliers

Disassembly Procedure

1. Use a hand grinder in order to cut through the swage ring.

2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.

Notice: Do not cut through the wheel drive shaft inboard or outboard boot during service.
Cutting through the boot may damage the sealing surface of the housing and the tripot or
the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt
© 2014 General Motors Corporation. All rights reserved.

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intrusion and premature wear of the constant velocity joint.

8. Spread spacer ring (2) with J 8059 .

9. Slide the spacer ring and tripot joint spider back on halfshaft bar (1).

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• The housing
13. Remove all traces of old grease and any contaminates. Dry all parts.

14. Inspect the following parts for damage or wear:

• The halfshaft inboard boot (4)
• The tripot joint spider assembly (2)
• The housing (1)
• The trilobal tripot bushing (3)
• The needle rollers

Assembly Procedure

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3. Mount J 41048 in a vise and proceed as follows:

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4. Align the following items:

• The halfshaft inboard boot (1)
• The housing
• The swage ring (2)

Tighten
Each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate between each
bolt until both sides are bottomed.

5. Install the spacer ring (2) on the halfshaft bar (1) in groove using J 8059 .

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Important: Ensure that the counterbored face of the tripot joint spider (2) faces toward the
end of the halfshaft bar (4).

6. Slide the tripot joint spider assembly (2) toward the spacer ring (1) as far as it will go on the
halfshaft bar (4).
7. Install the halfshaft bar retaining ring in the groove of the halfshaft bar.

Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).

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10. Position the larger new boot retaining clamp (2) on the halfshaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.

12. Slide the large diameter of the halfshaft inboard boot (2), with the larger clamp (3) in place,
over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.

Important: The halfshaft inboard boot must not be dimpled, stretched out or out of shape in
any way. If the halfshaft inboard boot is not shaped correctly, carefully insert a thin flat blunt
tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order
to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the
tool.

13. Position the joint assembly at the proper vehicle dimension.

14. Align the following items while latching:

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• The halfshaft inboard boot (3)

• The tripot housing (1)
• The large boot retaining clamp (2)
15. Latch the boot retaining clamp (2) using J 35566 .

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Wheel Drive Shaft Outer Joint and Boot Replacement

Tools Required
• J 35910 Earred Clamp Tool
• J 41048 Small Swage Tool
• J 8059 Snap Ring Pliers

Disassembly Procedure

1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot
retaining clamp.
2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. Discard the
boot retaining clamp.
3. Separate the outboard boot (5) from CV joint outer race (1) at the large diameter and slide
the boot (5) away from the CV joint along the bar (4).
4. Wipe the grease from the face of the CV joint inner race (2).
5. Spread the ears on the race retaining ring (3) using J 8059 and remove the CV joint
assembly from the bar (4).
6. Remove the boot (5) from the bar (4).

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7. Use a brass drift and a hammer to gently tap on the CV joint cage (1) until it is tilted enough
to remove the first chrome alloy ball (2).
8. Tilt cage in the opposite direction to remove the opposing ball (2).
9. Repeat this process until all six balls are removed.

10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the
CV joint outer race (1) and align the CV joint cage windows (3) with the lands of the CV joint
outer race (2).
11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).

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12. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands
of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
13. Pivot the inner race into the cage window (2) and remove the inner race (1).
14. Clean the following items thoroughly with cleaning solvent:
• The inner and outer race assemblies
• The CV joint cage
• The balls
15. Remove all traces of old grease and any contaminates.
16. Dry all the parts.

Assembly Procedure

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1. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and
the swage ring (2) onto the halfshaft bar.
2. Position the small end of the boot (1) into the boot groove (3) on the halfshaft bar.

3. Mount theJ 41048 in a vise and proceed as follows:

3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048 .
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J 41048 .
3.4. Before proceeding, ensure there are no pinch points on the boot. This could cause
damage to the boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.

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4. Align the following items:

• The boot (1)
• The swage ring (2)

Tighten
Tighten each bolt of theJ 41048 180 degrees at a time using a ratchet wrench. Alternate
between each bolt until both sides are bottomed.

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5. Put a light coat of grease from the service kit on the ball grooves of the inner race and the
outer race (1).
6. Hold inner race 90 degrees to the centerline of the cage (4) with the lands of the inner race
aligned with the windows of the cage and insert the inner race into the cage.
7. Hold the cage and the inner race 90 degrees to the centerline of the outer race (1) and align
the cage windows (3) with the lands of the outer race (2).

Important: Ensure that the retaining ring side of the inner race faces the halfshaft bar.

8. Place the cage (4) and the inner race into the outer race (1).
9. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing
ball.
10. Repeat this process until all six balls are in place.
11. Place approximately half the grease from the service kit inside the outboard boot and pack
the CV joint with the remaining grease.

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12. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove
on the bar.

Important: The outboard boot (1) must not be dimpled, stretched or out of shape in any
way. If the boot (1) is not shaped correctly, equalize the pressure in the boot (1) and shape
the boot (1) properly by hand.

13. Slide large diameter of the outboard boot (1) with the large boot retaining clamp (2) in place
over the outside of the CV joint outer race (3) and locate the boot lip in the groove on the CV
joint outer race (3).

14. Crimp the boot retaining clamp (1) using theJ 35910 , a breaker bar (3), and a torque

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wrench (2)

Tighten
Tighten the boot retaining clamp to 176 N·m (130 lb ft).

15. Check the gap dimension on the clamp ear. If the gap dimension is larger than shown,
continue tightening until gap dimension is reached.

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Wheel Drive Shaft Replacement

Tools Required
• J 2619-O1 Slide Hammer With Adapter
• J 29794 Extension
• J 33008-A Wheel Drive Shaft Remover
• J 42129 Wheel Hub Remover

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Important: Do NOT loosen the tie rod end jam nut.

3. Disconnect the outer tie rod end from the steering knuckle. Refer to Rack and Pinion Outer
Tie Rod End Replacement .
4. Insert a drift or punch (1) into the brake rotor and against the brake caliper in order to
prevent the wheel hub and bearing from turning.

Important: The wheel drive shaft spindle nut must not be reused. Replace the wheel drive
shaft spindle nut with a new nut whenever it is removed.

5. Remove and discard the wheel drive shaft spindle nut (2) retaining the wheel drive shaft to
the hub.
6. Remove the stabilizer©shaft
2014 link. Refer
General Stabilizer Shaft
toCorporation.
Motors Link
All rights Replacement .
reserved.

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Important: Be sure that the wheel speed sensor wiring harness is repositioned away from
the ball joint after disconnecting the electrical connector from the sensor.

7. Disconnect the electrical connector from the wheel speed sensor and reposition the wiring
harness away from the ball joint.
8. Disconnect the lower ball joint from the steering knuckle. Refer to Lower Control Arm
Replacement .
9. Install the J 42129 onto the wheel hub and secure with wheel nuts.

Important: Be sure to support the wheel drive shaft until it is fully removed from the
vehicle.

10. Using the J 42129 , disengage the wheel drive shaft from the wheel hub and bearing and
support the wheel drive shaft.

11. Assemble the J 2619-O1 , the J 29794 , and the J 33008-A .

12. Using the J 2619-O1 , the J 29794 , and the J 33008-A , disengage the wheel drive shaft (2)
from the transaxle (1).
13. Remove the wheel drive shaft from the vehicle.

Installation Procedure

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1. Install the wheel drive shaft (2) to the transaxle (1).

2. Verify that the wheel drive shaft is properly engaged to the transaxle by grasping the inner
tripot housing and pulling outward. Do not pull on the wheel drive shaft bar.

The wheel drive shaft will remain firmly in place when properly engaged.

3. Install the wheel drive shaft to the hub and bearing (2).
4. Connect the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement .
5. Connect the wheel speed sensor electrical connector.
6. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement .

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7. Insert a drift or punch (1) into the rotor and against the caliper in order to prevent the hub
and bearing from turning.

8. Install a new wheel drive shaft spindle nut to the wheel drive shaft.

Tighten
Tighten the wheel drive shaft spindle nut to 160 N·m (118 lb ft).

9. Connect the outer tie rod end to the steering knuckle. Refer to Rack and Pinion Outer Tie Rod
End Replacement .
10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
11. Lower the vehicle.

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Fastener Tightening Specifications

Specification
Application Metric English
Washer Solvent Container Nuts 6 N·m 53 lb in
Windshield Reinforcement Panel Bolts 9 N·m 80 lb in
Windshield Reinforcement Panel Nuts 9 N·m 80 lb in
Wiper Arm Nut 32 N·m 24 lb ft
Wiper Drive System Module Mounting Screws 8 N·m 71 lb in
Wiper Motor Mounting Screws 8 N·m 71 lb in

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Outside Moisture Sensor (W/CE1), Motor, and Pump

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Windshield Wiper Switch and Fuse

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Wiper/Washer Connector End Views

Table 1: Outside Moisture Sensor
Table 2: Windshield Washer Fluid Level Switch
Table 3: Windshield Washer Fluid Pump
Table 4: Windshield Wiper Motor

Outside Moisture Sensor

• 12064993
Connector Part Information
• 6 Way F Micro-Pack 100 Series (BLK)
Pin Wire Color Circuit No. Function
5 LT GRN 482 Rain Sense Signal 2
6 BLK 481 Rain Sense Signal 1
7 BLK/WHT 851 Ground
8 YEL 43 Accessory Voltage
9-10 -- -- Not Used

Windshield Washer Fluid Level Switch

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• 12162195
Connector Part
Information • 2 Way F Metri-Pack 150.2 Series Sealed, P2S
(BLK)
Pin Wire Color Circuit No. Function
A BLK 250 Ground
B BLK/WHT 99 Windshield Washer Fluid Level Signal

Windshield Washer Fluid Pump

• 12052635
Connector Part Information
• 2 Way F Metri-Pack 150 Series (BLK)
Pin Wire Color Circuit No. Function
A RED 228 Windshield Washer Pump Control
B BLK 250 Ground

Windshield Wiper Motor

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• 12176334
Connector Part Information
• 7 Way F Metri-Pack 280 Series (NAT)
Pin Wire Color Circuit No. Function
A -- -- Not Used
B YEL 143 Accessory Voltage
C BLK 150 Ground
D BLK 481 Rain Sense Signal 1
E GRY 478 Windshield Wiper Switch Signal 2
F LT GRN 482 Rain Sense Signal 2
G DK BLU 477 Windshield Wiper Switch Signal 1
H PPL 92 Windshield Wiper Motor High Speed

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Washer Pump Replacement

Removal Procedure

1. Drain the washer solvent container.

2. Remove the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement
in Body Front End.
3. Disconnect the washer hose from the washer pump.
4. Disconnect the electrical connector from the washer pump.

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5. Remove the washer pump from the washer solvent container.

Installation Procedure

1. Install the washer pump in the washer solvent container.

2. Connect the electrical connector to the washer pump.

3. Connect the washer hose to the washer pump.
4. Install the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
5. Fill the washer solvent container.

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Windshield Glass Cleaning

Clean the windshield with windshield cleaner, GM P/N 1050011 (Canadian P/N 992727) or
equivalent. The cleaner should not harm the paint finish or scratch the glass. The glass is clean
when the water no longer beads, but sheets across the entire glass surface.

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Windshield Outside Moisture Sensor Replacement

Removal Procedure

1. Remove the trim cover from the rain sensor module.

2. Release the windshield coupler clips.

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Installation Procedure

1. Connect the electrical connector to the rain sensor module.

2. Install the rain sensor module in the windshield coupler.
3. Fasten the windshield coupler clips.

4. Install the trim cover on the rain sensor module.

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Windshield Washer Solvent Container Replacement

Removal Procedure

1. Remove the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement
in Body Front End.
2. Disconnect the washer hose from the washer pump.
3. Disconnect the electrical connector from the washer pump.
4. Disconnect the electrical connector from the washer solvent level sensor.

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5. Remove the three nuts from the washer solvent container.

6. Remove the washer solvent container from the vehicle.

7. Remove the washer pump from the washer solvent container.

Installation Procedure

1. Install the washer pump in the washer solvent container.

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2. Install the washer solvent container on the vehicle.

3. Install the three nuts.

Tighten
Tighten the three nuts to 6 N·m (53 lb in).

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4. Connect the electrical connector to the washer solvent level sensor.

5. Connect the electrical connector to the washer pump.
6. Connect the washer hose to the washer pump.
7. Install the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.

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Windshield Washer Solvent Level Switch Replacement

Removal Procedure

1. Drain the washer solvent container.

2. Remove the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement
in Body Front End.
3. Disconnect the electrical connector from the washer solvent level sensor.

4. Remove the washer solvent level sensor

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Installation Procedure

1. Install the washer solvent level sensor in the washer solvent container.

2. Connect the electrical connector to the washer solvent level sensor.

3. Install the right front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
4. Fill the washer solvent container.

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Windshield Wiper Arm Replacement

Tools Required
J 39822 Wiper Arm Puller

Removal Procedure
1. Run the wipers into the Park position.
2. Disconnect the washer hose from the air inlet grille panel.

3. Remove the cover from the nut holding the wiper arm.
4. Remove the wiper arm nut.

Important: Use the J 39822 in order to remove the wiper arm from the pivot shaft.

5. Remove the arm from the pivot shaft.

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6. Depress the end of the wiper blade retaining clip and slide the blade off of the wiper arm
hook.
7. Bring the wiper arm hook out through the opening in the wiper blade.

Installation Procedure

1. Install the wiper blade onto the arm by placing the arm hook through the opening in the
wiper blade. Slide the arm hook onto the blade retaining clip until it clicks into position.

Important: The wiper system must be in the park position when installing the wiper arms. If
the wiper system is not in the park position, damage to the wiper system and the vehicle will

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occur.

2. Operate the wiper system and then turn the wiper control switch to the OFF position to
assure the wiper system is in the park position.

Important: Clean the wiper transmission pivot shaft knurls with a wire brush.

3. Install the wiper arm onto the pivot shaft while aligning the wiper blade with the locating
marks on the windshield. If the windshield does not have locating marks, locate the center of
the blades to the distance shown up from the base of the windshield.
• Passenger Side --112.1 mm (4.41 in)
• Driver Side -- 79.6 mm (3.13 in)

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4. Install the nut on the wiper arm pivot shaft.

Tighten
Tighten the nut to 32 N·m (24 lb ft).

5. Install the cover onto the nut.

Important: Lubricate the washer hose with windshield washer solvent to ease attachment to
the fitting on the air inlet grille panel.

6. Attach the washer hose to the fitting on the air inlet grille panel.
7. Operate the wipers and washers and check for proper operation.

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Windshield Wiper Blade Replacement

Removal Procedure

1. Push in the button of the wiper blade clip and remove the wiper blade from the inside radius
of the wiper arm.

2. Bring the wiper arm out through the opening in the wiper blade.

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Installation Procedure

1. Insert the hook of the wiper arm through the opening in the wiper blade.

2. Position the wiper blade pivot in the inside radius of the wiper arm hook.
3. Pull the wiper blade pivot into the wiper arm hook until the pivot locks into the hook.
4. Operate the wipers and check for proper operation.

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Windshield Wiper Motor Replacement

Tools Required
• J 39232 Wiper Linkage Separator
• J 39529 Wiper Linkage Installer

Removal Procedure

1. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement .

2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front
End.
3. Remove the three bolts and two nuts retaining the windshield frame reinforcement.
4. Remove the windshield frame reinforcement.

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5. Pull or push on the wiper transmission linkage to rotate the wiper motor crank arm (2) from
the park position (1) to the area opposite the park position (3).

6. Remove the harness grommet from the hole in the plenum.

7. Disconnect the wiper motor harness connector.
8. Push the harness and grommet through the hole in the plenum.
9. Remove the three screws retaining the wiper system drive module.

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10. Remove the wiper system drive module from the vehicle.

11. Remove the drive link from the wiper motor crank arm with the J 39232 .

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12. Remove the screws retaining the wiper motor.

13. Remove the wiper motor from the wiper drive system module.

Installation Procedure
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service procedure. Do not use paints,
lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These
coatings affect fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in order to avoid damage
to parts and systems.

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1. Install the wiper motor onto the wiper drive system module with the screws.

Tighten
Tighten the screws to 8 N·m (71 lb in).

2. Install the drive link onto the wiper motor crank arm with the J 39529 .

3. Lower the wiper module into the upper plenum with the nose of the wiper motor pointing
downward.
4. Rotate the wiper module so that the wiper motor nose points toward the rear of the vehicle.

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5. Install the wiper drive system module with the three screws.

Tighten
Tighten the three screws to 8 N·m (71 lb in).

6. Push the harness and grommet through the hole in the plenum.
7. Connect the wiper motor harness connector.
8. Install the harness grommet into the hole in the plenum.

9. Install the windshield frame reinforcement with the three bolts and two nuts.

Tighten
Tighten the three bolts and two screws to 9 N·m (80 lb in).

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10. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End.
11. Install the wiper arms. Refer to Windshield Wiper Arm Replacement .
12. Operate the wipers and check for proper operation.

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Windshield Wiper Transmission Replacement

Tools Required
• J 39232 Wiper Linkage Separator
• J 39529 Wiper Linkage Installer

Removal Procedure

1. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement .

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5. Pull or push on the wiper transmission linkage to rotate the wiper motor crank arm (2) from
the park position (1) to the area opposite the park position (3).

6. Remove the harness grommet from the hole in the plenum.

7. Disconnect the wiper motor harness connector.
8. Push the harness and grommet through the hole in the plenum.
9. Remove the three screws retaining the wiper system drive module.

