Professional Documents
Culture Documents
ar
INDICE
Diagramas Elctricos
Motor
15
733
782
825
SIR (Airbags)
855
871
Transmisin Automtica
900
Tren Delantero
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DIAGRAMAS ELECTRICOS
Electrical Center Identification Views
Document ID: 353473
Underhood Bussed Electrical Center (UBEC) Details (Base Pickup)
Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1
INT BATT
50A
2
ABS
3-4
5
IGN B
6
RAP
7
IGN A
8
STUD #2
Mini Fuses
9
11
12 VEH B/U
60A
50A
50A
40A
30A
Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT,
CIGAR LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used
Not Used
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RT TURN
LT TURN
LT TRN
RT TRN
10A
10A
10A
10A
17
RR PRK
10A
18
FR PRK
10A
19
20
LT HDLP
10A
21
RT HDLP
10A
22
ENG 1
10A
23
ECM B
20A
24
HORN
15A
25
ECM 1
15A
26
BTSI
10A
27
28
29
30
B/U LP
IGN E
FOG LP
25A
10A
15A
31
OXYSEN
20A
32
LR PRK
10A
33
34
35
36
37
38
3940
41
IGN C
PARK LP
HVAC
20A
20A
30A
CRANK
13
14
15
16
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42
HAZ LP
20A
43
VECHMSL
10A
44
45
STOP LP
20A
46
TBC
10A
Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51
52 HDLP GRD
53
54
CHMSL
Mini Relays
55
Starter
56
Diode
57
DRL
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Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1
INT BATT
50A
2
ABS
3-4
5
IGN B
6
RAP
7
IGN A
8
STUD#2
Mini Fuses
9
11
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN
60A
50A
50A
40A
30A
17
RR PRK
18
FR PRK
19
15A
10A
10A
10A
10A
Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT,
CIGAR LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used
Not Used
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LT HDLP
21
RT HDLP
22
ENG 1
23
ECM B
24
HORN
25
ECM 1
26
BTSI
27
28
29
30
B/U LP
A/C
IGN E
FOG LP
31
OXYSEN
32
LR PRK
33
34
35
36
37
38
3940
IGN C
PARK LP
ATC
HVAC
41
CRANK
10A
42
HAZ LP
20A
43
VECHMSL
10A
44
45
STOP LP
20A
46
TBC
10A
Not Used
Transfer Case Control Module, Manual Transmission
Clutch Start Switch, and Transmission Range Switch
(Automatic)
Hazard Switch
Dome and High Mounted Stop Lamp and Cruise Control
Module
Not Used
High Mounted Stop Lamp Relay and Stop Lamp Switch
Truck Body Control Module (TBC) and RFA Module
Assembly (Remote Keyless Entry)
20
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INT BATT
ABS
Description
Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51
A/C
52 HDLP GRD
53
FOG LP
54
CHMSL
Mini Relays
55
Starter
56
Diode
57
DRL
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50A
50A
40A
30A
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
AUX PWR Stud, UBEC
10A
10A
10A
15A
10A
10A
10A
10A
10A
10A
19
TRL PRK
10A
20
LT HDLP
10A
21
RT HDLP
10A
22
ENG 1
10A
23
ECM B
20A
24
HORN
15A
25
ECM 1
15A
26
BTSI
10A
27
28
29
30
B/U LP
A/C
IGN E
FOG LP
25A
10A
10A
15A
31
OXYSEN
20A
32
LR PRK
10A
3-4
5
IGN B
6
RAP
7
IGN A
8
STUD#2
Mini Fuses
9
TRL TRN
10 TRR TRN
11
TRL B/U
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN
17
RR PRK
18
FR PRK
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IGN C
HTD SEAT
PARK LP
ATC
RRDEFOG
HVAC
TRCHMSL
RR W/W
20A
20A
20A
20A
30A
30A
10A
15A
41
CRANK
10A
42
HAZ LP
20A
43
VECHMSL
10A
44
45
HTDMIR
STOP LP
10A
20A
46
TBC
10A
Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51
A/C
52 HDLP GRD
53
FOG LP
54
Mini Relays
55
Starter
56 RR DEFOG
Diode
57
DRL
Ignition Switch
Heated Seat Assembly
Park Lamp Relay and Headlamp Switch Assembly
Transfer Case Control Module
Rear Window Defogger
Blower Motor Relay/Blower Motor
Trailer Wiring Provision
Rear Window Wiper
Transfer Case Control Module, Manual Transmission
Clutch Start Switch, and Transmission Range Switch
(Automatic)
Hazard Switch
Dome and Mounted Stop Lamp and Cruise Control
Module
Heated Mirrors
Stop Lamp Switch, High Mounted Stop Lamp Relay
Truck Body Control Module (TBC) and RFA Module
Assembly (Remote Keyless Entry)
33
34
35
36
37
38
39
40
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Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1
INT BATT
60A
2
ABS
3-4
5
IGN B
6
RAP
7
IGN A
8
STUD
Mini Fuses
9
TRL TRN
10 TRR TRN
11 TRL B/U
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN
60A
50A
50A
40A
30A
17
RR PRK
18
FR PRK
10A
10A
10A
15A
10A
10A
10A
10A
Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT, CIGAR
LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used
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TRL PRK
10A
20
LT HDLP
10A
21
RT HDLP
10A
22
ENG 1
10A
23
ECM B
20A
24
25
26
LT HI
RT HI
HORN
15A
15A
10A
27
ECM 1
15A
28
DRL
15A
29
BTSI
10A
30
31
32
33
B/U LP
A/C
IGN E
FOG LP
25A
10A
10A
15A
34
OXYGEN
20A
35
LR PRK
10A
36
IGN C
37 HTD SEAT
38 PARK LP
39
ATC
40 RRDEFOG
41
HVAC
42 TRCHMSL
43 RR W/W
20A
20A
20A
20A
30A
30A
10A
15A
44
CRANK
10A
45
46
LD LEV
HI BEAM
25A
20A
19
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47
HAZ LP
48 VECHMSL
49
50
HTDMIR
STOP LP
51
TBC
Fuse/Circuit
Breaker
Rating
Description
Power
Door Lock and Side Window Switch Assembly,
30A
Windows/Circuit
Left and Right Side
Micro Relays
52
DRL
53
F/Pump
54
Horn
55
A/C
56
FOG LP
Mini Relays
57 LOW BEAM
58 STARTER
59 RR DEFOG
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CRUISE
GAUGES
ILLUM
MIR/LKS
CTSY LP
HVAC
10
TURN
11
CLSTR
12
PARK LPS
13
AUX PWR
14
PWR LKS
15
4WD
16
SIR
17
FRT WPR
18
19
RDO BATT
AMP F (Envoy
Only)
20
21
HVAC1
22
ABS
10A
1
2
Breaker A
HDLP SW
CIGAR LTR
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23
24
RR WPR
RDO IGN
Module Assembly
15A Rear Wiper Switch, Rear Window Washer Motor
10A Radio
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MOTOR
Key and Lock Cylinder Coding
Document ID: 102500
The lock cylinder keyway is designed so that other model keys will not enter a current
model lock cylinder. A single key is used for all locks on the vehicle.