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10. Remove the wiper system drive module from the vehicle.

11. Remove the drive links from the wiper motor crank arm and the wiper transmission drive
shafts with the J 39232 .

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12. Remove the screws retaining the wiper motor.

13. Remove the wiper motor from the wiper drive system module.

Installation Procedure
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service procedure. Do not use paints,
lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These
coatings affect fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in order to avoid damage
to parts and systems.

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1. Install the wiper motor onto the wiper drive system module with the screws.

Tighten
Tighten the screws to 8 N·m (71 lb in).

2. Install the drive links onto the wiper motor crank arm and the wiper transmission drive shafts
with the J 39529 .

3. Lower the wiper module into the upper plenum with the nose of the wiper motor pointing
downward.
4. Rotate the wiper module so that the wiper motor nose points toward the rear of the vehicle.

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5. Install the wiper drive system module with the three screws.

Tighten
Tighten the three screws to 8 N·m (71 lb in).

6. Push the harness and grommet through the hole in the plenum.
7. Connect the wiper motor harness connector.
8. Install the harness grommet into the hole in the plenum.

9. Install the windshield frame reinforcement with the three bolts and the two nuts.

Tighten
Tighten the three bolts and two screws to 9 N·m (80 lb in).

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Wiper Blade Element Cleaning

Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full
strength washer solvent. Then rinse the blade assemblies with clear water.

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Wiper Blade Element Replacement

Removal Procedure

Important: Replace the wiper blade element if it is removed from the wiper blade.

1. Remove the wiper blade from the wiper arm. Refer to Windshield Wiper Blade Replacement .
2. Remove the bottom claws of the wiper blade from the notches in the wiper blade element.
3. Pull the wiper blade element out through the wiper blade claws.

Installation Procedure

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Important: Keep the wiper blade claws in the rubber claw channel of the wiper blade
element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper
blade element.

1. Insert the open end of the wiper blade element into the bottom claws of the wiper blade.
2. Guide the wiper blade element through the wiper blade claw sets.

3. Engage the bottom claw of the wiper blade into the notches in wiper blade element.
4. Install the wiper blade onto the wiper arm. Refer to Windshield Wiper Blade Replacement .

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Wiper Chatter Repair

Some vehicles may exhibit a condition where the windshield wipers chatter and/or wipe unevenly.
Several items may contribute to this condition. To completely repair this condition, ALL of the items
listed should be tested and repaired as necessary.

• Clean the windshield glass.

• Clean the wiper blade elements.
• Perform the wiper arm pressure test.
• Inspect the wiper blade element set.

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Transmission Replacement
Tools Required
J 42640 Steering Column Anti-Rotation Pin

Removal Procedure

Notice: The wheels of the vehicle must be straight ahead and the steering column in the
LOCK position before disconnecting the steering column or intermediate shaft from the
steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which
may cause damage to the coil assembly.

1. Lock the steering column by installing J 42640 into the underside of the steering column.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.5L.

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4. Use a large flat-bladed tool in order to remove the range selector cable from the range
selector lever.
5. Remove the range selector cable with bracket from the transmission case and set aside.

6. Remove nut (5) and bolt (2) from the AIR pipe.

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7. Remove bolt (3) from the AIR pipe (2).

8. Remove the ground cable bolt (1) from the transaxle.

9. Disconnect the transaxle electrical connector C100 (2).

10. Remove the wiring harness (3) from the wiring harness retainer (1) on the transaxle.
11. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical -
3.5L.

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12. Remove the upper engine to transaxle case bolts (2-5).

13. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
14. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.

15. Remove both of the inner wheelhouse extensions. Refer to Wheelhouse Extension
Replacement in Body Front End.
16. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.

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Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear
stub shaft can result in damage to the steering gear or to the intermediate shaft. This
damage may cause loss of steering control, which could result in an accident and possible
personal injury.

17. Remove the intermediate shaft lower pinch bolt.

18. Disconnect the intermediate shaft from the power steering gear.
19. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement
in Power Steering System.

20. Remove the power steering gear mounting bolts.

21. Remove the power steering line retainers from the frame.
22. Secure the power steering gear to the exhaust manifold.

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23. Loosen the two mounting nuts (2) in order to allow removal of the brake pressure modulator
valve (1) from the bracket (3).
24. Remove the brake line retainers from the frame.

25. Remove the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .
26. Remove the frame. Refer to Frame Replacement in Frame and Underbody.
27. Remove the right and left drive axles from the transaxle. Refer to Wheel Drive Shaft
Replacement in Wheel Drive Shafts.
28. Disconnect the transmission oil cooler hoses from the transaxle. Refer to Transmission Fluid
Cooler Hose/Pipe Replacement .
29. Remove the transaxle fluid filler tube. Refer to .
30. Remove the torque converter cover. Refer to Torque Converter Cover Replacement .

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31. Mark the flywheel to converter relationship to ensure proper reassembly. Remove the
flywheel to torque converter bolts.

32. Support transaxle using an appropriate transaxle jack.

33. Disconnect vehicle speed sensor electrical connector.

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34. Remove the transaxle brace to transaxle bolts.

35. Remove the transaxle brace to engine bolts.
36. Remove the transaxle brace.

37. Remove the engine to transaxle case bolt (6) which is accessible through right wheel
opening.
38. Remove the remaining transaxle to engine bolt (1).
39. Remove the transaxle from vehicle using an appropriate transaxle jack.

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40. Remove the rear transaxle bracket (1) from the transaxle.

41. Remove the left transaxle bracket (1) from the transaxle.
42. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow
Test .

Installation Procedure

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1. Install the left transaxle bracket (1) to the transaxle.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the left transaxle bracket bolts.

Tighten
Tighten the left transaxle bracket bolts to 110 N·m (81 lb ft).

3. Install the rear transaxle bracket (1) to the transaxle.

4. Install the rear transaxle bracket bolts.

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Tighten
Tighten the rear transaxle bracket bolts to 63 N·m (46 lb ft).

5. Install the transaxle into the vehicle and align the engine alignment dowels (1 and 5).
6. Install the transaxle case to engine bolts (1 and 6).

Tighten
Tighten the lower transaxle bolts to 75 N·m (55 lb ft).

7. Install the transaxle brace.

8. Install the transaxle brace to engine bolts.

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Tighten
Tighten the transaxle brace to engine bolts to 65 N·m (48 lb ft).

9. Install the transaxle brace to transaxle bolts.

Tighten
Tighten the transaxle brace to transaxle bolts to 36 N·m (26 lb ft).

10. Connect vehicle speed sensor electrical connector.

11. Remove the transaxle jack.

Important:
• Align the mark made on the torque converter with the mark made on the flywheel made
in the disassembly unless installing a new converter.
• Tighten all the torque converter to flywheel bolts twice.

12. Install the flywheel to torque converter bolts.

Tighten
Tighten the flywheel to torque converter bolts to 63 N·m (47 lb ft).

13. Install the torque converter cover. Refer to Torque Converter Cover Replacement .
14. Install the transaxle fluid filler tube. Refer to .
15. Connect the transmission oil cooler hoses to the transaxle. Refer to Transmission Fluid Cooler
Hose/Pipe Replacement .

Important: Use care when installing the right side drive axle into the transaxle case. The
splined shaft of the drive axle can easily cut or distort the seal.

16. Install the left and the right drive axle into the transaxle. Refer to Wheel Drive Shaft
Replacement in Wheel Drive Shafts.
17. Install the frame. Refer to Frame Replacement in Frame and Underbody.

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18. Install the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .

19. Position the brake pressure modulator valve (1) into the bracket (3).

Tighten
Tighten the two nuts (2) to 10 N·m (89 lb in).

20. Install the brake line retainers onto the frame.

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21. Install the power steering gear mounting bolts.

Tighten
Tighten the bolts to 70 N·m (95 lb ft).

22. Install the power steering line retainers onto the frame.
23. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement
in Power Steering System.

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24. Connect the intermediate shaft to the power steering gear.

25. Install the intermediate shaft lower pinch bolt.

Tighten
Tighten the bolt to 45 N·m (33 lb ft).

26. Install both of the inner wheelhouse extensions. Refer to Wheelhouse Extension Replacement
in Body Front End.
27. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
28. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
29. Lower the vehicle.

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30. Install the upper transaxle case to engine bolts (2-5).

Tighten
Tighten the transaxle bolts to 75 N·m (55 lb ft).

31. Remove the engine support fixture.

32. Install the range selector cable bracket and cable.

Tighten
Tighten the range selector cable bracket nuts to 25 N·m (18 lb ft).

33. Install the range selector cable onto the range selector lever.
34. Check adjustment of the range selector cable. Re-adjust as needed. Refer to Range Selector
Lever Cable Adjustment .

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35. Connect the transaxle electrical connector C100 (2).

36. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.

37. Install ground cable and bolt (1) to transaxle.

Tighten
Tighten the ground cable bolt to 17 N·m (13 lb ft).

38. Install bolt (3) to AIR pipe (2).

Tighten
Tighten bolt (3) to 23 N·m (17 lb ft).

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39. Install nut (5) and bolt (2) to AIR pipe.

Tighten
Tighten nut (5) and bolt (2) to 23 N·m (17 lb ft).

40. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.5L.
41. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.

42. Remove the J 42640 from the steering column.

43. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications .
44. Inspect the transaxle fluid level. Refer to Transmission Fluid Check .
45. Inspect for fluid leaks.

Important: It is recommended that transmission adaptive pressure (TAP) information be

reset.

Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result,
The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be
affected as new TAP values are learned.

46. Reset the TAP values. Refer to Adapt Function .

47. Check the front end alignment.
48. Road test the vehicle and check for transaxle leaks.

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Transmission Replacement
Tools Required
• J 41623-B Cooler Quick Connect Tool
• J 41160 Transmission Jack Adapter

Removal Procedure
1. Remove the upper and lower air cleaner assemblies. Refer to Air Cleaner Assembly
Replacement in Engine Controls - 4.0L.

2. Disconnect the range selector cable terminal from the transaxle range selector lever.
3. Remove the nuts securing both the range selector cable bracket and heater pipe to the
transaxle. Position the range selector cable bracket and heater pipe aside.
4. Remove the Magnasteer wire from the retaining clip.
5. Disconnect the master cylinder brake pipe retainers from the side rail.

Important: Supporting the brake pipes above the body side rail is necessary while removing
the transaxle in order to prevent pinching of the brake pipes.

6. Remove the brake pipe retainers from the side rail and using mechanics wire, support the
brake pipes above the side rail.

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7. Reposition the main wiring harness to gain access to the upper transaxle to engine bolts (1).
8. Remove the transaxle to engine bolts (1). The remaining bolt (2) will temporally retain the
transaxle and will be removed from the underside of the vehicle.
9. Place a drain pan under the vehicle.

10. Remove the upper transaxle oil cooler pipe retaining bolt from the radiator fan shroud.
11. Disconnect the upper transaxle oil cooler pipe from the radiator using the J 41623-B . Install
plugs in the oil cooler pipe and the radiator to prevent fluid loss and contamination.

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12. Disconnect the lower transaxle oil cooler pipe from the transaxle and Install plugs in the oil
cooler pipe and the transaxle to prevent fluid loss and contamination. Refer to Cooler Pipe
Replacement .
13. Disconnect the transaxle vent tube from the accelerator bracket.
14. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical -
4.0L.
15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

16. Secure the vehicle to the front hoist pads.

17. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
18. Swing the stabilizer shaft downward in order to gain access to the power steering gear
retaining bolts.
19. Remove the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.

Important: The following are exceptions while following the frame removal procedure:
• Do not remove the front stabilizer shaft from the frame.
• Do not remove the A.I.R pump assembly from the vehicle. Retain the pump to the body
using mechanics wire.
• Do not remove the insulators from the frame.
• Do not remove the control arms from the frame.

20. Remove the front frame. Refer to Frame Replacement in Frame and Underbody.

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21. Remove the bolt securing the left transaxle brace to the transaxle.
22. Loosen the nut securing the left transaxle brace to the engine.
23. Remove the left transaxle brace from the powertrain assembly.

24. Remove the 3 ground connections from the side of the transaxle.
25. Disconnect the transaxle main electrical harness connector.

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26. Remove the bolt (2) securing the front transaxle brace (1) to the transaxle.
27. Remove the nut securing the secondary AIR pipe to the transaxle.

28. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
29. Remove the vehicle speed sensor heat shield (1) from the vehicle.
30. Disconnect the vehicle speed sensor electrical connector.

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31. Remove only the bolts securing the front transaxle brace to the transaxle.

32. Remove only the bolts securing the center transaxle brace to the transaxle.

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33. Disengage the right and left drive shafts (2) from the transaxle (1). The drive shafts do not
have to be removed from the wheels. Refer to Wheel Drive Shaft Replacement in Wheel Drive
Shafts.
34. Using mechanics wire, support the wheel drive shafts out of the way by tying them up to the
strut spring.
35. Remove the torque converter cover. Refer to Torque Converter Cover Replacement .

Important: Mark the flywheel to torque converter position so that they can be assembled in
the same position.

36. Remove the flywheel to torque converter bolts.

37. Position the power steering gear pressure hose to the right side of the vehicle in order to
clear the transaxle during removal.

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38. Support the transaxle using the J 41160 and a suitable transmission jack.
39. Secure the J 41160 to the transaxle.

40. Remove the nut (1) securing the left transaxle mount to the left transaxle mount bracket.

41. Remove the remaining transaxle to engine bolt (2).

42. Separate the transaxle from the engine.
43. Tilt the transaxle using the support jack enough to allow clearance for the starter nose cone.

Important: Ensure clearance is maintained between the transaxle and the following:
• The brake pipes
• The secondary AIR pipe
• The power steering pressure hose
• The wiring harnesses

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44. Carefully lower the transaxle from the vehicle.

45. Complete the following if transaxle replacement is necessary:
• Remove the transaxle cooler pipe, refer to Cooler Pipe Replacement
• Remove the left transaxle bracket, refer to Automatic Transmission Mount Bracket
Replacement - Left Side
• Remove the rear transaxle bracket, refer to Transmission Rear Mount Bracket
Replacement
46. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow
Test .

Installation Procedure
1. Complete the following if previously removed from the transaxle:
• Install the rear transaxle bracket, refer to Transmission Rear Mount Bracket Replacement
• Install the left transaxle bracket, refer to Automatic Transmission Mount Bracket
Replacement - Left Side
• Install the transaxle cooler pipe, refer to Cooler Pipe Replacement

Important: Ensure clearance is maintained between the transaxle and the following:
• The brake pipes
• The secondary AIR pipe
• The power steering pressure hose
• The wiring harnesses

2. Carefully raise the transaxle to the engine in a tilted position in order to clear the starter
nose cone.

Notice: Refer to Fastener Notice in the Preface section.

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3. Align the transaxle with the engine and position the transaxle onto the engine dowels.
4. Install the engine to transaxle bolt (2).

Tighten
Tighten the bolt to 75 N·m (55 Ib ft).

5. Connect the vehicle speed sensor electrical connector.

6. Install the engine to transaxle center brace and heat shield. Refer to Transmission Brace
Replacement .

7. Install the bolts securing the front transaxle brace to the transaxle.

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Tighten
Tighten the bolts to 50 N·m (37 Ib ft).

8. Raise the transaxle and install the nut (1) securing the transaxle mount to the transaxle
mount bracket.

Tighten
Tighten the nut to 75 N·m (55 Ib ft).

9. Remove the transmission jack and the J 41160 .

Important: Line up the flywheel and converter using the alignment marks made during

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disassembly.

10. Install the flywheel to converter bolts.

Tighten
Tighten the bolts to 60 N·m (44 Ib ft).

11. Install the torque converter cover assembly. Refer to Torque Converter Cover Replacement .

12. Install the engine to transaxle bracket lower bolt (1).

Tighten
Tighten the bolt to 50 N·m (37 Ib ft).

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13. Install the right and left drive shafts (2) to the transaxle (1). Refer to Wheel Drive Shaft
Replacement in Wheel Drive Shafts.

14. Install the 3 ground connections to the side of the transaxle.

Tighten
Tighten the bolts to 50 N·m (37 Ib ft).

15. Connect the transaxle main electrical harness connector.

16. Install the left transaxle brace to the powertrain assembly.

17. Install the bolt securing the left transaxle brace to the transaxle.

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Tighten
Tighten the left transaxle brace bolt to 50 N·m (37 Ib ft).

Tighten
Tighten the left transaxle brace nut to 41 N·m (30 Ib ft).

18. Install the front frame assembly to the vehicle. Refer to Frame Replacement in Frame and
Underbody.
19. Install the left front wheelhouse extension. Refer to Wheelhouse Extension Replacement in
Body Front End.
20. Install the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
21. Lower the vehicle.

22. Connect the lower transaxle oil cooler pipe to the transaxle. Refer to Cooler Pipe
Replacement .

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23. Install the upper transaxle oil cooler pipe to the radiator. Refer to Cooler Pipe Replacement .

24. Install the remaining transaxle to engine bolts (1).

Tighten
Tighten the bolts to 75 N·m (55 Ib ft).

25. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical -
4.0L.

26. Install the range selector cable bracket to the studs on the transaxle.
27. Install the heater pipe to the stud on the transaxle.
28. Install the nuts that retain the heater pipe and the range selector cable bracket to the

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transaxle.

Tighten
Tighten the nuts to 25 N·m (18 Ib ft).

29. Connect the range selector cable terminal (1) to the transaxle range selector lever.
30. Install the Magnasteer wire to the retaining clip.
31. Connect the transaxle vent tube to the accelerator bracket.
32. Install the brake pipe retainers to the side rail.
33. Install the upper and lower air cleaner assemblies. Refer to Air Cleaner Assembly
Replacement in Engine Controls - 4.0L.
34. Add DEXRON® VI transmission fluid as required. Refer to Fluid Capacity Specifications and
Transmission Fluid Check .
35. Check the front suspension alignment, adjust the toe as necessary.

Important: It is recommended that transmission adaptive pressure (TAP) information be

reset.

36. Reset the TAP values. Refer to Adapt Function .

37. Check the front end alignment.
38. Road test the vehicle and check for transaxle leaks.

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2001 Chevrolet Lumina
2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

2001-03 AUTOMATIC TRANSMISSIONS

Hydra-Matic 4T65-E Overhaul

APPLICATION

CAUTION: Flush oil cooler and oil cooler lines prior to transaxle
installation. Oil cooling system contamination may cause
premature transaxle failure. For additional information, see
LUBRICATION in appropriate SERVICING article.

TRANSAXLE APPLICATION
Application Transaxle Model (RPO Code)
Buick
Century (3.1L) 4T65-E (M15)
LeSabre (3.8L ) 4T65-E (MN3 Or M15)
Park Avenue (3.8L) 4T65-E (MN3 Or MN7)
Regal (3.8L) 4T65-E (M15 Or MN7)
Rendezvous (3.4L) 4T65-E (M15 Or M76)
Chevrolet
Impala (3.4L & 3.8L) 4T65-E (M15)
Lumina (3.1L) 4T65-E (M15)
Monte Carlo (3.4L & 3.8L) 4T65-E (M15)
Venture (3.4L) 4T65-E (M15 Or M76)
Oldsmobile
Aurora (3.5L) 4T65E (MN3)
Intrigue (3.5L) 4T65-E (MN3)
Silhouette (3.4L) 4T65-E (M15 Or M76)
Pontiac
Aztek (3.4L) 4T65-E (M15 Or M76)
Bonneville (3.8L) 4T65-E (MN3, M15 Or MN7)
Grand Prix
3.1L 4T65E (M15)
3.8L 4T65-E (M15 Or MN7)
Montana (3.4L) 4T65-E (M15 Or M76)

IDENTIFICATION
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TRANSAXLE

Transaxle has a metal identification plate or Service Replacement Transmission Assembly

(SRTA) plate attached to rear face of transaxle. See Fig. 1 . Transaxle RPO codes are MN3,
MN7, M15 or M76. The MN3 and MN7 are heavy duty models and have 10.2" (258 mm) torque
converters. The M15 model has a 9.6" (245 mm) torque converter. The M76 model is used in All
Wheel Drive (AWD) applications. For model build information on each RPO code, see Fig. 2 -
Fig. 9 .

Fig. 1: Locating Transaxle ID Plate & SRTA Plate Information

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 2: Identifying Model Build Information (2001 - MN3)

Courtesy of GENERAL MOTORS CORP.

Fig. 3: Identifying Model Build Information (2001 - MN7)

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Courtesy of GENERAL MOTORS CORP.

Fig. 4: Identifying Model Build Information (2001 - M15)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 5: Identifying Model Build Information (2001 - M76)

Courtesy of GENERAL MOTORS CORP.

Fig. 6: Identifying Model Build Information (2002 - MN3)

Courtesy of GENERAL MOTORS CORP.

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Fig. 7: Identifying Model Build Information (2002 - MN7)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 8: Identifying Model Build Information (2002 - M15)

Courtesy of GENERAL MOTORS CORP.

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Fig. 9: Identifying Model Build Information (2002 - M76)

Courtesy of GENERAL MOTORS CORP.

[email protected]

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 10: Identifying Model Build Information (2003 - MN3)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 11: Identifying Model Build Information (2003 - MN7)

Courtesy of GENERAL MOTORS CORP.

Fig. 12: Identifying Model Build Information (2003 - M15)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 13: Identifying Model Build Information (2003 - M76)

Courtesy of GENERAL MOTORS CORP.

GEAR RATIOS

TRANSAXLE GEAR RATIOS

Gear Range Gear Ratio
1st 2.921:1
2nd 1.568:1
3rd 1.000:1
4th 0.705:1
Reverse 2.385:1

DESCRIPTION & OPERATION

Hydra-Matic 4T65-E is a fully automatic front wheel drive electronically controlled transaxle.
Four forward ranges including overdrive are provided. Powertrain Control Module (PCM)
controls shift points using two shift solenoids. A vane-type oil pump supplies oil pressure. PCM
regulates oil pressure using pressure control solenoid valve. All vehicles equipped with 4T65-E
transaxle have an Electronically Controlled Capacity Clutch (ECCC) system. In ECCC system,
pressure plate does not fully lock to torque converter cover. It is precisely controlled to maintain
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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

a small amount of slippage between engine and turbine, reducing driveline torsional disturbances.

Multiplied torque from torque converter is transferred to transaxle by a sprocket and drive chain
(drive link) assembly. Other internal components consist of 4 multiple-disc clutches, roller clutch,
sprag clutch, 3 bands and compound planetary gear set. Final drive gear and differential
assemblies are an integral part of transaxle. See Fig. 14 -Fig. 20 .

NOTE: Drive chain may also be referred to as "drive link".

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 14: Identifying Hydra-Matic 4T65-E Transaxle Component Locations

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Courtesy of GENERAL MOTORS CORP.

Fig. 15: Exploded View Of Case Side Cover Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 16: Exploded View Of Transaxle Case Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 17: Exploded View Of 4th Clutch, Turbine Shaft, Output Shaft, & Drive & Driven
Sprocket Assembly Components
Courtesy of GENERAL MOTORS CORP. [email protected]

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 18: Exploded View Of Transaxle Internal Components (1 Of 2)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 19: Exploded View Of Transaxle Internal Components (2 Of 2)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 20: Exploded View Of Parking System Components

Courtesy of GENERAL MOTORS CORP.

LUBRICATION

NOTE: See appropriate SERVICING - A/T article.

TROUBLE SHOOTING

NOTE: Transaxle malfunctions may be caused by poor engine

performance, improper adjustments, fluid condition or failure of
hydraulic, mechanical or electronic components. Ensure all
concerns have been properly checked prior to transaxle overhaul.
See appropriate DIAGNOSIS article.

COMPONENT TESTS
TORQUE CONVERTER
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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Visual Inspection

Inspect and replace torque converter for the following conditions:

Overheated (torque converter will be blue in color).

ATF leaking at weld areas.
Damaged torque converter pilot.
Evidence of metal particles in torque converter, oil cooler, or cooler pipes.
Damaged torque converter stator, damaged pump, or damaged turbine.
Damaged or worn torque converter bushing.
Contaminated ATF due to engine coolant.

Inspect torque converter for stripped bolt hole threads. Repair as necessary.
Stator Check

With torque converter removed from vehicle, stator roller clutch can be checked by inserting 2
fingers into splined inner race of roller clutch and attempting to rotate race in both directions.
Inner race should rotate freely clockwise, but should not rotate or should be difficult to rotate
counterclockwise.
End Play Check

Mount Torque Converter End Play Fixture (J-35138) and Dial Indicator (J-8001) on torque
converter to check end play. End play should be 0-.020" (0-.50 mm). See Fig. 21 .

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 21: Measuring Torque Converter End Play

Courtesy of GENERAL MOTORS CORP.

TRANSAXLE DISASSEMBLY
TORQUE CONVERTER

Remove torque converter and turbine shaft "O" ring seal. See Fig. 22 . Install Holding Fixture (J-
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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

28664-B) onto transaxle. See Fig. 23 . Install transaxle and holding fixture into Base (J-3289-
20). Insert pin into base to hold transaxle in desired position.

Fig. 22: Removing Turbine Shaft "O" Ring Seal

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 23: Installing Transaxle Holding Fixture & Base

Courtesy of GENERAL MOTORS CORP.

TRANSFER CASE REMOVAL

CAUTION: ATF circulates between transaxle and transfer case. In

situations where transaxle related failures circulate debris
into transfer case, transfer case must be disassembled,
cleaned, and inspected for damage.

1. Remove output shaft snap ring. See Fig. 24 . Rotate transaxle 90 degrees. Remove transfer
case lower brace bolt. See Fig. 25 . Rotate transaxle 90 degrees.
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2. Remove transfer case side brace. See Fig. 26 . Remove transfer case-to-transaxle bolts. See
Fig. 27 .

CAUTION: During transfer case/output shaft removal, DO NOT use

excessive force or damage to bushings may occur.

3. Remove transfer case assembly from transaxle. See Fig. 28 . Remove transfer case lower
brace. See Fig. 29 . Remove case extension seal from transfer case. See Fig. 30 .
4. Position transaxle with case side cover facing down. Remove oil dam from transaxle. See
Fig. 31 . Install transfer case assembly onto Holding Fixture (J 44755). See Fig. 32 .
5. Using Slide Hammer (J-6125-1B) and Adapter (J-44467), remove output shaft. See Fig.
33 . Remove final drive sun gear. See Fig. 34 .
6. Remove sun gear thrust washer from transaxle. See Fig. 35 . Remove parking gear and
thrust bearing. See Fig. 36 . Remove final drive sun gear shaft. See Fig. 37 .

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Fig. 24: Locating Output Shaft Snap Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 25: Locating Transfer Case Lower Brace Bolt

Courtesy of GENERAL MOTORS CORP.

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Fig. 26: Locating Transfer Case Side Brace

Courtesy of GENERAL MOTORS CORP.

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Fig. 27: Locating Transfer Case-To-Transaxle Bolts

Courtesy of GENERAL MOTORS CORP.

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Fig. 28: Removing & Installing Transfer Case Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 29: Locating Transfer Case Lower Brace

Courtesy of GENERAL MOTORS CORP.

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Fig. 30: Removing & Installing Case Extension Seal (AWD)

Courtesy of GENERAL MOTORS CORP.

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Fig. 31: Removing & Installing Oil Dam (AWD)

Courtesy of GENERAL MOTORS CORP.

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Fig. 32: Installing Transfer Case Holding Fixture & Base

Courtesy of GENERAL MOTORS CORP.

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Fig. 33: Removing Output Shaft (AWD)

Courtesy of GENERAL MOTORS CORP.

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Fig. 34: Removing & Installing Final Drive Sun Gear (AWD)
Courtesy of GENERAL MOTORS CORP.

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Fig. 35: Removing & Installing Sun Gear Thrust Washer (AWD)
Courtesy of GENERAL MOTORS CORP.

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Fig. 36: Removing & Installing Parking Gear & Bearing (AWD)
Courtesy of GENERAL MOTORS CORP.

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Fig. 37: Removing & Installing Final Drive Sun Gear Shaft (AWD)
Courtesy of GENERAL MOTORS CORP.

REVERSE BAND SERVO [email protected]

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1. Using long screwdriver, depress reverse band servo cover by prying against holding fixture.
Pry retaining ring from reverse band servo cover. See Fig. 38 .
2. Remove screwdriver. Servo assembly will push servo cover up. Using small screwdriver,
pull servo cover "O" ring seal out through slot in case. Cut servo "O" ring seal. Depress
reverse band servo cover. Grasp one end of cut seal and pull from servo cover. Servo
assembly will push servo cover up. Remove servo cover, reverse band servo assembly and
reverse band servo piston return spring. See Fig. 39 .

Fig. 38: Removing & Installing Reverse Servo Assembly Cover

Courtesy of GENERAL MOTORS CORP.

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Fig. 39: Removing & Installing Reverse Servo Assembly

Courtesy of GENERAL MOTORS CORP.

FORWARD BAND SERVO

Position transaxle with oil pan facing up. Using long screwdriver, depress forward band servo
assembly cover by prying against work bench. Hold servo assembly and remove forward band
servo cover bolts. See Fig. 40 . Remove screwdriver. Servo assembly will push servo cover out.
If cover does not move, tap cover with mallet. Remove servo cover and cover seal. Remove servo
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assembly. Remove piston return spring from forward band servo. See Fig. 41 .

Fig. 40: Removing & Installing Forward Band Servo Cover

Courtesy of GENERAL MOTORS CORP.

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Fig. 41: Removing & Installing Forward Band Servo

Courtesy of GENERAL MOTORS CORP.

OIL PAN & FILTER

Remove oil pan bolts. Remove oil pan and gasket. Using screwdriver, pry oil filter out of case.
Pry oil filter seal out of case. DO NOT damage case sealing surface. See Fig. 16 . Inspect oil pan
magnet for steel particles. Excessive amounts of steel shavings indicates internal transaxle
damage. Using screwdriver, pry metal crimping away from top of oil filter and pull oil filter
apart. Inspect oil filter for clutch plate friction material, steel particles and Bronze slivers,
indicating bushing damage or internal transaxle damage.

ACCUMULATOR ASSEMBLY & 2-1 MANUAL BAND SERVO

1. Remove accumulator cover bolts from 1-2 and 2-3 accumulator cover. See Fig. 42 .
Remove bolts from 2-1 manual band servo cover. Using screwdriver, gently pry lube oil
pipe retainer from case. See Fig. 43 . Remove lube oil pipe from front differential carrier
internal gear lube hole. See Fig. 44 .
2. Remove 1-2 and 2-3 accumulator assembly and 2-1 manual band servo assembly together.
Remove pipe assembly. DO NOT twist pipe assembly. Remove cover gasket from 2-1
manual band servo.

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Fig. 42: Removing & Installing Accumulator & 2-1 Manual Band Covers
Courtesy of GENERAL MOTORS CORP.

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Fig. 43: Removing & Installing Lube Oil Pipe Retainer

Courtesy of GENERAL MOTORS CORP.

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Fig. 44: Exploded View Of Accumulator Components & 2-1 Manual Band Servo
Courtesy of GENERAL MOTORS CORP.

CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR

1. Position transaxle with control valve body cover facing up. Remove case side cover (control
valve body cover) bolts. See Fig. 45 . Remove cover and gaskets. See Fig. 15 . Using small
screwdriver, pry wiring harness electrical connectors off transaxle fluid pressure manual
valve position switch, 1-2 and 3-4 shift solenoid, 2-3 shift solenoid, TCC PWM solenoid,
pressure control solenoid and input speed sensor. Gently pull transaxle fluid temperature
sensor from clip. See Fig. 46 and Fig. 47 .
2. Lift wiring harness assembly off transaxle. Remove oil pump assembly bolts. DO NOT
remove No. 1 oil pump cover bolt at this time. See Fig. 48 . Remove wiring harness clip.
Lift oil pump assembly off control valve body. See Fig. 49 . Set oil pump assembly on its
cover.
3. Remove control valve body bolts. See Fig. 50 . Manual valve position switch is very
delicate, use care when handling. Carefully lift manual valve position switch off control
valve body. See Fig. 51 . Remove control valve body. See Fig. 52 . Remove 4 check balls
from case cover. See Fig. 53 . Remove 2 bolts retaining spacer plate and gaskets to valve
body. Remove spacer plate with 2 screen/seal assemblies and gaskets from valve body.
Remove 6 check balls from valve body. See Fig. 54 . Remove case cover pin.
4. Remove oil pump drive shaft from case cover. See Fig. 55 . Position transaxle so Vehicle
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Speed Sensor (VSS) is facing up. Remove VSS bolt and VSS. See Fig. 16 .

Fig. 45: Identifying Case Side Cover Bolt Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 46: Routing Transaxle Wire Harness

Courtesy of GENERAL MOTORS CORP.

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Fig. 47: Identifying Transaxle Electronic Component Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 48: Identifying Oil Pump Bolt Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 49: Removing & Installing Oil Pump Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 50: Identifying Valve Body Bolt Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 51: Removing & Installing Manual Valve Position Switch

Courtesy of GENERAL MOTORS CORP.

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Fig. 52: Removing Control Valve Body Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 53: Locating Case Cover Check Balls

Courtesy of GENERAL MOTORS CORP.

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Fig. 54: Locating Control Valve Body Check Balls

Courtesy of GENERAL MOTORS CORP.

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Fig. 55: Removing & Installing Oil Pump Drive Shaft

Courtesy of GENERAL MOTORS CORP.

OUTPUT SHAFT

1. Remove case extension bolts. Remove case extension and extension seal. See Fig. 56 .
Leave front differential carrier thrust washer and bearing on carrier. Rotate differential
carrier until differential carrier pinion shaft is in horizontal position.
2. Place Axle Remover Wedge (J 42562) between end of output shaft and differential pinion
shaft. Using hammer, strike axle removal wedge to compress snap ring and push output shaft
from differential side gear. See Fig. 57 . Remove differential carrier assembly and snap ring
from output shaft. See Fig. 58 . Remove output shaft assembly. See Fig. 59 .
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Fig. 56: Removing & Installing Case Extension

Courtesy of GENERAL MOTORS CORP.

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Fig. 57: Compressing Output Shaft Snap Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 58: Removing Differential Carrier Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 59: Removing Output Shaft

Courtesy of GENERAL MOTORS CORP.