The key identification is obtained from the five-character key code stamped on the
knockout portion of the key head. Knock the plugs out of the key head after code
numbers have been recorded. The code list, available to owners of key cutting
equipment from equipment suppliers, determines the lock combinations from the code
numbers.
Cutting Keys
After the code has been determined from the code list or the key code diagram, perform
the following steps:
1. Cut a blank key to the proper level of each of the tumbler positions.
2. Inspect the key operation in the lock cylinder.
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7. Press down the retainer (1) until fully seated in the depression.
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Important: Use a paste type grease, not a spray, for the following step.
18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed:
o The detent pins (1)
o The cylinder retainer (3)
Specification
Metric English
Accelerator Control Cable Bracket Nut
12 N-m 106 lb in
Accelerator Control Cable and Cruise Control Cable Bracket Nut 9 N-m 80 lb in
Accelerator Control Cable Bracket Stud to Intake Manifold
6 N-m 53 lb in
Accelerator Control Cable Bracket Stud to Throttle Body
12 N-m 106 lb in
Air Cleaner Adapter Stud
8 N-m 71 lb in
Air Conditioning (A/C) Compressor Mounting Bolt
50 N-m 37 lb ft
Balance Shaft Driven Gear Bolt
First Pass
20 N-m 15 lb ft
Application
Final Pass
Final Pass
Final Pass
35 degrees
12 N-m
35 N-m
50 N-m
12 N-m
25 N-m
106 lb in
26 lb ft
37 lb ft
106 lb in
18 lb ft
27 N-m 20 lb ft
70 degrees
95 N-m 70 lb ft
20 N-m 15 lb ft
73 degrees
105 N77 lb ft
m
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Final Pass
80 lb in
43 lb ft
106 lb in
53 lb in
30 N-m 22 lb ft
75 degrees
65 degrees
55 degrees
35 N-m 26 lb ft
60 N-m 44 lb ft
90 N-m 66 lb ft
20 N-m
2.4 Nm
25 N-m
50 N-m
15 lb ft
21 lb in
18 lb ft
37 lb ft
7 N-m 62 lb in
30 N-m 22 lb ft
25 N-m
25 N-m
30 N-m
20 N-m
30 N-m
20 N-m
20 N-m
20 N-m
2 N-m
20 N-m
100 Nm
12 N-m
18 lb ft
18 lb ft
22 lb ft
15 lb ft
22 lb ft
15 lb ft
15 lb ft
15 lb ft
18 lb in
15 lb ft
74 lb ft
106 lb in
9 N-m
58 N-m
12 N-m
6 N-m
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Final Pass
15 N-m
35 N-m
74 N-m
54 N-m
50 N-m
45 N-m
45 N-m
63 N-m
30 N-m
15 N-m
12 N-m
35 N-m
25 N-m
11 lb ft
26 lb ft
55 lb ft
40 lb ft
37 lb ft
33 lb ft
33 lb ft
46 lb ft
22 lb ft
11 lb ft
106 lb in
26 lb ft
18 lb ft
10 N-m 88 lb in
15 N-m 11 lb ft
30 N-m 22 lb ft
25 N-m
10 N-m
6 N-m
30 N-m
3 N-m
30 N-m
41 N-m
20 N-m
41 N-m
50 N-m
35 N-m
12 N-m
20 N-m
18 lb ft
88 lb in
53 lb in
22 lb ft
27 lb in
22 lb ft
30 lb ft
15 lb ft
30 lb ft
37 lb ft
26 lb ft
106 lb in
15 lb ft
3 N-m 27 lb in
12 N-m 106 lb in
15 N-m 11 lb ft
21 N-m 15 lb ft
35 N-m 26 lb ft
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Final Pass
12 N-m
12 N-m
25 N-m
25 N-m
90 N-m
12 N-m
20 N-m
106 lb in
106 lb in
18 lb ft
18 lb ft
66 lb ft
106 lb in
15 lb ft
41 N-m
20 N-m
41 N-m
50 N-m
41 N-m
50 N-m
36 N-m
30 lb ft
15 lb ft
30 lb ft
37 lb ft
30 lb ft
37 lb ft
27 lb ft
30 N-m 22 lb ft
25 N-m 18 lb ft
10 N-m 88 lb in
35 N-m 26 lb ft
35 N-m 26 lb ft
10 N-m 88 lb in
25 N-m 18 lb ft
30 N-m 22 lb ft
15 N-m 11 lb ft
12 N-m 106 lb in
40 N-m 29 lb ft
12 N-m 106 lb in
9 N-m 80 lb in
47 N-m 35 lb ft
12 N-m 106 lb in
5 N-m 44 lb in
9 N-m 80 lb in
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16 N-m
47 N-m
12 N-m
25 N-m
25 N-m
45 N-m
12 lb ft
35 lb ft
106 lb in
18 lb ft
18 lb ft
33 lb ft
Application
Specification
Metric
English
General Data
Engine Type
V6
Regular Production Option (RPO) Code LF6 VIN Code X, and RPO Code
L35 VIN Code W
Displacement
Bore
Stroke
Compression Ratio
Firing Order
Balance Shaft
Rear Bearing Journal Clearance
4.3L
262 CID
101.60 mm
4.012 in
88.39 mm
3.480 in
9.2:1
165432
1.52 mm
0.060 in
42 kPa at
1,000 RPM
6 psig at
1,000 RPM
125 kPa at
2,000 RPM
18 psig at
2,000 RPM
166 kPa at
4,000 RPM
24 psig at
4,000 RPM
0.0500.088 mm
0.0020
0.0035 in
38.085
38.100 mm
1.49941.500 in
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Camshaft
End Play
Journal Diameter
Runout
Connecting Rod
Connecting Rod Bearing Clearance
(Production)
Crankshaft
Crankshaft Bearing Clearance (Journal
#1Production)
0.0010
0.0090 in
1.8677
1.8696 in
0.0010 in
(Maximum)
7.207.30 mm
0.2830.287 in
6.546.64 mm
0.2570.261 in
6.977.07 mm
0.2740.278 in
6.766.86 mm
0.2660.270 in
0.065 mm
0.0026 in
0.0380.078 mm
0.0015
0.0031 in
0.0250.076 mm
0.0010
0.0030 in
0.150.44 mm
0.0060.017 in
57.116
57.148 mm
2.2487
2.2497 in
0.00508 mm
(Maximum)
0.00030 in
(Maximum)
0.025 mm
(Maximum)
0.0010 in
(Maximum)
0.007 mm
(Maximum)
0.0002 in
(Maximum)
0.025 mm
(Maximum)
0.0010 in
(Maximum)
0.020.508 mm
0.0008
0.0020 in
0.0280.058 mm
0.0011
0.0023 in
0.0254
0.2286 mm
47.440
47.490 mm
0.025 mm
(Maximum)
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0.02540.05 mm
0.0010
0.0020 in
0.0250.063 mm
0.0010
0.0250 in
0.0500.20 mm
0.0020.008 in
62.199