FRONT DIFFERENTIAL CARRIER END PLAY CHECK

1. Ensure thrust washer and bearing are on front differential carrier. Install case extension seal
onto case extension, if removed. Install case extension onto transaxle. See Fig. 56 . Install 2
case extension bolts. DO NOT tighten bolts to specification. Only tighten bolts until case
extension is fully seated.
2. Position transaxle with case extension facing up. Install Aligning Tool (J-26958) and dial
indicator. See Fig. 60 . Zero dial indicator. Use Snap Ring Remover (J-28585) or large
screwdriver to lift front differential carrier. Pry up on VSS reluctor wheel through sensor
hole in case extension.
3. Note dial indicator measurement. End play should be .005-.025" (.13-.64 mm). Record
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measurement for reassembly reference. If dial indicator reading is less than .005" (.13 mm),
install next smaller size thrust washer, and check end play. If dial indicator reading is more
than .025" (.64 mm), install next larger size thrust washer, and check end play. For available
thrust washer sizes, see CARRIER-TO-CASE SELECTIVE THRUST WASHER
SIZES table under TRANSAXLE REASSEMBLY.

Fig. 60: Measuring Front Differential Carrier End Play

Courtesy of GENERAL MOTORS CORP.

MANUAL VALVE LINK & OIL DAM

1. Remove manual shift detent bolt and manual shift detent. See Fig. 61 . Compress manual
valve link spring. Lift link off manual valve. See Fig. 62 .
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2. Position manual valve so valve will not interfere with case cover removal. Remove oil dam
from case. See Fig. 63 . Using small screwdriver, pry input speed sensor clip out of case
cover. Use care when handling speed sensor. Carefully pull input speed sensor out of case
cover. See Fig. 64 .

Fig. 61: Removing & Installing Manual Shift Detent

Courtesy of GENERAL MOTORS CORP.

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Fig. 62: Removing Spring Link From Manual Valve

Courtesy of GENERAL MOTORS CORP.

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Fig. 63: Removing & Installing Oil Dam

Courtesy of GENERAL MOTORS CORP.

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Fig. 64: Removing & Installing Input Speed Sensor

Courtesy of GENERAL MOTORS CORP.

CASE COVER & GASKETS

Remove indicated case cover bolts. See Fig. 65 . Hold manual valve in place. Lift case cover and
thrust washers off case. See Fig. 66 . Remove upper and lower case cover gaskets. See Fig. 67 .

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Fig. 65: Identifying Case Cover Bolt Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 66: Removing & Installing Case Cover

Courtesy of GENERAL MOTORS CORP.

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Fig. 67: Removing & Installing Case Cover Gaskets

Courtesy of GENERAL MOTORS CORP.

4TH CLUTCH SHAFT & PLATES

Remove 4th clutch backing plate, composition plates and steel plates. Remove 4th clutch shaft.
Remove drive link lube scoop. See Fig. 68 .

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Fig. 68: Removing & Installing 4th Clutch Components

Courtesy of GENERAL MOTORS CORP.

DRIVE & DRIVEN SPROCKETS

Drive Chain (Drive Link) Stretch Check

Ensure driven sprocket support assembly and both sprockets are fully seated. Pull drive link
toward case at indicated location. See Fig. 69 . Measure distance between case and drive link. If
measurement is .126" (3.2 mm) or more, drive link may be reused. If measurement is less
than .126" (3.2 mm), replace drive link.
Drive & Driven Sprocket Disassembly

1. Remove 4th clutch shaft thrust washer. Remove drive sprocket thrust washer. Washer may
be stuck to case cover. Remove VSS reluctor wheel. Note location of drive link assembly
master link. Master link is different color than other links and may be facing up or down
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toward case.

CAUTION: Note drive link direction prior to removal. Drive link must
be installed in same direction during reassembly.

2. Lift drive and driven sprockets with drive link out of case. Lift both sides evenly. It may be
necessary to tap turbine shaft up gently with a rubber mallet. Remove drive and driven
sprocket thrust washers. See Fig. 70 . Thrust washers may be stuck to sprockets.

Fig. 69: Checking Drive Chain (Drive Link) Stretch

Courtesy of GENERAL MOTORS CORP.

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Fig. 70: Removing & Installing Drive & Driven Sprockets

Courtesy of GENERAL MOTORS CORP.

DRIVEN SPROCKET SUPPORT ASSEMBLY

Insert 2 case cover bolts into driven sprocket support assembly. See Fig. 71 . Grasp bolts and lift
support assembly. Remove thrust washer from 2nd clutch housing. Washer may be stuck to
support assembly.

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Fig. 71: Removing & Installing Driven Sprocket Support Assembly

Courtesy of GENERAL MOTORS CORP.

INPUT & 2ND CLUTCH ASSEMBLIES

1. Adjust collar on Final Drive/Clutch Remover/Installer (J-33381-A) to ensure threaded rod

is fully loosened. Install Remover/Installer into 2nd clutch housing assembly. Tighten
threaded rod until rod is finger tight. Lift up on remover/installer with 2nd clutch and input
clutch assemblies attached. Sprag clutch assemblies will also be attached. See Fig. 72 .
2. Place complete assembly on bench. Loosen threaded rod and remove remover/installer. Lift
2nd clutch housing assembly off input clutch housing. Remove input clutch housing thrust
bearing from input housing. Remove selective thrust washer from input clutch housing. See
Fig. 73 . [email protected]

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Fig. 72: Removing & Installing Input & 2nd Clutch Assemblies
Courtesy of GENERAL MOTORS CORP.

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Fig. 73: Removing & Installing 2nd Clutch Housing

Courtesy of GENERAL MOTORS CORP.

REVERSE BAND & REACTION DRUM

Tilt band to disengage band from anchor pin in case. Remove reverse band. See Fig. 74 . Lift
reverse reaction drum from transaxle case. See Fig. 75 .

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Fig. 74: Removing & Installing Reverse Band

Courtesy of GENERAL MOTORS CORP.

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Fig. 75: Removing & Installing Reverse Reaction Drum

Courtesy of GENERAL MOTORS CORP.

INPUT CLUTCH HOUSING END PLAY CHECK

All Wheel Drive

1. Install final drive sun gear shaft. See Fig. 37 . Use petroleum jelly to retain parking gear
thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. See Fig.
36 . Install final drive sun gear. See Fig. 34 .
2. Install End Play Checking Tool (J-44472). See Fig. 76 . Install bolts and tighten securely to
prevent tool deflection during end play measurement.
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3. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and
sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer
to lift input clutch housing. See Fig. 72 . Install input clutch housing assembly into case.
Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input
clutch housing.
4. Using 2 bolts, install End Play Gauge (J-33386) onto case. See Fig. 77 . Tighten bolts to
securely hold end play gauge. Tighten end play checking tool finger tight to eliminate
differential carrier end play.
5. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not
fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge,
measure end play between end play gauge and thrust washer.
6. Record measurement for proper end play clearance during reassembly. End play should be
0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during
transaxle reassembly. If end play is greater than .006" (.15 mm), select next size larger thrust
washer and recheck. For input clutch thrust washer identification, see INPUT CLUTCH
THRUST WASHER IDENTIFICATION table under TRANSAXLE REASSEMBLY.
7. Remove end play checking tool. See Fig. 76 . Install remover/installer into input clutch
housing. Tighten threaded rod of remover/installer until rod is finger tight. Using
remover/installer, lift input clutch housing assembly (sprag clutch assemblies will also be
attached) from case.
8. Position transaxle so oil pan is facing down. Remove final drive sun gear, parking gear,
parking gear thrust bearing and final drive sun gear shaft.
Except All Wheel Drive

1. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and
sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer
to lift input clutch housing. See Fig. 72 . Install input clutch housing assembly into case.
Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input
clutch housing.
2. Remove remover/installer from input clutch housing. Install case extension with Output
Shaft Loading/Aligning Tool (J-26958), Adapter Plug (J-26958-10) and Loading Tool
Adapter (J-43425) attached to case extension. See Fig. 78 . Using 2 bolts, install End Play
Gauge (J-33386) onto case. See Fig. 77 . Tighten bolts to securely hold gauge. Tighten
aligning tool finger tight in order to eliminate differential carrier end play. See Fig. 78 .
3. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not
fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge,
measure end play between end play gauge and thrust washer.
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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

4. Record measurement for proper end play clearance during reassembly. End play should be
0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during
transaxle reassembly. If end play is greater than .006" (.15 mm), select next size larger thrust
washer and recheck. For input clutch thrust washer identification, see INPUT CLUTCH
THRUST WASHER IDENTIFICATION table under TRANSAXLE REASSEMBLY.
5. Remove end play gauge. Install remover/installer into input clutch housing. Lift input clutch
housing from case. Remove aligning tool, adapter plug and loading tool adapter from case
extension.

Fig. 76: Installing End Play Checking Tool (AWD)

Courtesy of GENERAL MOTORS CORP.
[email protected]

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Fig. 77: Checking Input Clutch Housing End Play

Courtesy of GENERAL MOTORS CORP.

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Fig. 78: Installing Aligning Tool & Adapters To Case Extension

Courtesy of GENERAL MOTORS CORP.

CASE EXTENSION & DIFFERENTIAL CARRIER

Remove case extension bolts. Remove case extension and remove seal. Remove differential
carrier thrust washer and thrust bearing. See Fig. 56 . Remove differential carrier assembly.
[email protected]

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Remove differential sun gear shaft. Remove thrust bearing from differential carrier sun gear.
Bearing may be stuck to carrier assembly. Remove differential carrier (final drive) sun gear.
Remove parking gear. Remove thrust bearing from differential carrier internal gear. See Fig. 79 .

Fig. 79: Removing & Installing Differential Carrier Components

Courtesy of GENERAL MOTORS CORP.

INPUT & REACTION CARRIER

Position transaxle with case cover facing up. Remove input carrier assembly. See Fig. 80 .
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Remove input carrier and reaction carrier lube dam. See Fig. 81 . Lube dam may be stuck to
input carrier assembly. Remove thrust bearing from reaction carrier. Remove reaction carrier
assembly.

Fig. 80: Removing Input Carrier Assembly

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 81: Removing Reaction Carrier Assembly

Courtesy of GENERAL MOTORS CORP.

REACTION SUN GEAR & 2-1 MANUAL BAND

Remove thrust bearing from reaction sun gear. Remove reaction sun gear assembly. See Fig. 82 .
Tilt band to disengage 2-1 manual band assembly from anchor pin. Remove 2-1 manual band
from case. See Fig. 83 .

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Fig. 82: Removing & Installing Reaction Sun Gear

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 83: Removing & Installing 2-1 Manual Band

Courtesy of GENERAL MOTORS CORP.

1-2 SUPPORT DRUM & FORWARD BAND

Install Support Remover/Installer (J-38358) onto 1-2 support drum assembly. Lift
remover/installer with 1-2 support drum out of case. See Fig. 84 . Tilt band to disengage band
from anchor pin. Remove forward band from case. See Fig. 85 .

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Fig. 84: Removing & Installing 1-2 Support Drum

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 85: Removing & Installing Forward Band & Thrust Washer
Courtesy of GENERAL MOTORS CORP.

FINAL DRIVE INTERNAL GEAR

Remove thrust washer from final drive internal gear. Use snap ring remover or large screwdriver
to remove final drive internal gear retaining ring. Lift final drive internal gear out of case by
depressing parking pawl to clear case. See Fig. 86 .
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Fig. 86: Removing & Installing Final Drive Internal Gear

Courtesy of GENERAL MOTORS CORP.

PARKING SYSTEM COMPONENTS

1. Using side cutting pliers, remove manual shift shaft pin. DO NOT cut through pin. Protect
case with piece of wood or rubber under pliers when removing pin. See Fig. 87 . Remove
manual valve link and spring from manual shift detent lever. Remove manual shift detent
lever nut from manual shift shaft. Remove manual shift detent lever and remove parking
pawl actuator. See Fig. 88 .
2. Position transaxle with reverse band servo bore facing up. Pull manual shift shaft out of
case. Using small screwdriver, pry manual shift shaft seal from case. Remove parking pawl
actuator guide pin. Remove parking [email protected]
pawl actuator guide from case. Remove actuator guide
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seal from guide. See Fig. 89 .

Fig. 87: Removing Manual Shift Shaft Pin

Courtesy of GENERAL MOTORS CORP.

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Fig. 88: Removing Manual Shift Shaft Components & Parking Pawl Actuator
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 89: Removing & Installing Parking Pawl Actuator Guide

Courtesy of GENERAL MOTORS CORP.

COMPONENT DISASSEMBLY & REASSEMBLY

CASE COMPONENTS

Inspection

1. Inspect components still on transaxle case for the following:

Loose, cross-threaded, or damaged ATF cooler pipe fittings.

Loose, missing, or damaged transaxle name plate.

Loose, plugged, or damaged vent assembly.

Loose, cross-threaded, or damaged oil pressure test hole plug.

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2. Inspect transaxle case for the following:

Damaged or porous gasket sealing surfaces.

Stripped or damaged bolt or screw holes (repair with thread insert).

Damaged or porous case oil passages.

Damaged snap ring grooves or housing splines.

Loose, missing, or damaged band anchor pins.

Damaged or porous case surfaces.

Plugged drain back holes for torque converter oil seal.

Disassembly & Reassembly

If vent is damaged, use pliers and pry bar to remove vent. See Fig. 90 . Use hammer and punch to
install vent. If oil pressure test hole plug was removed, install plug and tighten to specification.
See TORQUE SPECIFICATIONS .

[email protected]

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Fig. 90: Locating Transaxle Vent & Oil Pressure Test Hole Plug
Courtesy of GENERAL MOTORS CORP.

DRIVE SPROCKET SUPPORT

Inspection

Inspect drive sprocket support for the following:

Damaged splines.
Damaged drive sprocket support bearing.
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Damaged turbine shaft bushing (pressed inside support).

Remove drive sprocket support bearing and/or drive sprocket support assembly only if damaged.
Disassembly & Reassembly

Using slide hammer and Universal Seal Remover (J-23129), remove torque converter seal. See
Fig. 91 . If damage is visible to drive sprocket support bearing, use slide hammer and
Bushing/Bearing Remover (J-26941) to remove bearing from drive sprocket support. See Fig.
92 . Remove drive sprocket support bolts and remove drive sprocket. See Fig. 93 . Install NEW
bearing using drive handle and bearing installer. See Fig. 92 . Install drive sprocket support.
Install and tighten drive sprocket support bolts to specification. See TORQUE
SPECIFICATIONS . Using Seal Installer (J-28540) and mallet, install NEW torque converter
seal.

[email protected]

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Fig. 91: Removing Torque Converter Seal

Courtesy of GENERAL MOTORS CORP.

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Fig. 92: Removing & Installing Drive Sprocket Bearing

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 93: Removing & Installing Drive Sprocket Support

Courtesy of GENERAL MOTORS CORP.

PARKING SYSTEM COMPONENTS

Inspection & Reassembly

1. Inspect park system components for the following:

Worn park pawl actuator guide.

Damaged or bent park pawl actuator assembly.

Damaged manual shift shaft detent lever or IMS detent lever.

Worn, stripped, or bent manual shift shaft.

Bent or damaged manual valve link.

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Kinked or bent manual valve link spring.

Replace components as necessary. See Fig. 94 .

2. Install NEW shift shaft seal into case using 9/16" socket and hammer. See Fig. 95 . Install
NEW parking pawl actuator guide "O" ring seal onto parking pawl actuator guide. Install
actuator guide into case. Align slot for actuator guide pin in parking pawl with pin hole in
case. Install actuator guide pin using mallet. See Fig. 89 .
3. Install manual shift shaft detent lever onto manual shift shaft. Install nut on shift shaft and
tighten to specification. See TORQUE SPECIFICATIONS . Install detent lever onto
parking pawl actuator. Install manual shift shaft detent lever assembly and parking pawl
actuator assembly into case. See Fig. 96 .
4. Align groove for manual shift shaft pin with pin hole in case. Install manual shift shaft pin
using mallet. See Fig. 97 .

[email protected]

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Fig. 94: Inspecting Parking System Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 95: Installing Shift Shaft Seal

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 96: Installing Manual Shift Shaft Components & Pawl Actuator
Courtesy of GENERAL MOTORS CORP.

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Fig. 97: Installing Manual Shift Shaft Pin

Courtesy of GENERAL MOTORS CORP.

DIFFERENTIAL CARRIER INTERNAL GEAR

Inspection

Inspect differential carrier internal gear assembly for the following:

Damaged or worn bushings.

Plugged lube oil holes.
Damaged case splines.
Damaged or worn gear teeth. [email protected]

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Damaged or worn park pawl assembly.

Damaged snap ring.

Replace components as necessary. See Fig. 98 .

Fig. 98: Inspecting Differential Carrier Internal Gear Assembly

Courtesy of GENERAL MOTORS CORP.

DIFFERENTIAL CARRIER

Disassembly

1. Using feeler gauge, measure differential carrier planetary pinion gear end play. End play
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should be .009-.025" (.23-.64 mm). See Fig. 99 . If end play is not as specified, repair
differential carrier assembly as necessary.

NOTE: Ensure pinion gears are installed in same direction as

removed. If gears are installed upside down, noise may result
due to change in wear pattern.

2. Using screwdriver remove retaining ring from front differential carrier. See Fig. 100 .
Remove planetary pinion gear pin, thrust washers, roller bearings, spacer and pinion gear.
See Fig. 101 . Remove remaining planetary pinions in same manner. Remove differential
carrier sun gear thrust bearing.
3. Place final drive carrier components into oil pan to ensure roller bearings are not lost. Using
drift pin and hammer remove differential pinion shaft retaining pin. See Fig. 102 . Remove
differential pinion gear shaft, gears, pinion gear thrust washers, side gears and side gear
thrust washers. See Fig. 103 .
Inspection

1. Inspect differential carrier assembly for the following:

Damaged or worn teeth, bearing rollers, washers, or pins on differential planetary
pinion gear.
Damaged or worn teeth or splines on final drive sun gear.

Damaged or worn teeth, splines, or thrust washers on differential side gear.

Damaged or worn teeth, thrust washers, or shaft on differential pinion gear.

Damaged or worn lugs or splines on parking gear.

Damaged VSS reluctor wheel.

Damaged internal gear/parking gear thrust bearing, differential carrier/sun gear thrust
bearing or differential carrier/case thrust bearing.
Damaged or worn differential carrier/case selective thrust washer.

Damaged differential/final drive carrier housing.

Replace components as necessary. See Fig. 56 , Fig. 101 , Fig. 103 and Fig. 104 . If VSS
reluctor wheel is damaged, see VEHICLE SPEED SENSOR RELUCTOR WHEEL .

2. Inspect final drive sun gear shaft for the following:

Damaged or worn splines.

Cracks at lube oil holes.

[email protected]

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Damaged or worn bearing journals.

Reassembly

1. Assemble differential side gears and thrust washers into carrier. Using petroleum jelly, stick
thrust washers onto pinion gears. Assemble pinion gears and thrust washers into differential
carrier. See Fig. 103 . Rotate gears into position. Slide differential pinion shaft into carrier
through pinion gears. Align holes in pinion shaft retaining pin to hole in carrier housing.
Using drift pin and hammer, install pinion shaft retaining pin into carrier. See Fig. 102 .
2. Apply petroleum jelly to inside of differential carrier planetary pinion gear. For each
planetary pinion gear, insert roller bearing spacer onto pin. Spacer must be inserted between
2 rows of roller bearings. Install roller bearings into gear one at a time. Differential ratio of
2.86:1 or 2.84:1 has 2 rows of 18 rollers. All other gear ratios have 2 rows of 22 rollers.
See Fig. 105 . Occasionally twist pinion gear pin to help align rollers.
3. Install differential carrier sun gear thrust bearing into carrier housing. See Fig. 101 .
Remove planetary pinion gear pin from its pinion gear. DO NOT move rollers out of
position. Attach 2 pinion gear thrust washers on each side of pinion gear. Ensure position of
pinion gears in housing is same as when disassembled. Install pinion gear assemblies into
carrier housing. Install planetary pinion gear pins. Install retaining ring over planetary
pinion gear pins. See Fig. 100 .
4. Install final drive sun gear with chamfered side toward parking gear into carrier assembly.
Install parking gear onto final drive sun gear shaft. Install final drive sun gear shaft/parking
gear assembly into final drive sun gear. Apply petroleum jelly to parking gear side of
parking gear thrust bearing and install onto parking gear. See Fig. 104 .

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Fig. 99: Checking Differential Carrier Pinion Gear End Play

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 100: Removing & Installing Differential Carrier Snap Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 101: Exploded View Of Final Drive Planetary Pinion

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 102: Removing & Installing Differential Pinion Gear Shaft Roll Pin
Courtesy of GENERAL MOTORS CORP.

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Fig. 103: Exploded View Of Differential Side & Pinion Gears

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 104: Differential Carrier Thrust Washer Installation

Courtesy of GENERAL MOTORS CORP.

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Fig. 105: Installing Final Drive Planetary Gear Roller Bearings

Courtesy of GENERAL MOTORS CORP.

VEHICLE SPEED SENSOR RELUCTOR WHEEL

NOTE: DO NOT remove reluctor wheel unless damaged.

Disassembly & Reassembly

To remove reluctor wheel, install flat metal stock over output shaft opening. Position Bearing
Remover (J-22888) arms onto outer edges of reluctor wheel. Position bearing remover shaft onto
flat metal stock. Pull wheel off of carrier. See Fig. 106 . To reassemble, heat reluctor wheel
slightly. Using plastic mallet, install reluctor wheel onto carrier by tapping evenly around reluctor
[email protected]

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wheel edge.

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[email protected]

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Fig. 106: Removing VSS Reluctor Wheel

Courtesy of GENERAL MOTORS CORP.

CASE EXTENSION

Inspection

Inspect case extension for the following:

Damaged or porous sealing surface for case extension seal.

Damaged or porous sealing surface for VSS.
Damaged or porous sealing surface for right drive shaft oil seal.
Damaged bolt holes.
Worn or damaged front differential carrier bushing or output shaft bearing assembly.
Porous or damaged case extension housing.

Repair as necessary. See Fig. 107 .

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Fig. 107: Inspecting Case Extension

Courtesy of GENERAL MOTORS CORP.

FORWARD BAND

Inspection

1. Inspect forward band assembly for the following:

Damaged or severely worn friction material.

Damaged apply or anchor pin features.

2. Inspect differential carrier internal gear thrust washer for damage. Replace components as
necessary. See Fig. 85 .
[email protected]

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1-2 SUPPORT ROLLER CLUTCH

Disassembly

Using small screwdriver, gently pry thrust bearing off of 1-2 support drum. Lift 1-2 support roller
clutch assembly out of 1-2 support drum. See Fig. 108 .
Inspection

Inspect 1-2 support roller clutch components for the following:

Scored or burned contact surface for manual 2-1 band on 1-2 support drum.
Damaged or worn forward drum bushing.
Damaged or worn inner race of 1-2 support roller clutch.
Damaged or worn 1-2 clutch roller assembly.
Damaged thrust bearing.

Replace components as necessary. See Fig. 109 .

Reassembly

Install 1-2 roller clutch assembly into 1-2 support drum. Note position of cage assembly to inner
race. See Fig. 110 . Install thrust bearing onto 1-2 support drum. Press down with hand pressure
only.
Functional Check

Position 1-2 support drum on bench. Install reaction sun gear assembly into 1-2 support drum.
Rotate reaction sun gear counterclockwise. Rotate 1-2 support drum clockwise. See Fig. 111 .
Roller clutch should move freely in indicated directions. Roller clutch should lock in opposite
direction. If roller clutch does not function as described, clutch is not assembled correctly.
Reassemble as necessary.

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Fig. 108: Removing 1-2 Roller Clutch

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 109: Inspecting 1-2 Roller Clutch & 1-2 Support Drum
Courtesy of GENERAL MOTORS CORP.

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Fig. 110: Installing 1-2 Roller Clutch Into 1-2 Support Drum
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 111: Checking 1-2 Support Roller Clutch Operation

Courtesy of GENERAL MOTORS CORP.

2-1 MANUAL BAND

Inspection

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Inspect 2-1 manual band for cracked, separated or worn friction material. Inspect for cracks
around apply lugs. Replace components as necessary. See Fig. 83 .

REACTION SUN GEAR & DRUM

Inspection

Inspect reaction sun gear and drum for the following:

Worn or scored bushings.

Damaged reaction sun gear teeth.
Band apply area of drum for discoloration or wear.
Welds connecting sun gear to drum for voids or cracks.
Worn or damaged 1-2 support outer race.

Replace components as necessary. See Fig. 112 .

[email protected]

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Fig. 112: Inspecting Reaction Sun Gear Assembly

Courtesy of GENERAL MOTORS CORP.

INPUT & REACTION CARRIER

Inspection

1. Using feeler gauge, check for excessive pinion gear end play in input carrier and reaction
carrier assemblies. End play should be .009-.030" (.23-.76 mm). If end play is not as
specified, replace appropriate component. See Fig. 113 .
2. Inspect thrust bearings, reaction carrier and input carrier for the following:
Damaged cage.

Damaged or missing rollers.

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Damage to pinion teeth.

Damage to internal gear teeth.
Damage to spline teeth.

Replace components as necessary. See Fig. 114 .

Fig. 113: Measuring Input & Reaction Carrier Pinion End Play
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 114: Input & Reaction Carrier Thrust Bearing Installation

Courtesy of GENERAL MOTORS CORP.

REVERSE REACTION DRUM

Inspection

NOTE: This step has been revised due to ATRA TSB No. 579, dated
November 2000.

1. Inspect for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and
reverse reaction drums have splines with 25-degree sides and have tendency to strip. New
design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-
degree sides.
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2. Inspect reverse reaction drum for cracks, damaged splines or distortion. See Fig. 75 .
Replace drum if necessary.

INPUT & 3RD SPRAG CLUTCHES

Disassembly

1. Remove input and 3rd sprag clutch assemblies from input clutch housing. See Fig. 115 .
Remove and discard spiral lock retaining ring from input clutch sprag outer race retainer.
Remove 3rd clutch sprag assembly and input clutch sprag assembly from input and 3rd
clutch sprag inner race. See Fig. 116 . Remove input and 3rd clutch sprag inner race and
input sun gear spacer from input sun gear.

NOTE: DO NOT disassemble sprag elements.

2. Remove 3rd clutch sprag outer race retainer. Remove input and 3rd clutch sprag end
bearings and input and 3rd clutch sprag center bearing from sprag outer races. Remove 3rd
clutch and input clutch sprag assemblies from sprag outer races. See Fig. 117 .
Inspection

Inspect outer races for worn or damaged splines, scoring on inside diameter of races, wear or
cracks. Inspect sprag components for flat spots. Inspect cage assemblies for distortion or broken
ribbon tabs. Inspect end bearings and center bearing for cracks. Check input sun gear spacer for
worn or damaged splines, or wear and cracks. Inspect input sun gear for worn or damaged splines
or plugged lube holes or cracks. See Fig. 116 and Fig. 117 . Replace components as necessary.
Reassembly

1. Position input clutch sprag outer race on flat surface with flat side facing down. Insert end
bearing with flat side down into input clutch sprag outer race. Insert input sprag into outer
race. See Fig. 117 .
2. Position 3rd clutch sprag outer race on flat surface with beveled side facing down. Install
center bearing into 3rd clutch. Install 3rd sprag into 3rd clutch outer race. Lip on sprag cage
must be facing up. Insert input and 3rd clutch sprag end bearing into third clutch sprag outer
race with flat side up. See Fig. 117 .
3. Install input clutch sprag assembly onto input and 3rd clutch sprag inner race with flat side
of input clutch sprag outer race facing down. Install 3rd clutch sprag assembly onto input
and 3rd clutch sprag inner race with beveled side of 3rd clutch sprag outer race facing input
clutch sprag assembly. Install 3rd clutch sprag outer race retainer onto 3rd clutch sprag
outer race. See Fig. 117 . [email protected]

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NOTE: Use new retaining ring. DO NOT attempt to reinstall old

retaining ring. Ensure spiral lock retaining ring is seated in
groove on inner race. Tabs and slots on retaining ring must
lock.

4. Using small flat-blade screwdriver, install retaining ring onto input clutch sprag. Assemble
spacer onto input sun gear. Install input and 3rd sprag clutch assemblies onto input sun gear.
See Fig. 118 .
Input Clutch & 3rd Sprag Clutch Functional Check

Hold input sun gear stationary. 3rd sprag clutch outer race should rotate only in counterclockwise
direction and lock in clockwise direction. Input sprag clutch outer race should rotate in clockwise
direction and lock in counterclockwise direction. See Fig. 119 .

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Fig. 115: Removing & Installing Input & 3rd Clutch Sprag Assemblies
Courtesy of GENERAL MOTORS CORP.

Fig. 116: Disassembling Input & 3rd Clutch Sprag Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 117: Exploded View of Input & 3rd Clutch Sprag Assemblies
Courtesy of GENERAL MOTORS CORP.

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Fig. 118: Assembling 3rd Clutch Sprag Assembly & Input Sun Gear
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 119: Checking Rotation Of Input & 3rd Sprag Assemblies

Courtesy of GENERAL MOTORS CORP.

INPUT CLUTCH & 3RD CLUTCH

Disassembly

1. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove
input clutch backing plate. Remove all input clutch plate assemblies. Remove input clutch
waved plate and input clutch apply plate. See Fig. 120 .
2. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove 3rd
clutch backing plate. Remove 3rd clutch plate assembly. Remove 3rd clutch waved plate.
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See Fig. 121 . Remove input shaft thrust bearing. See Fig. 122 .
3. Using spring compressor and adapter, compress 3rd clutch spring assembly. Using snap ring
pliers, remove retaining ring from input clutch housing. See Fig. 123 . DO NOT over
expand retaining ring during removal. Remove adapter, spring compressor and 3rd clutch
spring assembly. Remove 3rd clutch piston and seal. See Fig. 124 .
4. Using spring compressor, compress input clutch spring and retainer assembly. Using snap
ring pliers, remove retaining ring from input clutch housing. See Fig. 125 . DO NOT over
expand retaining ring during removal. Remove spring compressor. Remove 3rd clutch piston
housing, spring assembly and input clutch piston. See Fig. 126 .
5. Remove 3rd clutch piston inner seal, 3rd clutch housing "O" ring seal and input clutch
piston inner seal. Cut and remove input shaft oil seal rings. DO NOT damage grooves on
shaft when oil seal ring is removed. See Fig. 127
Inspection

1. Inspect input clutch housing for the following:

Plugged feed passages.

Worn or damaged splines.

Input shaft bushing wear.

Seal ring groove nicks or burrs.

Crack or blocked fluid passages in input shaft.

Damage or wear to thrust bearing in input clutch housing.

Replace components as necessary. See Fig. 128 .

2. With check ball in seated position, add ATF to input clutch housing, and inspect for leaks. If
check ball assembly leaks, see INPUT CLUTCH HOUSING CHECK BALL VALVE .
Inspect input clutch piston for cracks or damage to seal grooves. Inspect for wear on piston
lugs. Inspect input clutch and 3rd clutch spring assemblies for damaged cage or distorted or
missing springs. DO NOT attempt to reuse 3rd clutch piston and seal. See Fig. 124 and Fig.
126 . Check input shaft thrust bearing for damage or wear. See Fig. 122 . Replace
components as necessary.
Reassembly

1. Lubricate NEW input clutch piston inner seal with ATF. Using Input Clutch Inner Piston
Seal Protector (J-37361), install input clutch piston inner seal onto input clutch housing. See
Fig. 129 . Install NEW "O" ring seal in input clutch housing. See Fig. 130 . Lubricate NEW
3rd clutch piston inner seal with ATF. Using Third Clutch Inner Piston Seal Protector (J-
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37362), install 3rd clutch piston inner seal onto input clutch housing. See Fig. 131 .
2. Lubricate NEW input clutch piston outer seal with ATF, install seal onto piston. See Fig.
132 . Install input clutch piston into input clutch housing. Install input clutch spring and
retainer into input clutch housing. Install 3rd clutch piston housing into input clutch housing.
See Fig. 126 . Using spring compressor and snap ring pliers, install retaining ring in 3rd
clutch housing. See Fig. 125 . Remove spring compressor.
3. Lubricate NEW 3rd clutch piston assembly with ATF and install into input housing. Install
3rd clutch spring assembly into input housing. See Fig. 124 . Using spring compressor,
adapter and snap ring pliers, install 3rd clutch housing retaining ring. See Fig. 123 .
4. Insert 3rd clutch waved plate into input housing. Install first external splined plate with steel
side against waved plate. Place composition side of all plates facing up. Install 3rd clutch
plates into input housing. Start by inserting a steel 3rd clutch plate with external splines.
Alternate with internal splined plates. Install 3rd clutch backing plate with UP marking
facing up. Install retaining ring into input housing. See Fig. 121 .
5. Install input clutch apply plate into input housing with notched side of teeth facing
downward against retaining ring on 3rd clutch backing plate. Install input clutch waved
plate. Install input clutch plates starting with an input clutch steel plate and alternating with
input clutch composition plate. Install input clutch backing plate with tapered teeth side
facing up. Install retaining ring on input clutch housing. See Fig. 120 . Install input shaft
thrust bearing into input clutch housing. See Fig. 122 .
Input Clutch & 3rd Clutch Functional Check

Using rubber tipped air nozzle, apply a maximum of 20 psi (1.4 kg/cm2 ) air pressure at indicated
fluid passage holes. See Fig. 133 . Ensure input clutch and 3rd clutch apply. If clutch does not
apply, recheck component reassembly.

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Fig. 120: Removing & Installing Input Clutch Components

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 121: Removing & Installing 3rd Clutch Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 122: Removing & Installing Input Shaft Thrust Bearing

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 123: Removing & Installing 3rd Clutch Spring Retaining Ring
Courtesy of GENERAL MOTORS CORP.

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[email protected]

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Fig. 124: Removing & Installing 3rd Clutch Piston

Courtesy of GENERAL MOTORS CORP.

Fig. 125: Removing & Installing Input Clutch Retaining Ring

Courtesy of GENERAL MOTORS CORP.

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Fig. 126: Removing & Installing Input Clutch Piston Components

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 127: Removing Input Clutch Housing Seals

Courtesy of GENERAL MOTORS CORP.

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[email protected]

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Fig. 128: Inspecting Input Clutch Housing

Courtesy of GENERAL MOTORS CORP.

Fig. 129: Installing Input Clutch Piston Inner Seal

Courtesy of GENERAL MOTORS CORP.

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Fig. 130: Installing 3rd Clutch Housing "O" Ring Seal

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 131: Installing 3rd Clutch Piston Inner Seal

Courtesy of GENERAL MOTORS CORP.

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Fig. 132: Removing & Installing Input Clutch Piston Outer Seal
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 133: Checking Input & 3rd Clutch Operation

Courtesy of GENERAL MOTORS CORP.

INPUT CLUTCH HOUSING CHECK BALL VALVE

NOTE: Remove check ball valve only if inspection or leak check indicates
problem with check ball valve.

Disassembly & Reassembly

Using 1/4" drift and hammer, remove check ball valve from input clutch housing. To reassemble,
use 3/8" drift and hammer to install check ball valve into input clutch housing. See Fig. 134 .
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Fig. 134: Installing Input Clutch Housing Check Ball Valve

Courtesy of GENERAL MOTORS CORP.