62.217 mm
2.4488
2.4495 in
62.191
62.215 mm
2.4485
2.4494 in
62.179
62.203 mm
2.4480
2.4489 in
0.005 mm
(Maximum)
0.0002 in
(Maximum)
0.025 mm
(Maximum)
0.0010 in
(Maximum)
0.007 mm
(Maximum)
0.025 mm
(Maximum)
0.0003 in
(Maximum)
0.0010 in
(Maximum)
101.618
101.643 mm
0.0127 mm
(Maximum)
0.05 mm
(Maximum)
0.025 mm
(Maximum)
0.012 mm
(Maximum)
0.025 mm
(Maximum)
4.0007
4.0017 in
0.00050 in
(Maximum)
0.002 in
(Maximum)
0.0010 in
(Maximum)
0.0005 in
(Maximum)
0.0010 in
(Maximum)
0.10 mm
(Maximum)
0.004 in
(Maximum)
0.05 mm
(Maximum)
0.002 in
(Maximum)
Crankshaft Runout
Cylinder Bore
Diameter
Out-of-Round (Production)
Out-of-Round (Service)
Taper (Service)
Cylinder Head
Surface Flatness
Exhaust Manifold
Surface Flatness
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Intake Manifold
Surface Flatness
Oil Pan
Oil Pan Alignment at Rear of Engine
Block
0.10 mm
(Maximum)
0.004 in
(Maximum)
0.3 mm
(Maximum)
0.011 in
(Maximum)
Piston
Piston Bore Clearance (Production)
Piston Pin
Clearance in Piston (Production)
Diameter
0.0180.061 mm
0.075 mm
(Maximum)
0.0130.023 mm
0.025 mm
(Maximum)
23.545
23.548 mm
0.0210.040 mm
(Interference)
0.0007
0.0024 in
0.0029 mm
(Maximum)
0.0005
0.0009 in
0.0010 in
(Maximum)
0.9270
0.9270 in
0.0008
0.0016 in
(Interference)
0.0100.016 in
0.460.66 mm
(Maximum)
0.0180.026 in
(Maximum)
0.5 mm
(Maximum)
0.19 in
(Maximum)
0.8 mm
(Maximum)
0.31 in
(Maximum)
0.0300.070 mm
0.0012
0.0027 in
0.0400.080 mm
0.0015
0.0031 in
0.085 mm
(Maximum)
0.0033 in
(Maximum)
0.250.76 mm
0.0100.029 in
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Valve System
Valve Face Angle
Valve Head Edge Margin
Valve Lash
Valve Lifter
0.035 in
(Maximum)
0.0460.096 mm
0.0018
0.0037 in
0.10 mm
(Maximum)
0.0039 in
(Maximum)
45 degrees
0.79 mm
(Minimum)
0.031 in
(Minimum)
0.4280 in
9.887 mm
0.3890 in
10.527 mm
0.4140 in
10.215 mm
0.4020 in
Hydraulic Roller
1.5:1
46 degrees
0.05 mm
(Maximum)
0.002 in
(Maximum)
1.5752.362 mm 0.0650.098 in
0.891.52 mm
0.0350.060 in
51.3 mm
2.02 in
42.9243.43 mm 1.6701.700 in
42.9243.43 mm 1.6701.700 in
338374 N at
43.2 mm
832903 N at
32.3 mm
7684 lb at
1.70 in
187203 lb at
1.27 in
0.90 mm
(Maximum)
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0.0250.069 mm
0.0010
0.0027 in
0.0250.094 mm
0.0010
0.0037 in
0.0250.069 mm
0.0010
0.0027 in
0.0250.094 mm
0.0010
0.0037 in
12 mm
0.03937
0.07874 in
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2.
3.
Checks
Action
Engine performance diagnosis procedures are covered in Engine Controls and
should be consulted for diagnosis of any Driveability, Emissions, or
Malfunctioning Indicator Lamp (MIL) concerns.
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4.
5.
6.
7.
Intake Manifold
Leaks
Coolant
Consumption
Oil Consumption
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o
o
o
Abnormal Internal
Engine Noises
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1.
2.
3.
4.
5.
Ensure that the vehicle batteries are in good condition, and fully charged.
Operate the vehicle until the engine is at normal operating temperature.
Disconnect the positive ignition coil wire plug from the ignition coil.
Disconnect the fuel injector electrical connector.
Remove all of the spark plugs.
Notice: Do not insert objects into the throttle plate opening. Damage to the
throttle body can result, requiring replacement of the throttle body assembly.
Valves leaking
Compression is low on the first compression stroke. The compression
does not build up on the following strokes, and does not reach normal.
Compression does not improve much, if at all, when you add oil.
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15. If one or more cylinders fails to meet the minimum specified compression,
repair or replace all damaged or worn components and test the engine again.
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Upper Engine View 2 4.3L L35/LF6 (ST, GMT150) Document ID: 41410
Upper Engine View 2
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Upper and Lower Intake Manifold View 4.3L L35/LF6 Document ID: 356346
Upper and Lower Intake Manifold View
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8. Remove the PCV valve hose assembly form the intake manifold and the valve
rocker arm cover.
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12. Remove the accelerator and cruise control cable bracket from the throttle body.
Leave the accelerator and cruise control cables and the engine wiring harness on
the bracket.
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15. Remove the upper intake manifold. Refer to Intake Manifold Disassemble in
Engine Mechanical - 4.3L
16. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in
Engine Mechanical - 4.3L
Installation Procedure
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3. Install the bracket for the engine wiring harness on the lower intake manifold
stud.
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.