INPUT SHAFT OIL SEAL RINGS

Input Shaft Oil Seal Ring Replacement

1. Remove solid oil seal rings from input shaft. Inspect seal ring grooves for nicks or burrs.
Lubricate each oil seal ring, and position individually onto Seal Protector (J-34741-1). See
Fig. 135 .
2. Quickly slide each seal into ring groove when protector is in position. Using Seal Driver (J-
34741-2), push ring over seal protector. Size seal with Seal Sizer (J-34741-3). Gently twist
seal sizer over each seal. Leave sizer in place until input clutch housing installation.
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Fig. 135: Installing & Sizing Seal Rings To Housing

Courtesy of GENERAL MOTORS CORP.

INPUT CLUTCH HOUSING & SPRAG CLUTCHES

Reassembly

Using small screwdriver, align teeth of input clutch plate assembly with 3rd clutch plate
assembly. Ensure sprag assembly is fully seated into housing. Insert combined input sprag clutch
and 3rd sprag clutch assembly into input clutch housing assembly. See Fig. 115 .

2ND CLUTCH ASSEMBLY

Disassembly

Using flat-blade screwdriver, remove retaining ring from 2nd clutch housing. Remove backing
plate, composition plates, steel plates, apply plate and waved plate. See Fig. 136 . Using spring
compressor, compress 2nd clutch piston spring. Remove retaining ring. See Fig. 137 . Remove
2nd clutch spring assembly and 2nd clutch piston. See Fig. 138 .
Inspection

1. Inspect 2nd clutch housing for the following:

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Leaking or damaged ball check valve. Turn housing to seat check ball. Using ATF,
check for leaking or damaged check ball valve in 2nd clutch housing. If check ball
assembly leaks, replace check ball assembly. See 2ND CLUTCH HOUSING
CHECK BALL VALVE .
Scored or worn bushings.
Discolored band surface or wear on drum caused by excess heat.
Flatness of band surface on drum.
Damaged reverse reaction drum splines.
Cracks in welds.

Replace components as necessary. See Fig. 139 .

NOTE: This step has been revised due to ATRA TSB No. 579, dated
November 2000.

2. Check for damaged reverse reaction drum splines. See Fig. 75 . Original 2nd clutch and
reverse reaction drums have splines with 25-degree sides and have tendency to strip. New
design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-
degree sides. Check for cracks in welds. Inspect backing plate and waved plate for cracks
and heat spots. Inspect steel and composition plates for wear, lining separation, pitting,
flaking or damage. See Fig. 136 .
3. Inspect apply ring and spring assembly for damage. Inspect piston and piston seals for
damage. Inspect 2nd clutch housing for damaged inner piston seal. See Fig. 138 .
Reassembly

1. Install Adapter (J-41992-3) into NEW 2nd clutch piston. Install piston and adapter into
Protector (J-41992-1). Install piston assembly into 2nd clutch housing. Center inner seal
protector onto hub by pressing down on center of protector. Install Piston Installer (J-
41992-2) onto protector. Legs of installer go into slots of protector. Use hand pressure to
press down on installer until piston is seated. See Fig. 140 .
2. Install 2nd clutch spring assembly into housing. Install retaining ring. See Fig. 137 . Install
waved plate. Install apply plate into 2nd clutch housing with DN or DOWN marking
toward piston. Install composition plates and steel plates, starting with composition plate
and alternating each plate. Install backing plate and retaining ring. See Fig. 136 .

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Fig. 136: Exploded View Of 2nd Clutch Friction Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 137: Removing & Installing 2nd Clutch Piston Spring Retaining Ring
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 138: Exploded View Of 2nd Clutch Piston & Spring

Courtesy of GENERAL MOTORS CORP.

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Fig. 139: Inspecting 2nd Clutch Housing

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 140: Installing 2nd Clutch Piston

Courtesy of GENERAL MOTORS CORP.

2ND CLUTCH HOUSING CHECK BALL VALVE

Disassembly & Reassembly

NOTE: If check ball valve does not leak, DO NOT replace.

Remove check ball valve from housing using 1/4" drift and hammer. See Fig. 141 . Tap in NEW
check ball assembly using same drift and hammer. See Fig. 142 .

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Fig. 141: Removing 2nd Clutch Housing Check Ball Valve

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 142: Installing 2nd Clutch Housing Check Ball Valve

Courtesy of GENERAL MOTORS CORP.

REVERSE BAND

Inspection

Inspect reverse band for cracks, scoring, lining separation or wear on fiber material. Inspect
apply lug for cracks. Replace components as necessary. See Fig. 74 .

DRIVEN SPROCKET SUPPORT ASSEMBLY

Disassembly

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Using appropriate spring compressor, compress 4th clutch spring assembly. Remove snap ring
from driven sprocket support assembly. See Fig. 143 . Remove spring compressor, spring
assembly and 4th clutch piston from driven sprocket support assembly. Remove inner seal from
driven sprocket support assembly hub. Remove oil seal rings and 4-lobed ring seals from driven
sprocket support assembly. See Fig. 144 . Remove outer seal from piston. See Fig. 145 .
Inspection

1. Inspect driven sprocket support components for the following:

Worn or cut oil seal rings.

Rolled or cut second clutch housing oil seal ring seals.

Damage to piston seal surface in driven sprocket support.

Blocked or porous oil passages in driven sprocket support.

A leaking or missing cup plug.

Damaged 4th clutch piston.

Cracked or distorted 2nd clutch housing thrust washer.

Distorted or missing springs in 4th clutch spring assembly.

Driven sprocket bearing assembly for foreign material and missing, flat or damaged
rollers.
2. Replace Teflon oil seal rings if cut or damaged, or if complete overhaul is being performed.
Check all seal ring grooves for debris, burrs or damage. See Fig. 144 .
Reassembly

1. Lubricate NEW inner and outer seal with ATF prior to installation. Install outer seal on 4th
clutch piston. See Fig. 145 . Install inner 4th clutch piston seal onto driven sprocket support
hub. See Fig. 146 .
2. Install 4th clutch piston into driven sprocket support and align components. Install 4th
clutch spring assembly into piston. See Fig. 144 . Using spring compressor, compress spring
assembly and install snap ring. See Fig. 143 . Lubricate NEW oil seal rings for 2nd clutch
housing. Install oil seal rings and 4-lobed ring seals onto driven sprocket support hub. See
Fig. 144 .
2nd & 4th Clutch Functional Check

1. For this test, attach driven sprocket support assembly and 2nd clutch housing thrust washer
onto 2nd clutch housing assembly. See Fig. 147 .
2. Apply 20 psi (138 kPa) of compressed air to feed holes marked 2 and 4, and listen for 2nd
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and 4th clutch application. See Fig. 148 . Hold pressure for 5 seconds. If clutches do not
apply and hold, disassemble driven sprocket support components.
3. Inspect all seals and clutches for proper assembly. Reassemble and repeat functional check.
When clutches apply and hold correctly, remove driven sprocket support assembly and 2nd
clutch housing thrust washer from 2nd clutch housing assembly. See Fig. 147 .

Fig. 143: Compressing 4th Clutch Spring Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 144: Exploded View Of Driven Sprocket Support

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 145: Removing & Installing 4th Clutch Piston Outer Seal
Courtesy of GENERAL MOTORS CORP.

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Fig. 146: Removing & Installing 4th Clutch Inner Seal To Driven Sprocket Support Hub
Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 147: Assembling Components For 2nd & 4th Clutch Functional Air Check
Courtesy of GENERAL MOTORS CORP.

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Fig. 148: Checking 2nd & 4th Clutch Operation

Courtesy of GENERAL MOTORS CORP.

DRIVEN SPROCKET SUPPORT BEARING

Disassembly & Reassembly

Using Driver Handle (J-8092), Bearing Remover (J-34129) and hammer, drive driven sprocket
support bearing from support. See Fig. 149 . To reassemble, position driven sprocket support
bearing assembly so markings on edge of bearing are facing up. Using Driver Handle (J-8092),
Bearing Installer (J-34126) and hammer, seat bearing flush to or below support hub. See Fig.
150 .
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Fig. 149: Removing Driven Sprocket Support Bearing

Courtesy of GENERAL MOTORS CORP.

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Fig. 150: Installing Driven Sprocket Support Bearing

Courtesy of GENERAL MOTORS CORP.

INPUT, 2ND, 3RD & SPRAG CLUTCHES [email protected]

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Reassembly

1. Install selective thrust washer and thrust bearing assembly onto input clutch housing
assembly. See Fig. 73 . Using small screwdriver, align 2nd clutch teeth. Install 2nd clutch
housing assembly onto 2nd clutch hub of input clutch housing assembly.
2. Install Final Drive/Clutch Remover/Installer (J-33381-A) into 2nd clutch housing and input
clutch housing. Sprag clutch assemblies will also be attached. See Fig. 72 . Tighten
threaded rod until rod is finger tight.

DRIVE SPROCKET & TURBINE SHAFT

NOTE: DO NOT damage grooves under oil seal rings.

Disassembly

Cut oil seal rings from turbine shaft. Remove oil seal rings. Remove drive sprocket retaining ring.
Remove drive sprocket from turbine shaft. See Fig. 151 .
Inspection

1. Inspect driven sprocket and drive sprocket for the following:

Worn or chipped teeth.

Uniform teeth size.

Stripped or damaged splines.

Bearing surface damage.

Replace components as necessary. See Fig. 152 and Fig. 153 .

2. Inspect 4th clutch shaft, driven sprocket and drive sprocket thrust washers for wear or
cracks.
3. Inspect turbine shaft for a cracked sleeve, damaged bushing journals or stripped or damaged
splines. Replace components as necessary.
Reassembly

1. Insert turbine shaft into drive sprocket and install retaining ring. See Fig. 151 .
2. Install Turbine Shaft Seal Installer/Expander (J-29569-1) onto chain side of turbine shaft.
Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil seal
rings into position. See Fig. 154 .
3. Using Turbine Shaft Seal Installer/Compressor (J-29569-2), size chain side turbine shaft oil
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seal rings. See Fig. 155 .

4. Install Turbine Shaft Seal Installer/Expander (J-29829-1A) onto converter side of turbine
shaft. Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil
seal ring into position. See Fig. 156 .
5. Using Turbine Shaft Seal Installer/Compressor (J-29829-2), size converter side turbine shaft
oil seal ring. See Fig. 157 .

Fig. 151: Removing Turbine Shaft Oil Seal Rings & Drive Sprocket
Courtesy of GENERAL MOTORS CORP.

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Fig. 152: Inspecting Driven Sprocket Assembly

Courtesy of GENERAL MOTORS CORP.

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Fig. 153: Inspecting Drive Sprocket & Turbine Shaft Assembly

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 154: Installing Turbine Shaft Oil Seal Rings (Chain Side)
Courtesy of GENERAL MOTORS CORP.

Fig. 155: Sizing Turbine Shaft Oil Seal Rings (Chain Side)
Courtesy of GENERAL MOTORS CORP.

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Fig. 156: Installing Turbine Shaft Oil Seal Rings (Converter Side)
Courtesy of GENERAL MOTORS CORP.

Fig. 157: Sizing Turbine Shaft Oil [email protected]

Rings (Converter Side)
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Courtesy of GENERAL MOTORS CORP.

DRIVE & DRIVEN SPROCKET COMPONENTS

Inspection

Inspect drive chain assembly for cracks, binding links or damage. Check input speed sensor
reluctor wheel for damaged teeth, worn or damaged thrust surface and damaged or missing
locating pins. Replace components as necessary. See Fig. 158 .
Reassembly

NOTE: For drive and driven sprocket component reassembly, see

TRANSAXLE REASSEMBLY .

Fig. 158: Inspecting Drive Link Assembly & Input Speed Sensor Reluctor Wheel
Courtesy of GENERAL MOTORS CORP.

4TH CLUTCH COMPONENTS

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Inspection

1. Inspect 4th clutch for the following conditions:

Wear or damage to steel plates.

Peened splines, flaking, or worn composition plates.

2. Inspect 4th clutch shaft for the following:

Cut or worn 4th clutch plate splines.

Stripped input sun gear splines.

Damaged bushing journal.

Cracks or damage to hub or shaft.

Replace components as necessary. See Fig. 68 .

NOTE: For 4th clutch component reassembly, see TRANSAXLE

REASSEMBLY .

CASE COVER COMPONENTS

CAUTION: Valve springs can be tightly compressed. Use care when

removing retainers and plugs.

NOTE: DO NOT remove any bore plugs unless inspection indicates

replacement is necessary.

Disassembly

Remove manual valve. Remove 3-4 accumulator piston cylinder and 3-4 accumulator piston "O"
ring seal. Use low pressure compressed air from valve body side if necessary for removal.
Remove 3-4 accumulator piston outer and inner spring, piston and pin from valve body side of
case cover. Remove actuator feed limit valve spring retainer, spring and valve. See Fig. 159 .
Inspection

1. Inspect 3-4 accumulator piston cylinder for porosity, scored pin or nicked or grooved piston
sleeve. Inspect piston pin for scoring and free movement in piston bore. Inspect springs for
distorted or broken coils. Inspect piston cylinder for porosity or cracks. Inspect for rough or
scored seal surface, or cut seal. Inspect check ball, spring and bore plug. See Fig. 159 .
2. DO NOT remove blow-off check balls unless damaged. Inspect manual valve, link and
spring link for damage. Check manual valve for binding or looseness in case cover. Check
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case cover plugs and orifice cup plug. Replace plugs if loose, plugged or missing.
3. Inspect shaft bearing for damage. DO NOT remove bearing unless bearing is damaged.
Inspect oil seal for missing garter spring or for cut lip seal.
4. Inspect case cover for porosity, interconnected fluid passages, cracks or rough machined
surfaces.
5. Inspect input speed sensor for damaged or missing magnet, damaged housing, bent or
missing electrical terminals, or damaged speed sensor clip.
Bearing Replacement

NOTE: When installing NEW bearing, part number should be visible (facing
upward).

Place case cover on clean flat surface with spacer plate mating surface up. Using Driver Handle
(J-8092), Bearing Remover/Installer (J-41991) and hammer, drive out bearing from case cover.
See Fig. 160 . To install, place case cover on clean flat surface with case mating surface up.
Drive bearing into case cover. See Fig. 161 .
Reassembly

Install NEW 3-4 accumulator piston cylinder "O" ring seal onto 3-4 accumulator piston cylinder.
Install 3-4 accumulator piston outer and inner spring into 3-4 accumulator piston cylinder. Install
NEW 3-4 accumulator piston seal onto 3-4 accumulator piston. Insert 3-4 accumulator piston into
3-4 accumulator piston cylinder. Using a slight twisting motion, insert 3-4 accumulator piston
cylinder into case cover. Insert 3-4 accumulator piston pin through front of case cover and into 3-
4 accumulator piston. Install manual valve into case cover. Install actuator feed limit valve, spring
and spring retainer into case cover. See Fig. 159 .

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Fig. 159: Exploded View Of Case Cover Components

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 160: Removing Case Cover Bearing

Courtesy of GENERAL MOTORS CORP.

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Fig. 161: Installing Case Cover Bearing

Courtesy of GENERAL MOTORS CORP.

LEFT AXLE SHAFT OIL SEAL

Reassembly

NOTE: When drive axle is removed from transaxle for any reason, inspect
axle sealing surface (tripot shank) for corrosion. If corrosion is
evident, clean surface with 320-grit cloth or equivalent. Clean off
any remaining debris with ATF. Wipe surface dry and reinstall drive
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axle free of any build up.

Install NEW left axle shaft oil seal onto Left Side Axle Seal Installer (J-34115). Using left side
axle seal installer and mallet, install left side axle oil seal assembly. See Fig. 162 .

Fig. 162: Installing Left Side Axle Oil Seal

Courtesy of GENERAL MOTORS CORP.

OUTPUT SHAFT

Inspection

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Inspect output shaft for damaged bushing journals, stripped splines or retaining ring groove
damage. See Fig. 17 .

VEHICLE SPEED SENSOR

Inspection

Check for damaged connector, cracked housing, signs of rotor damage or cuts or nicks on seal.
See Fig. 16 .

CONTROL VALVE BODY

Cleaning

CAUTION: DO NOT use solvent to clean solenoid valves or neoprene

seals. DO NOT use shop rags to clean valve body
components. Handle parts carefully to avoid nicks and
scratches.

Clean control valve body thoroughly in clean solvent. Move valves with a pick or small
screwdriver to dislodge any dirt or debris. Use air nozzle to dry control valve body and to blow
out all passages. Gently probe small passages with a piece of identification tag wire or equivalent.
Inspection

1. Inspect control valve body for worn or damaged oil pump drive shaft bearing journal (not
serviceable separately from control valve body), damaged or porous casting, damaged
sealing surfaces and debris in fluid passages.
2. Before disassembly, inspect control valve body components using small pick or screwdriver
for valves binding or sticking in bores or bushings, broken, missing or damaged springs,
missing or damaged retainers, damaged solenoid valves or debris in valve line-ups or
solenoid valves.
3. During disassembly, inspect control valve body for worn or damaged valves, valve bores or
bushings, broken, missing or damaged springs, missing or damaged retainers, damaged
solenoid valves, debris in valve line-ups or solenoid valves.
4. Inspect Transmission Fluid Pressure (TFP) manual valve position switch assembly for
damaged electrical connector terminals, damaged seals, damaged switch membranes or
debris on switch membranes. See Fig. 47 .
Disassembly

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WARNING: Control valve body springs can be tightly compressed. Use

care when removing retainers and plugs.

Thoroughly clean and air dry control valve body. Remove each valve train, noting location of
each component. Some valves are under spring pressure, cover bores when removing retainers.
Remove retainers with small screwdriver. Position valves, springs and bushings on clean surface
in order removed. See Fig. 163 & Fig. 164 .
Reassembly

To reassemble valve body components, reverse disassembly procedure. Ensure all components are
installed in original locations. See Fig. 163 & Fig. 164 .

Fig. 163: Control Valve Body Assembly Disassembled View - (1 of 2)

Courtesy of GENERAL MOTORS CORP.

Callouts For Fig. 163

Callout Component Name
301 Control Valve Body Machined
302 Line Boost Valve and Bushing Retainer
303 Line Boost Valve Bore Plug
304 Line Boost Valve
305 TCC PWM Solenoid Valve O-Ring Seal
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306 TCC PWM Solenoid Valve O-Ring Seal

307 Pressure Control Solenoid Valve O-Ring Seal
309 Reverse Boost Valve Bushing
310 Reverse Boost Valve
311 Pressure Regulator Valve Spring Outer
312 Pressure Regulator Valve Inner Spring
313 Pressure Regulator Valve
314d 1-2, 3-4 Shift Solenoid Valve Retainer
314e Pressure Control Solenoid Valve Retainer
314f TCC PWM Solenoid Valve Retainer
314g TCC Regulator Apply Valve Bore Plug Retainer
315 1-2, 3-4 Shift Solenoid Valve Assembly
316a 1-2, 3-4 Shift Solenoid Valve O-Ring Seal
316b Pressure Control Solenoid Valve O-Ring Seal
317 1-2 Shift Valve Spring
318 1-2 Shift Valve
320 Torque Signal Regulator Valve Spring
321 Torque Signal Regulator Valve
322 Pressure Control Solenoid Valve Assembly
323 Line Pressure Relief Valve Spring
324 Line Pressure Relief Valve
325 Line Pressure Relief Valve Spring Retainer
326 TCC Regulator Apply Valve Spring
TCC Regulator Apply Valve - Some Models have touch activated
327
Power
TCC Regulator Apply Valve - Some Models have touch activated
327
Power
328 TCC Regulator Apply Valve Bore Plug O-Ring Seal
329 TCC Regulator Apply Valve Bore Plug
334 TCC PWM Solenoid Valve Assembly
335 TCC Control Valve
336 TCC Control Valve Spring

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Fig. 164: Control Valve Body Assembly Disassembled View - (2 of 2)

Courtesy of GENERAL MOTORS CORP.

Callouts For Fig. 164

Callout Component Name
301 Machined Control Valve Body
314a 1-2 Accumulator Valve Retainer
314b 4-3 Manual Downshift Valve Retainer
314c 2-3 Shift Solenoid Valve Retainer
315b 2-3 Shift Solenoid Valve Assembly
316 O-Ring Seal
339 1-2 Accumulator Valve Bore Plug
340 3-4 Accumulator Valve Spring
341 3-4 Accumulator Valve - Some Models have touch activated Power
341 3-4 Accumulator Valve - Some Models have touch activated Power
342 2-3 Accumulator Valve Bore Plug Retainer
343 2-3 Accumulator Valve Bore Plug
344 2-3 Accumulator Valve
345 2-3 Accumulator Valve Bushing
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346 2-3 Accumulator Valve Spring

350 1-2 Accumulator Valve
351 1-2 Accumulator Valve Spring
353 3-2 Manual Downshift Valve Retainer
354 3-2 Manual Downshift Valve Bore Plug
355 3-2 Manual Downshift Valve Spring
356 3-2 Manual Downshift Valve
357 2-3 Shift Valve
359 4-3 Manual Downshift Valve Bore Plug
360 4-3 Manual Downshift Valve
361 4-3 Manual Downshift Valve Spring
362 3-4 Shift Valve
385 2-3 Accumulator Valve Bushing Assembly Retainer

CONTROL VALVE BODY SPACER PLATE

Inspection

1. Inspect control valve body spacer plate for plugged holes, damaged sealing surfaces, or
plugged or damaged screen/seal assemblies. Inspect each check ball seat on spacer plate for
excessive peening. Place check ball on each seat. Using flashlight, look for visible light
between check ball and seat. See Fig. 165 . If light is visible between check ball and seat,
replace spacer plate. For check ball locations, see Fig. 53 and Fig. 54 .

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Fig. 165: Checking Spacer Plate For Excessive Peening

Courtesy of GENERAL MOTORS CORP.

OIL PUMP ASSEMBLY

WARNING: Valve springs can be tightly compressed. Use care when

removing retainers and plugs.

CAUTION: Oil pump slide, seal, vanes and rotor are factory selected for
size. DO NOT switch parts with another pump.

Disassembly

Remove oil pump cover bolt and oil pump cover. Remove pump rotor, vane rings, vanes, oil seal
ring and slide "O" ring seal. Remove outer and inner oil pump prime springs, slide seal and slide
seal support. Remove slide pivot pin. Remove outlet screen. See Fig. 166 .

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Inspection & Reassembly

CAUTION: Laser marks on oil pump body indicate size of selective parts
used in assembly. If correct parts are not selected for
replacement, damage to oil pump and transaxle will occur.

1. Inspect oil pump for the following:

Worn, scored or gouged pump slide.

Cracks, wear or damage to rotor or vanes.

Cuts or damage to seals.

Broken priming springs.

Damaged oil pump drive shaft bearing (bearing is not serviced separately from rotor).

See Fig. 166 .

2. Inspect oil pump body for the following:

Porosity

Worn, scored or damaged pump pocket.

Interconnected oil passages.

Damaged machined surfaces.

3. Inspect pump outlet screen for damage or debris. Inspect oil pump cover for cracks, wear or
gouges from pump vanes.
4. Measure pump rotor, oil pump vanes and oil pump slide. See Fig. 167 . Select proper
replacement size. See OIL PUMP COMPONENT SPECIFICATIONS table.
5. Install outlet screen into oil pump body. Install slide seal support and slide seal into slot on
pump slide. Install pump slide and slide pivot pin into pump body.
6. Install outer and inner priming springs into pump body. Install 1st vane ring into pump body.
Insert pump slide "O" ring seal and slide oil seal ring into pump slide. See Fig. 166 .
7. Insert rotor into pump body. Install pump vanes into rotor. Pump vanes must be flush with
top of rotor. Install 2nd vane ring onto rotor. Install pump cover and bolt. Tighten bolt to
specification. See TORQUE SPECIFICATIONS .

OIL PUMP COMPONENT SPECIFICATIONS

Component Thickness - In. (mm)
Pump Rotor .7068-.7072 (17.953-17.963)
.7072-.7076 (17.963-17.973)
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.7076-.7080 (17.973-17.983)
.7080-.7084 (17.983-17.993)
Pump Slide .7070-.7074 (17.957-17.967)
.7074-.7078 (17.967-17.977)
.7078-.7081 (17.977-17.987)
.7081-.7085 (17.987-17.997)
Pump Vane .7064-.7071 (17.943-17.961)
.7071-.7078 (17.961-17.979)
.7078-.7085 (17.979-17.997)
Pump Body (Depth Measurement) .7087-.7091 (18.000-18.010)
.7091-.7094 (18.010-18.020)
.7094-.7098 (18.020-18.030)
.7098-.7102 (18.030-18.040)

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Fig. 166: Exploded View Of Oil Pump Assembly

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 167: Measuring Pump Slide, Rotor & Vanes

Courtesy of GENERAL MOTORS CORP.

WIRING HARNESS

Inspection

Inspect wiring harness for cut or pinched wires, cut wire insulation, bent or broken electrical
connectors or damaged terminals. See Fig. 168 .

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Fig. 168: Inspecting Wire Harness

Courtesy of GENERAL MOTORS CORP.

CASE SIDE COVER

NOTE: Case side cover gasket and channel plate seal may be reused if not
damaged.

Inspection

Inspect case side cover for damaged or porous gasket sealing surfaces, and damaged or stripped
bolt holes. Inspect case side cover gasket and channel plate seal for damage. See Fig. 169 .

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Fig. 169: Inspecting Case Side Cover & Gaskets

Courtesy of GENERAL MOTORS CORP.

THERMO ELEMENT ADJUSTMENT

If thermo element replacement is necessary, remove retainers, pins and thermo element. Remove
plate element. See Fig. 170 . For NEW element, set thermo pin height with Height Gauge (J-
34094-A). See Fig. 171 . Install plate element. Install pin and retainer assemblies, and set height
with height gauge. Install NEW thermo element. "V" shape in thermo element must contact
element plate.

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Fig. 170: Exploded View Of Thermo Element

Courtesy of GENERAL MOTORS CORP.

[email protected]

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Fig. 171: Using Thermo Element Height Gauge

Courtesy of GENERAL MOTORS CORP.

2-1 MANUAL BAND SERVO

Disassembly

Remove servo piston cylinder from servo cover. Remove "O" ring seal from servo piston
cylinder. Remove piston assembly, servo piston spring and servo exhaust screen from cylinder.
Remove servo piston seal from piston. Using small screwdriver, remove retaining ring from servo
piston pin. Remove servo piston, cushion spring and spring retainer from servo piston pin. See
Fig. 172 .
Inspection

Inspect 2-1 manual band servo components for the following:

Damaged, worn or porous servo piston cylinder.

Damaged, worn or porous servo piston.
Damaged or worn servo piston pin.
Broken or damaged servo piston spring.
Broken or damaged servo piston cushion spring.
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Damaged or plugged servo exhaust screen.

Damaged servo cover seal.
Damaged servo piston seal.
Damaged servo piston cylinder "O" ring seal.
Reassembly

Install servo piston spring retainer, cushion spring and servo piston onto servo piston pin. Install
servo piston pin retaining ring. Install servo piston seal onto piston. Lubricate seal with ATF.
Install servo exhaust screen and servo piston cylinder "O" ring seal onto cylinder. Lubricate "O"
ring seal with ATF. Attach servo piston spring to piston assembly. Install servo piston assembly
into cylinder assembly and set assemblies aside.

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Fig. 172: Exploded View Of 2-1 Manual Band Servo

Courtesy of GENERAL MOTORS CORP.

ACCUMULATOR COMPONENTS

Disassembly

CAUTION: DO NOT mix up springs or pistons. Be sure to install correct

springs in correct bore.

1. Remove 7 remaining accumulator cover bolts from accumulator assembly. Remove

accumulator cover and spacer plate from accumulator housing. Disassemble 1-2 and 2-3
accumulator pistons, piston pins, outer springs and cushion springs from accumulator
housing (springs are model dependent). Remove piston oil seal rings from 1-2 and 2-3
accumulator pistons. See Fig. 173 .
2. Disassemble 2-1 manual band servo and forward band servo oil pipes, lube oil pipe
assembly from accumulator cover, and 2-1 manual band servo cover. Disassemble lube oil
pipe, hose clamps, oil hose, lube oil pipe retainer and lube oil pipe with washer. See Fig.
174 .
Inspection

1. Inspect accumulator housing, accumulator cover spacer plate and accumulator cover for the
following:
Damaged oil pipe holes in accumulator cover.

Damaged, improperly machined or porous accumulator cover.

Bent or damaged accumulator cover spacer plate.

Stripped or damaged bolt holes in accumulator housing.

Damaged, worn, improperly machined or porous accumulator housing.

Leaking, loose or missing cup plugs in accumulator housing.

2. Inspect accumulator pistons, springs, seals and pins for the following:
Broken or collapsed piston outer springs.

Broken or collapsed piston cushion springs.

Bent or worn accumulator piston pins.

Damaged, worn or porous accumulator pistons.

Damaged accumulator piston seals.

3. Inspect servo and lube oil pipe components and 2-1 manual band servo cover for the
following:
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Damaged lube, and servo oil pipe holes in servo cover.

Damaged, improperly machined or porous servo cover.
Bent, plugged or damaged lube and servo oil pipes.
Plugged or damaged lube oil hose.
Damaged hose clamps and/or lube oil pipe retainer.
Missing lube oil pipe washer.
Reassembly

1. Install piston oil seal rings onto 1-2 and 2-3 accumulator pistons. Lubricate oil seal ring with
ATF. Assemble 1-2 and 2-3 piston pins and pistons. Assemble 1-2 and 2-3 accumulator
piston springs and piston assembly into accumulator housing. See Fig. 173 .
2. Assemble accumulator spacer plate and cover onto accumulator housing. Install accumulator
bolts and tighten to specification. See TORQUE SPECIFICATIONS .
3. Assemble lube oil pipe, oil hose, hose clamps, pipe retainer and pipe with washer. See Fig.
174 . Install 2-1 manual band servo and forward band servo oil pipes into accumulator
assembly. Install 2-1 manual band servo and forward band servo oil pipes into 2-1 manual
band servo cover. Install lube oil pipe assembly into accumulator assembly.

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Fig. 173: Exploded View Of Accumulator Components

Courtesy of GENERAL MOTORS CORP.

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Fig. 174: Removing & Installing 2-1 Manual Band Servo Pipes
Courtesy of GENERAL MOTORS CORP.

OIL PAN & FILTER

Inspection

1. Inspect for damaged sealing surface. Inspect for dented or cracked bottom pan surface.
Inspect oil pan gasket for bent or damaged seal core, damaged rubber seal surface or
damaged gasket. Check oil pan magnet for damage or misalignment. Clean oil pan, gasket
and magnet. See Fig. 16 .

FORWARD BAND SERVO

Disassembly
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Dissemble servo piston spring from servo assembly. Remove servo piston oil seal ring from servo
piston. Remove servo pin retaining ring from servo piston pin. Disassemble servo piston, servo
piston cushion spring, retainer and servo piston pin. See Fig. 16 .
Inspection

Inspect forward band servo components for the following:

Damaged, worn or porous servo piston.

Damaged servo piston oil seal ring.
Damaged, worn or porous servo cover.
Damaged servo cover seal.
Broken or collapsed servo piston return spring.
Broken or collapsed servo piston cushion inner spring.
Broken or collapsed servo piston cushion outer spring.
Damaged or worn servo piston apply pin.

See Fig. 175 .

Reassembly

Assemble servo piston, servo piston cushion springs, retainer and servo piston pin. Install servo
pin retaining ring onto servo piston pin. Install servo piston oil seal ring onto servo piston. Install
servo piston spring onto servo assembly. See Fig. 175 .

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Fig. 175: Exploded View Of Forward Band Servo

Courtesy of GENERAL MOTORS CORP.

REVERSE BAND SERVO

Disassembly

Remove return spring from reverse band servo assembly. Remove oil seal ring from servo piston.
Using a small screwdriver, remove retaining ring from servo piston apply pin. Disassemble servo
piston, servo piston cushion springs, servo piston cushion spring retainer and servo piston apply
pin. See Fig. 176 .
Inspection

Inspect reverse band servo components for the following:

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Damaged, worn or porous servo piston.

Damaged servo piston oil seal ring.
Damaged, worn or porous servo cover.
Damaged servo cover "O" ring seal.
Damaged servo cover retaining ring.
Broken or collapsed servo piston return spring.
Broken or collapsed servo piston cushion springs.
Damaged or worn servo piston apply pin.

See Fig. 176 .

Reassembly

Assemble servo piston, cushion springs, cushion spring retainer and servo piston apply pin. Install
retaining ring onto servo piston apply pin. Install oil seal ring onto servo piston. Install return
spring onto servo assembly. See Fig. 176 .

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Fig. 176: Exploded View Of Reverse Band Servo

Courtesy of GENERAL MOTORS CORP.

TRANSAXLE REASSEMBLY

NOTE: End play checks performed during TRANSAXLE DISASSEMBLY

procedure must be rechecked at appropriate reassembly stage. For
thrust washer, thrust bearing, bushing and seal installation
direction and location during reassembly, refer to appropriate
illustration. See Fig. 188 -Fig. 192 .

TRANSAXLE

1. Install shift and park linkage components into case. See PARKING SYSTEM
COMPONENTS under COMPONENT DISASSEMBLY & REASSEMBLY. Install final
drive internal gear assembly into case. Align parking pawl with parking pawl actuator.
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Using long screwdriver, install retaining ring into case. See Fig. 86 .
2. Position transaxle with oil pan flange facing down. Ensure sun gear thrust bearing is
installed into differential carrier. Install differential carrier sun gear. Step in sun gear must
be pointing toward parking gear. Install parking gear. Install internal gear thrust bearing
into differential carrier. Ensure bearing is positioned properly. Install sun gear shaft into
differential carrier. See Fig. 104 . Install differential carrier into case. See Fig. 177 .

Fig. 177: Installing Differential Carrier Assembly

Courtesy of GENERAL MOTORS CORP.

3. Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto
case extension. Install case extension onto transaxle case. See Fig. 56 . Install and tighten 2
case extension bolts only until case extension is seated into case. DO NOT torque bolts.
4. Position transaxle case with flange for case cover facing up. Install forward band into case.
Locate band onto forward band anchor pin and apply pin feature in case opening. Install
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thrust washer onto final drive internal gear. See Fig. 85 .