4. Install the engine wiring harness bracket nut.
Tighten
Tighten the engine wiring harness bracket nut to 12 N-m (106 lb in).
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5. Install the accelerator and cruise control cable bracket to the throttle body.
6. Install the accelerator and cruise control cable bracket nuts.
Tighten
Tighten the accelerator and cruise control cable bracket nuts to 9 N-m (80 lb in).
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8. Install the cruise control cable, if equipped to the throttle shaft and the bracket.
Refer to Cruise Control Cable Replacement in Cruise Controls.
9. Install the accelerator cable to the throttle shaft and the bracket. Refer to
Accelerator Control Cable Replacement in Engine Controls - 4.3L Engine
Controls.
10. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge
Solenoid Valve Replacement in Engine Controls.
11. Connect the PCV valve hose assembly to the intake manifold and the valve
rocker arm cover.
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9. Disconnect the accelerator control cable from the throttle shaft and the
accelerator cable bracket. Refer to Accelerator Control Cable Replacement in
Engine Controls.
10. Disconnect the cruise control cable, if equipped from the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Control.
11. Remove the accelerator cable bracket from the throttle body and the intake
manifold.
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17. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and
exhaust manifold.
18. Disconnect the fuel supply and return pipes at the rear of the intake manifold.
Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine
Controls.
19. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
20. Disconnect the vacuum brake booster hose
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24. Remove the lower intake manifold. Refer to Intake Manifold Removal .
25. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in
Engine Mechanical - 4.3L .
Installation Procedure
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11. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake
manifold and the exhaust manifold.
Tighten
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m
(18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m
(22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).
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20. Install the accelerator cable and cruise control bracket to the throttle body.
Tighten
Tighten the accelerator cable and cruise control bracket nuts to 9 N-m (80 lb in).
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23. Install the cruise control cable, if equipped to the bracket and the throttle shaft.
Refer to Cruise Control Cable Replacement in Cruise Control.
24. Install the water pump inlet hose to the intake manifold.
25. Install the heater hose to the intake manifold.
26. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement
in Engine Cooling.
27. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine
Cooling.
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30. Connect the PCV tube to the air cleaner outlet duct.
31. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
Removal Procedure
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4. Remove the PCV valve hose assembly from the valve rocker arm cover.
5. Disconnect the engine coolant temperature (ECT) gauge sensor.
6. Partially drain the engine coolant. Refer to Cooling System Draining and Filling
in Engine Cooling.
7. Remove the radiator inlet hose from the water outlet. Refer to Engine Coolant
Thermostat Replacement in Engine Cooling.
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Installation Procedure
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2. 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.
Install the exhaust gas recirculation (EGR) valve inlet pipe into the intake and
exhaust manifolds.
Tighten
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m
(18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m
(22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).
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3. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement
in Engine Cooling.
4. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine
Cooling.
5. Install the PCV valve hose assembly to the valve rocker arm cover.
6. Connect the ECT gauge sensor.
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1. Remove the PCV tube from the air cleaner outlet duct and the valve rocker arm
cover.
2. Disconnect the spark plug wires from the spark plugs for the right side of the
engine. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
3. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.
4. Unfasten the heater hose retainer above the valve rocker arm cover.
5. Move and secure the heater hoses aside.
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6. Remove the bolt holding the engine wiring harness bracket to the generator.
7. Disconnect the crankcase position (CKP) sensor electrical connector.
8. Move and secure the engine wiring harness aside.
9. Remove the bolts and the right valve rocker arm cover.
10. Clean all sealing surfaces. Refer to Valve Rocker Arm Cover Cleaning and
Inspection in Engine Mechanical - 4.3L .
Installation Procedure
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8. Connect the spark plug wires to the spark plugs for the right side of the engine.
Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
9. Install the PCV tube to the air cleaner outlet duct and the valve rocker arm
cover.
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Installation Procedure
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1. Remove the valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L .
2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
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Installation Procedure
Tools Required
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1. Important: The exhaust valve oil seal has the letters EX (1) molded into the top
of the seal. The seal material is brown in color (2) with a white stripe (3) painted
on the outside diameter of the seal or the material may be off-white in color (2)
with no paint stripe. The intake valve seal is black in color. The exhaust and
intake valve seals are not interchangeable.
Select the proper valve stem oil seal for the specific valve guide.
2. Lubricate the valve stem oil seal and the outside diameter of the valve guide
with clean engine oil.
3. Assemble the valve stem oil seal onto the valve guide using the J 42073 and a
hammer.
4. Install the valve stem oil seal onto the valve guide until the installation tool
bottoms against the valve spring seat.
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5. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed
against the valve guide.
There should be a 1 2 mm (0.03937 0.07874 in) gap between the bottom edge
of the seal and the valve guide.
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Use the J 38606 if the clearance does not permit use of J 5892-D .
Notice: Make sure that the valve stem keys are properly seated in the valve
spring cap. Engine damage could occur if not properly installed.
10. Install the valve stem keys.
Use grease in order to hold the valve stem keys in place.
11. Carefully release the valve spring pressure, making sure the valve stem keys stay
in place.
12. Remove the J 5892-D or the J 38606 and the J 22794 .
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13. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
14. Install the valve rocker arms to the cylinder head.
Refer to Valve Rocker Arm and Push Rod Replacement in Engine Mechanical 4.3L .
Tools Required
J 3049-A Valve Lifter Remover
Removal Procedure
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Installation Procedure
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2. Install the valve lifter pushrod guide. Refer to Valve Lifter Installation .
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9. Disconnect the exhaust pipe from the exhaust manifold. Refer to Exhaust
Manifold Pipe Replacement in Engine Exhaust.
10. Lower the vehicle to the proper height.
11. Remove the front tire to gain access to the rear exhaust manifold bolts. Wheel
Removal in Tire and Wheels.
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Installation Procedure
1. Sub-assemble the spark plug wire shields, bolts, and NEW gaskets to the
exhaust manifold.
The stud installs in the front hole.
2. Raise the vehicle to the proper height.
3. Install the exhaust manifold to the engine. Refer to Exhaust Manifold
Installation in Engine Mechanical - 4.3L .
4. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire
Harness Replacement in Engine Electrical.
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6. Install the front tire. Refer to Wheel Installation in Tire and Wheels.
7. Raise the vehicle.
8. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
9. Lower the vehicle.
10. 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.
Install the radiator inlet hose support bracket and nut.
Tighten
Tighten the radiator inlet hose support bracket nut to 36 N-m (27 lb ft).