5. Install 1-2 support drum. See Fig. 84 . Position 2-1 band on anchor pin. See Fig. 83 . Install
reaction sun gear and drum. See Fig. 82 . Ensure sun gear and drum fully engage 1-2
support roller clutch. Check roller clutch for correct operation. See Fig. 111 .
6. Install reaction carrier/sun gear thrust bearing onto reaction carrier. Install reaction carrier
into transaxle case and rotate carrier so pinions engage reaction sun gear. Install thrust
bearing and lube dam onto input carrier. Install input carrier into transaxle case and rotate
carrier so pinions engage reaction carrier internal gear. See Fig. 114 .
7. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch
hubs must engage clutch plates. Install input clutch roller clutch and sprag assemblies into
case using Final Drive/Clutch Installer (J-33381). DO NOT install 2nd clutch housing,
thrust bearing or thrust washer at this time.
8. Check input clutch housing end play. See INPUT CLUTCH HOUSING END PLAY
CHECK under TRANSAXLE DISASSEMBLY. Using feeler gauge, check clearance
between thrust washer and end play gauge. Clearance must be .0-.006" (.0-.15 mm). If
clearance is not as specified, use different thrust washer. See INPUT CLUTCH THRUST
WASHER IDENTIFICATION table. Remove input clutch assembly.

INPUT CLUTCH THRUST WASHER IDENTIFICATION

Washer ID
No. Color Thickness - In. (mm)
1 Orange/Green .114-.118 (2.90-3.00)
2 Orange/Black .120-.124 (3.05-3.15)
3 No Color .126-.130 (3.20-3.30)
4 White .132-.136 (3.35-3.45)
5 Blue .138-.142 (3.50-3.60)
6 Pink .144-.148 (3.65-3.75)
7 Brown .150-.154 (3.80-3.90)
8 Green .156-.159 (3.95-4.05)
9 Black .161-.165 (4.10-4.20)
10 Purple .167-.171 (4.25-4.35)
11 Purple/White .173-.177 (4.40-4.50)

NOTE: This step has been revised due to ATRA TSB No. 579, dated
November 2000.

9. Check for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and
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reverse reaction drums have splines with 25-degree sides and have tendency to strip. New
design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) has splines with 10-
degree sides. Install reverse reaction drum. See Fig. 75 .
10. Install reverse band into case, locating band on anchor pins. See Fig. 74 . Install selective
thrust washer and thrust bearing onto input clutch assembly. Install thrust bearing with large
race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must
engage input clutch hub. See Fig. 73 .
11. Install final drive/clutch installer into assembled input and second clutch housing assemblies.
Tighten threaded rod of final drive/clutch installer until rod is finger tight. Using final
drive/clutch installer, lift input and second clutch housing assembly, and install input and
second clutch housing assembly into case. See Fig. 72 . Ensure input clutch housing
assembly is fully seated. Ensure second clutch housing is .500" (13 mm) above top of
reverse band assembly.
12. Install thrust washer onto driven sprocket support, and hold washer in position with
petroleum jelly. Install driven sprocket support into case. See Fig. 71 . Ensure support is
flush with or below case.
13. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. Fig. 70 .
Assemble drive and driven sprockets into drive chain assembly as follows: If old drive link
is being reinstalled, assemble drive link and sprockets with master link (different color link)
facing in same direction as removed. See DRIVE & DRIVEN SPROCKETS under
TRANSAXLE DISASSEMBLY. If NEW drive link assembly is being installed, assemble
drive link and sprockets with master link facing upward.
14. Install drive link assembly and sprockets into case. A slight rocking motion may be required
to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket.
See Fig. 70 . Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See DRIVE
& DRIVEN SPROCKETS under TRANSAXLE DISASSEMBLY.
15. Install 4th clutch shaft thrust washer onto driven sprocket. Insert 4th clutch shaft into
transaxle case through driven sprocket. See Fig. 68 . Shaft must fully seat into input sun
gear. Install drive link lube scoop into case.
16. Install fourth clutch apply plate over fourth clutch shaft assembly and into driven sprocket
support with machined side towards driven sprocket. Install remaining 4th clutch plates,
starting with composition plate and alternating with steel plates. Clutch plates should align
in driven sprocket support. See Fig. 68 .
17. Install pistons and pins into case cover. Install springs into case cover. See Fig. 159 . Install
case cover gaskets. See Fig. 67 . Install 4th clutch shaft and drive sprocket thrust washers
onto case cover. See Fig. 66 .
18. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch

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plates. See Fig. 17 . Install case cover bolts. See CASE COVER BOLT
SPECIFICATIONS table. Tighten case cover bolts to specification. See TORQUE
SPECIFICATIONS .

CASE COVER BOLT SPECIFICATIONS

Bolt No. (1) Diameter - In. Length - In.
(mm) (mm)
1 0.24 (6) 1.3 (32)
2 0.24 (6) 1.6 (40)
3 0.31 (8) 2.0 (50)
4 0.24 (6) 1.2 (30)
(1) For bolt location, refer to illustration. See Fig. 65

19. Install oil dam into case. See Fig. 63 . Connect manual valve link to manual valve. See Fig.
62 . Install manual shift detent and bolt. See Fig. 61 . Tighten bolt to specification. See
TORQUE SPECIFICATIONS .
20. Install input speed sensor and clip into case cover. See Fig. 64 .
21. On 2 wheel drive models, check front differential carrier end play. See FRONT
DIFFERENTIAL CARRIER END PLAY CHECK under TRANSAXLE
DISASSEMBLY. Install appropriate thrust washer on to input shaft and hold in position
with petroleum jelly. See CARRIER-TO-CASE SELECTIVE THRUST WASHER
SIZES table. Tighten case extension bolts to specification. See TORQUE
SPECIFICATIONS .
22. Install oil pump drive shaft. See Fig. 55 . Install 2 large check balls and 4 small check balls
into control valve body. See Fig. 54 . Install 4 check balls into case cover. See Fig. 53 . Use
petroleum jelly to hold check balls in position.
23. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into
case cover. Install valve body-to-spacer plate gasket, spacer plate and case cover-to-spacer
plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto
control valve body. See Fig. 178 .

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Fig. 178: Installing Control Valve Body Spacer Plate & Gaskets
Courtesy of GENERAL MOTORS CORP.

24. Install control valve body onto case cover. Use case cover pin and turbine sleeve in case
cover as guides. Ensure check balls do not drop out of control valve body during
reassembly. See Fig. 179 . Install manual valve position switch onto control valve body. See
Fig. 51 .
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Fig. 179: Installing Control Valve Body

Courtesy of GENERAL MOTORS CORP.

25. Install control valve body bolts. See VALVE BODY BOLT SPECIFICATIONS table.
Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with
bolts at center of control valve body. If bolts are tightened at random, valve bores may
become distorted and prevent proper valve operation. Tighten valve body bolts to
specification. See TORQUE SPECIFICATIONS .
26. Install oil pump assembly onto control valve body. See Fig. 49 . Install oil pump bolts in
specified locations. See OIL PUMP BOLT SPECIFICATIONS table. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Install electronic components and
wiring harness. Ensure wire connectors are installed in correct locations. See Fig. 46 .

VALVE BODY BOLT SPECIFICATIONS

Bolt No. (1) Diameter - In. Length - In. (mm)
(mm)
1 0.24 (6) 2.6 (65)
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2 0.24 (6) 2.4 (60)

3 0.24 (6) 1.2 (30)
4 0.24 (6) 1.8 (45)
5 0.24 (6) 2.2 (55)
6 0.24 (6) 3.7 (95)
7 0.31 (8) 3.5 (90)
8 0.24 (6) 0.8 (20)
9 0.24 (6) 3.3 (85)
(1) For bolt location, refer to illustration. See Fig. 50

OIL PUMP BOLT SPECIFICATIONS

Bolt No. (1) Diameter - In. Length - In. (mm)
(mm)
1 0.24 (6) 0.8 (20)
2 0.24 (6) 3.7 (95)
3 0.24 (6) 3.3 (85)
(1) For bolt location, refer to illustration. See Fig. 48

27. Install side cover gasket and seal onto transaxle case. See Fig. 15 . Install case side cover.
See Fig. 45 . Tighten side cover bolts to specification. See TORQUE
SPECIFICATIONS .

NOTE: 2-1 manual servo pipe should be installed in accumulator

housing center hole, and lube oil pipe should be installed in
right side hole. See Fig. 44 . Forward servo pipe cannot be
installed in incorrect hole due to a larger pipe diameter.

28. Install 2-1 manual band servo and cover gasket into case. Lubricate gasket with ATF. See
Fig. 180 . Ensure servo piston pin engages band. Install accumulator and 2-1 manual band
servo cover assembly into case. See Fig. 181 . Install lube oil pipe into case at lube hole for
differential carrier internal gear. Lock lube oil pipe retainer into case. See Fig. 43 . Install
cover bolts for 2-1 manual band servo. Install accumulator cover and bolts. See Fig. 42 .
Tighten bolts to specification. See TORQUE SPECIFICATIONS .
29. Using socket and mallet, install NEW oil filter seal. See Fig. 182 . Install oil filter and pan
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gasket into case. Install oil pan and tighten bolts to specification. See TORQUE
SPECIFICATIONS .

Fig. 180: Installing 2-1 Manual Band Servo & Seal

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 181: Installing Accumulator & 2-1 Manual Band Servo Cover Assembly
Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 182: Installing Oil Filter Seal

Courtesy of GENERAL MOTORS CORP.

30. Position transaxle so oil pan is facing up. Install servo cover seal onto forward band servo
cover. Install forward band servo assembly into servo cover. Pivot servo assembly into servo
cover to prevent piston oil seal ring from being damaged. Install servo and cover assembly
into case. See Fig. 41 .
31. Using long screwdriver, pry against work bench to compress forward band servo assembly.
See Fig. 40 . Hold servo assembly compressed. Install 3 forward band servo cover bolts and
tighten to specification. See TORQUE SPECIFICATIONS .
32. Position transaxle so oil pan is facing down. Install "O" ring seal onto reverse servo cover.
Install servo and cover assembly [email protected]
case. See Fig. 39 . Use a long screwdriver to depress
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reverse band servo cover by prying against transaxle holding fixture. See Fig. 38 . Hold
reverse band servo assembly compressed. Using a small screwdriver, install reverse band
servo cover retaining ring.
33. Install VSS. Install "O" ring onto turbine shaft. Install torque converter.
34. On 2WD models, affix outboard and inboard drive shaft retaining rings onto output shaft.
DO NOT push to hard during installation of output shaft, or damage to bushings or bearings
may occur. Carefully install output shaft into transaxle. Extend shaft through differential
side gear. On AWD models, DO NOT install output shaft until after performing
TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK and reinstalling
transfer case.

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

Washer ID No. Color Thickness - In. (mm)
1 Orange .055-.059 (1.40-1.50)
2 White .059-.063 (1.50-1.60)
3 Blue .063-.067 (1.60-1.70)
4 Pink .067-.071 (1.70-1.80)
5 Brown .071-.075 (1.80-1.90)
6 Green .075-.079 (1.90-2.00)
7 Black .079-.083 (2.00-2.10)
8 Purple .083-.087 (2.10-2.20)
9 Purple/White .087-.091 (2.20-2.30)
10 Purple/Blue .091-.094 (2.30-2.40)

TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK

NOTE: ATF circulates between transaxle and transfer case. In situations

where transaxle related failures circulate debris into transfer case,
transfer case must be disassembled, cleaned, and inspected for
damage.

1. Position transaxle so case side cover is facing down. Install final drive sun gear shaft. See
Fig. 37 . Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install
parking gear thrust bearing and parking gear. See Fig. 36 . Install final drive sun gear. See
Fig. 34 .
2. Install bolts to end play checking tool and tighten securely to prevent tool deflection during
end play measurement. See Fig. 76 . Hand tighten end play checking tool to remove end
play. Install gauge bar onto case mounting surface.
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3. Measure distance from case mounting surface, bottom of gauge bar to top of final drive sun
gear. See Fig. 183 . This measurement is dimension "A". Remove gauge bar and end play
checking tool.
4. Install gauge bar onto carrier. Measure distance from bottom of gauge bar to transfer case.
See Fig. 184 . This measurement is Dimension B1. Measure distance from bottom of gauge
bar to thrust bearing. See Fig. 185 . This measurement is Dimension B2. Subtract
Dimension B2 from Dimension B1. This is Dimension "B". For available thrust washer
sizes, refer to illustration. See Fig. 186 .
5. Remove gauge bar from transfer case. Remove final drive sun gear. Install selective washer.
See Fig. 35 . Install final drive sun gear. See Fig. 34 .

Fig. 183: Checking Transaxle-To-Transfer Case End Play (1 Of 3)

Courtesy of GENERAL MOTORS CORP.

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Fig. 184: Checking Transaxle-To-Transfer Case End Play (2 Of 3)

Courtesy of GENERAL MOTORS CORP.

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 185: Checking Transaxle-To-Transfer Case End Play (3 Of 3)

Courtesy of GENERAL MOTORS CORP.

[email protected]

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2001-03 AUTOMATIC TRANSMISSIONS Hydra-Matic 4T65-E Overhaul

Fig. 186: Transfer Case Selective Washer Specifications

Courtesy of GENERAL MOTORS CORP.

TRANSFER CASE INSTALLATION

NOTE: Oil dam must be installed with oil passage notch aligned to
passage in case. Incorrect alignment will cause oil flow
stoppage and damage to transaxle.

1. Install case extension seal. See Fig. 30 . Line up notch to hole in case and install oil dam.
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See Fig. 31 .
2. Install transfer case lower brace. See Fig. 29 . Install and hand tighten transfer case lower
brace bolts. Rotate transaxle so oil pan is facing floor. Install transfer case assembly onto
transaxle. See Fig. 187 .
3. Install 5 transfer case-to-transaxle bolts. See Fig. 27 . Torque bolts in sequence. Tighten
transfer case bolts No. 1 and 2 in 2 passes; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an
additional 160 degrees. Tighten transfer case bolt No. 3; 1st pass 26 ft. lbs. (35 N.m), and
2nd pass an additional 70 degrees. Tighten transfer case bolts No. 4 and 5 to 30 ft. lbs. (40
N.m).
4. Install transfer case side brace to case and hand tighten bolts. Tighten bolts to 23 ft. lbs. (31
N.m) in numerical sequence (1, 2, 3, 4, 5). See Fig. 26 . Install transfer case lower brace-to-
transaxle bolt and tighten to 42 ft. lbs. (56 N.m) See Fig. 25 . Tighten transfer case lower
brace-to-transaxle bolts to 23 ft. lbs. (31 N.m).
5. Affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to
hard during installation of output shaft, or damage to bushings or bearings may occur.
Carefully install output shaft into transaxle. Extend shaft through differential side gear.

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Fig. 187: Installing Transfer Case

Courtesy of GENERAL MOTORS CORP.

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Fig. 188: Identifying Thrust Washer Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 189: Identifying Thrust Bearing Locations
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Courtesy of GENERAL MOTORS CORP.

Fig. 190: Identifying Bushing Locations

Courtesy of GENERAL MOTORS CORP.

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Fig. 191: Identifying Lip Seal Locations

Courtesy of GENERAL MOTORS CORP.

Fig. 192: Identifying "O"Ring & Seal Locations

Courtesy of GENERAL MOTORS CORP.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Case Cover Bolt (1)
Bolt No. 3 18 (25)
Bolts No. 1, 2 & 4 (2)

Case Extension Bolt 26 (35)

Case Side Cover Bolt (3) 18 (25)
Control Valve Body Bolt (4)
Bolts No. 1-5 (2)

Bolt No. 6 12 (16)

Bolt No. 7 18 (25)
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Bolt No. 8 (5)

Bolt No. 9 (2)

Drive Sprocket Support Bolt 18 (25)

Manual Shaft-To-Detent Lever Nut 24 (32)
Oil Cooler Fitting 28 (38)
Shift Shaft Nut 23 (31)
Transfer Case-To-Transaxle Bolt
Bolts No. 1 & 2 (6)

Bolt No. 3 (7)

Bolts No. 4 & 5 30 (40)

Transfer Case Lower Brace-To-Transaxle Bolt 23 (31)
Transfer Case Lower Brace-To-Transaxle Lower Bolt 42 (56)
Transfer Case Side Brace Bolt 23 (31)
2-1 Manual Band Servo Cover Bolt 18 (25)
INCH Lbs. (N.m)
Accumulator Bolt 106 (12)
Accumulator Cover-To-Case Bolt 106 (12)
Forward Band Servo Cover Bolt 106 (12)
Manual Valve Shift Detent Bolt 106 (12)
Oil Pan Bolt 120 (14)
Oil Pressure Test Plug 106 (12)
Oil Pump Bolt (8)
Bolt No. 1 71 (8)
Bolts No. 2 & 3 106 (12)
Vehicle Speed Sensor Bolt 106 (12)
(1) See Fig. 65 .

(2) Tighten bolts to 106 INCH lbs. (12 N.m).

(3) See Fig. 45 .
(4) See VALVE BODY BOLT SPECIFICATIONS table.
(5) Tighten bolts to 71 INCH lbs. (8 N.m).

(6) Tighten bolts in 2 passes, 1st pass 26 ft. lbs. (35 N.m) and 2nd pass an additional 160

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degrees.
(7) Tighten bolt in 2 passes, 1st pass 26 ft. lbs. (35 N.m) and 2nd pass an additional 70
degrees.
(8) See OIL PUMP BOLT SPECIFICATIONS table.

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS
Application End Play - In. (mm)
Differential Carrier Planetary Pinion Gears .009-.025 (.23-.64)
Front Differential Carrier .005-.025 (.13-.64)
Input Carrier Pinion Gears .009-.030 (.23-.76)
Input Clutch Housing 0-.006 (0-.15)
Reaction Carrier Pinion Gear .009-.030 (.23-.76)
Torque Converter 0-.020 (0-.50)

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