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14. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
15. Install the air cleaner outlet duct to the throttle body.
16. Connect the PCV tube to the air cleaner outlet duct.
Removal Procedure
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Installation Procedure
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5. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
6. Lower the 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 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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4. Remove the air cleaner outlet duct from the throttle body.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls - 4.3L .
6. Remove the engine cooling fan assembly. Refer to Fan Clutch Replacement in
Engine Cooling .
Important: Do not evacuate the A/C system. The A/C pipes can remain on the
compressor.
7. Remove the air conditioning compressor, if equipped, and move aside. Refer to
Air Conditioning Compressor Replacement in HVAC Systems - Manual .
8. Remove the nuts holding the power steering pump rear bracket to the engine.
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9. Important: The power steering pump can remain on the power steering pump
mounting bracket. The power steering pump hoses can remain attached to the
power steering pump.
Remove the power steering pump mounting bracket and secure out of the way.
10. Remove the power steering pump mounting bracket stud from the cylinder head.
11. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L
12. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in
Engine Mechanical - 4.3L
13. Remove the spark plug wire harness and the support.
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14. Remove the ground wires at the rear of the cylinder head.
15. Remove the fuel line bracket bolt at the rear of the cylinder head.
16. Remove the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L
Installation Procedure
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2. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L
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10. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten
Tighten the power steering pump rear bracket nuts to 41 N-m (30 lb ft).
11. Install the air conditioning compressor, if equipped. Refer to Air Conditioning
Compressor Replacement in HVAC Systems - Manual .
12. Install the engine cooling fan. Refer to Fan Clutch Replacement in Engine
Cooling in Engine Cooling.
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14. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 4.3L .
16. Install the air cleaner outlet duct onto the throttle body.
17. Connect the PCV tube to the air cleaner outlet duct.
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Installation Procedure
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11. Fill the engine coolant system. Refer to Cooling System Draining and Filling in
Engine Cooling .
12. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 4.3L .
14. Install the air cleaner outlet duct onto the throttle body.
15. Connect the PCV tube to the air cleaner outlet duct.
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Installation Procedure
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4. 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.
Install the crankshaft balancer bolt.
Tighten
1. Tighten the crankshaft balancer bolt to 95 N-m (70 lb ft).
2. Tighten the pulley bolts to 58 N-m (43 lb ft).
5. Install the front differential carrier shield, if equipped.
6. Install the steering linkage shield, if equipped. Refer to Steering Linkage Shield
Replacement in Steering Linkage (Non-Rack and Pinion).
7. Lower the vehicle.
8. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 4.3L .
9. Install the fan shroud assembly. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
10. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
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Removal Procedure
Installation Procedure
Tools Required
J 35468 Oil Seal Installer
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Installation Procedure
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2. Install the CKP sensor with a NEW seal (O-ring). Refer to Crankshaft Position
Sensor Replacement in Engine Controls.
3. Install the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical 4.3L .
4. Install the water pump. Refer to Water Pump Replacement in Engine Cooling.
5. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in
Engine Mechanical - 4.3L .
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1. Remove the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
2. Remove the crankshaft position sensor reluctor ring.
Installation Procedure
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2. Install the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
Tools Required
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3. Notice: In order to rotate the crankshaft, in the end of the crankshaft install a
short bolt with the same threads or use the crankshaft balancer bolt with
sufficient spacers to keep from damaging the threads of the bolt.
Check the timing chain free play. Refer to Timing Chain and Sprockets Removal
.
4. Rotate the crankshaft until:
1. The timing marks on both sprockets line up.
2. The number four cylinder is at top dead center (TDC) of the compression
stroke.
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Installation Procedure
Tools Required
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1. Install the crankshaft balancer key into the keyway in the crankshaft (if
removed).
The crankshaft balancer key should be parallel to the crankshaft or with the front
of the key slightly lower.
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.
3. Use the J 5590 and a hammer in order to install the crankshaft sprocket.
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5. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position
and the camshaft sprocket is aligned at the 6 o'clock position.
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Installation Procedure
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Tools Required
J 26941Bushing/Bearing Remover
J 38834Balance Shaft Service Kit
Removal Procedure
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4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of
the engine block.
5. Install the bearing , washer and nut on the J 38834-1.
6. Hold the J 38834-1 and turn the nut clockwise until the balance shaft rear
bearing is removed.
3. Discard the balance shaft rear bearing.
Installation Procedure
Tools Required
Camshaft Replacement
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13. Remove the camshaft. Refer to Camshaft Removal in Engine Mechanical - 4.3L
.
Installation Procedure
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5. Install the crankshaft position sensor reluctor ring. Refer to Crankshaft Position
Sensor Reluctor Ring Replacement in Engine Mechanical - 4.3L .
6. Install the valve lifters and the valve pushrods. Refer to Valve Lifter
Replacement in Engine Mechanical - 4.3L .
7. Install the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
8. Install the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L .
9. Important: Rotate the engine to align the crankshaft balancer marks with the
front cover marks for cylinder number one top dead center. When the alignment
marks on the camshaft sprocket and the crankshaft sprocket are aligned the
engine is at cylinder number four top dead center,
Rotate the engine to align the crankshaft balancer marks (1) and (4) with the
engine front cover marks (2) and (3) for cylinder number one top dead center.
10. Install the distributor. Refer to Distributor Replacement in Engine Electrical.
11. Install the valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement in Engine Mechanical - 4.3L .
12. Install the condenser, if equipped. Refer to Air Conditioning Condenser
Replacement in HVAC Systems with A/C - Manual.
13. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
14. Fill the engine cooling system. Refer to Cooling System Draining and Filling in
Engine Cooling.
15. Recharge the air conditioning system, if equipped. Refer to Refrigerant
Recovery and Recharging in HVAC Systems with A/C - Manual.
16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
17. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
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1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Position a suitable container to catch the engine oil.
3. Remove the engine oil filter (except Four Wheel Drive vehicle).
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4. Disconnect the engine oil cooler pipes (RWD vehicle) from the oil filter adapter.
Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
5. Disconnect the remote oil filter inlet and outlet hoses (Four Wheel Drive
vehicle) from the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe
Replacement
6. Remove the bolts for the oil filter adapter RWD vehicle or the oil pipe adapter
Four Wheel Drive vehicle.
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Installation Procedure
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3. Install the oil filter adapter with a NEW oil filter adapter gasket.
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Tighten
Tighten the oil filter adapter bolts to 21 N-m (15 lb ft).
5. Connect the engine oil cooler pipes (RWD vehicle) to the oil filter adapter. Refer
to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
6. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle) to
the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe Replacement .
7. Install the engine oil filter (except Four Wheel Drive vehicles). Refer to Engine
Oil and Oil Filter Replacement in Engine Mechanical - 4.3L .
8. Lower the vehicle.
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1.
2.
3.
4.
Installation Procedure
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Installation Procedure
1. Apply sealer, GM P/N 12346004 or equivalent, to the area where the oil level
indicator fits into the engine block.
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4. 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.
Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to 12 N-m (106 lb in).
5. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement in
Engine Mechanical - 4.3L .
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Installation Procedure
Crankshaft Rear Oil Seal and Housing Replacement Document ID: 439513
Removal Procedure
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1. Important: Do not remove the crankshaft rear oil seal housing if only replacing
the crankshaft rear oil seal.
Remove the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical
- 4.3L .
2. Remove the transmission assembly.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
3. Remove the engine flywheel. Refer to Engine Flywheel Replacement in Engine
Mechanical - 4.3L .
4. Remove the three bolts and the one nut holding the crankshaft rear oil seal
housing to the engine.
5. Remove the crankshaft rear oil seal housing.
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6. Remove and discard the crankshaft rear oil seal housing gasket.
7. Clean all sealing surfaces.
8. Inspect the crankshaft rear oil seal housing for warping, cracks, wear, or
damage.
Installation Procedure
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2. Important: When installing a NEW crankshaft rear oil seal housing the
crankshaft rear oil seal will come with the housing. Use the following procedure.
Refer to Crankshaft Rear Oil Seal and Housing Replacement in Engine
Mechanical - 4.3L if reusing the crankshaft rear oil seal housing.
Install the NEW crankshaft rear oil seal housing with the crankshaft rear oil seal
to the engine block using the following procedure.
Important: Do not oil or grease the crankshaft rear oil seal lip or the
crankshaft seal area.
1. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a
guide to ease the seal lip over the end of the crankshaft.
2. Push the crankshaft rear oil seal housing with the crankshaft rear oil seal,
fully onto the crankshaft until the housing is against the gasket and the
engine.
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.
3. Install the three bolts and the one nut to the crankshaft rear oil seal housing.
Tighten
Tighten the crankshaft rear oil seal housing bolts and nut to 12 N-m (106 lb in).
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4. Disconnect the engine oil cooler pipes (RWD vehicle) from the oil filter adapter.
Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
5. Disconnect the remote oil filter inlet and outlet hoses (Four Wheel Drive
vehicle) from the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe
Replacement
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7. Remove the oil filter adapter and the oil filter adapter gasket.
8. Discard the oil filter adapter gasket.
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Installation Procedure
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2. Install a NEW seal (O-ring) into the groove in the oil filter adapter.
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4. 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.
Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to 21 N-m (15 lb ft).
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Installation Procedure
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Tighten
Tighten the engine flywheel bolts in sequence to 100 N-m (74 lb ft).
4. Install the transmission. Refer to Transmission Replacement in Automatic
Transmission - 4L60-E.
Engine Replacement
Removal Procedure
Notice: If the engine is damaged internally and a new engine assembly is installed in
the vehicle, ensure that all foreign material is flushed out of the cooling system. You
must also flush out the oil cooler system. Failure to rid the oil cooler system of debris
can result in engine damage.
Tool Required
J 41427 Engine Lift Bracket
1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove the underbody shields.
4. Remove the braces from the engine to the transmission (manual transmission
only). Refer to Transmission Replacement in Manual Transmission - New
Venture.
5. Remove the exhaust pipe from the exhaust manifolds. Refer to Exhaust
Manifold Pipe Replacement in Engine Exhaust.
6. Disconnect the oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler
Hose/Pipe Replacement in Engine Cooling.
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive
vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement in Engine
Mechanical - 4.3L .
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8. Remove the bolt holding the starter wire harness and if equipped, transmission
cooler lines.
9. Remove the starter. Refer to Starter Replacement in Engine Electrical.
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19. Remove the PCV tube from the right valve rocker arm cover and the air cleaner
outlet duct.
20. Remove the air cleaner outlet duct from the throttle body.
21. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.
22. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
23. Remove the inlet and outlet radiator hoses from the engine. Refer toRadiator
Hose Replacement in Engine Cooling.
24. Disconnect the heater hoses from the engine. Refer to Heater Hoses
Replacement in Heating and Ventilation (Non A/C).
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29. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
30. Remove the bolts holding the ground wires to the right cylinder head.
Caution: 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.
31. Remove the accelerator cable from the throttle shaft and the accelerator cable
bracket. Refer to Accelerator Control Cable Replacement in Engine Controls.
32. Remove the cruise control cable, if equipped from the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Control.
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33. Remove the accelerator control cable bracket from the throttle body.
34. Remove the water pump pulley. Refer to Water Pump Replacement in Engine
Cooling.
35. Remove the A/C compressor, if equipped. Refer to Air Conditioning
Compressor Replacement in HVAC Systems with A/C - Manual.
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43. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
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2.
Install the J 41427 marked RIGHT REAR.
3.
Install the retaining bolts.
4.
Remove the left front lower intake manifold bolts.
5.
Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of
the engine.
Install the retaining bolts.
6.
Tighten
Tighten the retaining bolts to 15 N-m (11 lb ft).
Installation Procedure
Notice: If the engine is damaged internally and a new engine assembly is installed in
the vehicle, ensure that all foreign material is flushed out of the cooling system. You
must also flush out the oil cooler system. Failure to rid the oil cooler system of debris
can result in engine damage.
Tool Required
J 41427 Engine Lift Bracket
1. Install the engine into the vehicle.
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Tighten
1.
2.
3.
Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m (18 lb ft).
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m (22 lb ft).
Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).
7. Install the water outlet. Refer to Water Pump Replacement in Engine Cooling.
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8. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls.
9. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
Tighten
Tighten the fuel pipe bracket bolt to 30 N-m (22 lb ft).
10. Connect the EVAP canister purge solenoid valve pipe. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.
11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
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13. Install the power steering pump mounting bracket and the three bolts and the
nut.
Tighten
Tighten the power steering pump mounting bracket bolts and nuts to 41 N-m
(30 lb ft).
14. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten
Tighten the power steering pump rear bracket nuts to 41 N-m (30 lb ft).
15. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor
Replacement in HVAC Systems with A/C - Manual.
16. Install the water pump pulley. Refer to Water Pump Replacement in Engine
Cooling.
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17. Install the accelerator control cable bracket to the throttle body.
Tighten
Tighten the bolt to 9 N-m (80 lb in).
Caution: 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.
18. Install a NEW accelerator control cable. Refer to Accelerator Control Cable
Replacement in Engine Controls.
19. Install the cruise control cable, if equipped to the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Controls.
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22. Install the stud holding the ground wires to the right cylinder head.
Tighten
Tighten the stud to 35 N-m (26 lb ft).
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29. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
30. Install the transmission.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.
31. Install the transfer case, if equipped.
o Refer to Transfer Case Replacement in Transfer Case - NVG 236 (Two
Speed Automatic).
o Refer to Transfer Case Replacement (With Automatic Transmission) in
Transfer Case - NVG 136-NP4 (One Speed Automatic).
32. Install the front propeller shaft (Four Wheel Drive vehicle only). Refer to Front
Propeller Shaft Replacement in Propeller Shaft.
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36. Connect the oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler
Hose/Pipe Replacement in Engine Cooling.
37. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle).
Refer to Remote Oil Filter Adapter Pipe Replacement in Engine Mechanical 4.3L .
38. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
39. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement in
Engine Mechanical - 4.3L .
40. Install the braces from the engine to the transmission. Refer to Transmission
Replacement in Manual Transmission - New Venture.
41. Install the underbody shields.
42. Lower the vehicle.
43. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement in
Engine Mechanical - 4.3L .
44. Fill the cooling system with coolant. Refer to Cooling System Draining and
Filling in Engine Cooling
45. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
46. Recharge the air conditioning system, if equipped. Refer to Refrigerant
Recovery and Recharging in HVAC Systems with A/C - Manual.
47. Operate and test the engine. Refer to Engine Set-Up and Testing .
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1. Remove the bolts and the fan & water pump pulley using the J 41240 .
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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.
Use the J 23523-F in order to remove the crankshaft balancer.
1. Install the J 23523-F plate and bolts onto the crankshaft balancer.
Tighten
Tighten the bolts to 25 N-m (18 lb ft).
2. Install the J 23523-F forcing screw into the plate.
3. Rotate the J 23523-F forcing screw clockwise in order to remove the
crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer.
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5. Note the position and length of any front groove pins (crankshaft balancer) (if
applicable).
Distributor Removal
Document ID: 42613
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2. Remove the engine coolant temperature (ECT) sensor wire connector (if
equipped) from the engine wiring harness bracket.
3. Remove the lower intake manifold bolts.
Important: The intake manifold may be removed as an assembly. Do not
remove the specific intake manifold components unless component service is
required.
Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the
fuel system are properly sealed.
Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless
service is required.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold gaskets.
Description
DTC
Type*
P0218
Transmission Fluid
Overtemperature
Default Action
DTC P0218 stores in VCM
history
The VCM freezes shift
adapts from being updated
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P0502
P0503
P0712
P0713
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D
D
P0740
P0742
P0748
P0753
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P0758
P0785
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P1870
Transmission Component
Slipping
P1875
*DTC Types:
Range Reference
Document ID: 19380
Range Reference Table
Range
Gear
OD
D
2
1
1st 2nd 3rd 4th 1st 2nd 3rd 1st** 2nd 1st 2nd***
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Gear Ratio
3.059:1
1-2 Shift
ON* ON* ON* ON OFF OFF ON ON OFF OFF ON OFF ON OFF
Solenoid
2-3 Shift
ON* ON* ON* ON ON OFF OFF ON ON OFF ON ON ON ON
Solenoid
A A A A
A
2-4 Band
Reverse
A
Input
Clutch
Overrun
A
A
A A
A
Clutch
Forward
A A A A A A A
A
A A
A
Clutch
Forward
Sprag
H H H H H H
H
H H
H
Clutch
Assembly
3-4
A A A
Clutch
Lo/Roller
H H H H
Clutch
Lo/Rev
A
A
A
Clutch
a = Applied
h = Holding
on = The solenoid is energized.
off = The solenoid is de-energized.
*Shift Solenoid state is a function of vehicle speed and may change if the vehicle
speed increases sufficiently in Park, Reverse or Neutral. However, this does not
affect the operation of the transmission.
**Manual SecondFirst gear is electronically prevented under normal operating
conditions.
***Manual FirstSecond gear is only available above approximately 4856 km/h
(3035 mph).
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2
3
4
OFF
OFF
ON
ON
OFF
OFF
1.625:1
1.000:1
0.696:1
Shift Speed
Document ID: 201386
Shift Speed (1998 S/T Truck)
M
31 @ 32 @
23
TC
+/ 100 +/ 100 3-1
12 Shift @ 23 Shift @
34 Shift @
RPM RPM Wide Wide Ap
+/ 250 RPM +/ 200 RPM +/ 150 RPM Output Output Open Open @ 1
Output Shaft Output Shaft Output Shaft Shaft Shaft Throttle Throttle Thr
Speed
Speed
Speed
Speed Speed Shift
Shift (RP
12 25 50 12 25 50 12 25 50
% of TPS
Trans
Axle
Cal
2.2L (LN2)
A
4
683 840 1208 998 1522 2257 1575 2100 3465
4.3L (LF6/L35)
A
3.08/3.43 566 817 1131 985 1299 2011 1383 1697 2577
B 3.08/3.42/3.73 529 761 1057 909 1205 1882 1290 1586 2390
C
3.42/3.73 521 747 1042 906 1200 1857 1268 1563 2378
N/A
893
1575
5500
N/A
N/A
N/A
796
740
725
1383
1290
1268
5000
5000
5000
19
18
16
16
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394.
396.
Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid
Valve
1998 Domestic S/T Cell 44 Figure 1 Component Locator View Document ID: 255876
Brake Control Module Connector C3 Locator View
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1998 Domestic S/T Cell 44 Figure 2 Component Location View Document ID: 255877
Forward Wiring Sensor Locator Views
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1998 Domestic S/T Cell 44 Figure 3 Component Location View Document ID: 255878
LH Front Fender Area Locator View
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1998 Domestic S/T Cell 44 Figure 4 Component Location View Document ID: 255879
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Wire Color
BRN
LT GRN
PPL
YEL/BLK
TAN/WHT
PPL
PPL
BLK
12065425
10 Way F Metri-Pack 150 Series (BLK)
Circuit No.
241
867
420
1827
799
1807
680
450
Function
Ignition 3 Power
ABS Indicator Lamp Control
Brake Switch Input
Not Used
Vehicle Speed Input
ABS Diagnostic Link (UART)
Serial Data (Class 2)
Brake Warning lamp Control
Signal Ground
Not Used
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Wire Color
LT BLU
DK GRN
YEL
TAN
12124662
4 Way F Metri-Pack 150 Series (BRN)
Circuit No.
830
872
873
833
Function
LF Wheel Speed Sensor High
Not Used
RF Wheel Speed Sensor High
LF Wheel Speed Sensor Low
RF Wheel Speed Sensor Low
Wire Color
RED
BLK
12085030
2 Way F Metri-Pack 630 Series P2S (BLK)
Circuit No.
442
150
Function
Motor and Solenoid Power
Power Ground
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Installation Procedure
Important: Do not reuse the old mounting screws. Always install new mounting screws
with the new EBCM.
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1. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.
Connect the four electrical connectors to the EBCM.
2. Install EBCM (2) on to the BPMV (4).
Notice: Refer to Fastener Notice in Cautions and Notices.
3. Install the four new T-25 Torx screws (1) in the EBCM (2).
Tighten
Tighten the four T-25 Torx screws to 5 N-m (39 lb in) in an X-pattern.
4. Connect the negative battery cable.
5. Revise the tire calibration using the Scan Tool
6. Go to Diagnostic System Check in Antilock Brake System .
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Installation Procedure
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3. Install the three allen bolts (11) that fasten the combination valve (12) to the
BPMV (4).
Tighten
Tighten the three allen bolts to 8 N-m (6 lb ft), then to 16 N-m (12 lb ft).
Important: Do not reuse the old EBCM mounting bolts. Always install new
mounting bolts with the new EBCM.
4. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.
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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Tighten
Tighten the four bolts to 5 N-m (39 lb in) in an X-pattern.
6. Install EHCU (9) to bracket.
7. Install the three BPMV (4) to bracket retaining bolts.
Tighten
Tighten the three bolts to 9 N-m (7 lb ft).
Tighten
Tighten the three bolts to 25 N-m (20 lb ft).
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13. Install the two fuse block mounting bolts from the EBCM bracket.
14. Connect the negative battery cable.
Important: Verify that the combination valve metering rod is depressed during
bleeding.
15. Bleed the brake system. Refer to Antilock Brake System Automated Bleed
Procedure in Antilock Brake System .
16. Go to Diagnostic System Check.
1.
2.
3.
4.
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13. Bleed the system as many times as necessary in order to obtain the appropriate
feel of the pedal.
Installation Procedure
Important: After installation, calibrate the new EBCM to the tire size that is
appropriate to the vehicle. Refer to Tire Size Calibration and to Trim Level Calibration
portions of ABS Operation in Antilock Brake System .
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Important: Do not reuse the old mounting screws. Always install new mounting screws
with the new EBCM.
1. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.
Connect the four electrical connectors to the EBCM.
2. Install EBCM (2) on to the BPMV (4).
Notice: Refer to Fastener Notice in Cautions and Notices.
3. Install the four new T-25 Torx screws (1) in the EBCM (2).
Tighten
Tighten the four T-25 Torx screws to 5 N-m (39 lb in) in an X-pattern.
4. Connect the negative battery cable.
5. Revise the tire calibration using the Scan Tool
6. Go to Diagnostic System Check in Antilock Brake System .
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Removal Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Raise vehicle.
Remove tire and wheel. Refer to Wheel Removal in Tires and Wheels .
Remove brake caliper. Refer to Brake Caliper Replacement in Disc Brakes .
Remove the hub and rotor. Refer to Brake Rotor Replacement in Disc Brakes .
Remove wheel speed sensor mounting clip on the control arm.
Remove wheel speed sensor mounting clip on the frame rail.
Disconnect wheel speed sensor electrical connector (2).
Remove the sensor mounting screw (5).
Important: The wheel speed sensor mounts into a bore that leads to the center
of the sealed bearing. Use caution when cleaning or working around the bore.
Do not contaminate the lubricant inside the sealed bearing. Failure to do so can
lead to premature bearing failure.
9. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO
NOT use a screwdriver, or other device. Prying will cause the sensor body to
break off in the bore.
Notice: Do not attempt to remove the stainless steel shim from the bearing
assembly. The shim is permanently attached. If the shim is damaged or bent,
replace the bearing assembly. Failure to comply will result in diminished sensor
and ABS performance.
Remove wheel speed sensor from hub and bearing assembly (5).
Installation Procedure
Important: The new speed sensor will have a new O-ring. Dispose of the old Oring. Lubricate the new O-ring lightly with bearing grease prior to installation.
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You may also lubricate the sensor just above and below the new O-ring. DO
NOT lubricate the bore.
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Important: Lubricate the threads of the adjusting rod before turning the nut
2. Lubricate the threads of the adjusting rod using Lubriplate GM P/N 1050109 or
the equivalent.
The park brake must be adjusted any time the park brake cables have been replaced or
disconnected, if the park brake shoes have been replaced or if under heavy foot pressure
the pedal travel is less than half the pedal total travel. Before adjusting the park brake,
check the condition of the service brakes. Refer to Brake Pad Inspection in Disc Brakes
.
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10. Install the rotor. Refer to Brake Rotor Replacement in Disc Brakes .
11. Install the wheel and the tire.
12. Adjust the rear park brake cables. Refer to Park Brake Cable Service/Adjustment
in Park Brake .
13. Lower the vehicle.
Removal Procedure
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Inspection Procedure
Installation Procedure
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1. Lubricate the park brake assembly. Refer to Park Brake Lubrication in Park
Brake .
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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 park brake lever mounting bolts and the nut.
Tighten
Tighten the bolts and the nut to 25 N-m (18 lb ft).
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Installation Procedure
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1. Connect the rear park brake cable(s) to the park brake lever.
1. Slide the brake cable into the brake backing plate opening.
2. Install the cable retainer into the backing plate.
3. Verify the cable retainer fingers expand when the cable retainer is
inserted into the backing plate.
4. Pull the cable end fitting as far rearward as possible.
5. Install the cable end fitting into the parking brake lever.
2. Install the brake shoes and drum(s). Refer to Brake Shoe Replacement in Drum
Brakes.
3. Route the rear cable(s) through the attachments and guides at the frame and/or
axle and/or equalizer.
4. Verify the cable retainers fingers expanded and the retainers are secure at all
locations for cable(s) removed.
Important: When routing the cable(s) through the guide loop, route the left side
cable first.
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1. Raise the vehicle and support the vehicle with safety stands. Refer toLifting and
Jacking the Vehicle in General Information.
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Installation Procedure
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Wire Color
BRN
LT GRN
PPL
YEL/BLK
TAN/WHT
PPL
PPL
BLK
12065425
10 Way F Metri-Pack 150 Series (BLK)
Circuit No.
241
867
420
1827
799
1807
680
450
Function
Ignition 3 Power
ABS Indicator Lamp Control
Brake Switch Input
Not Used
Vehicle Speed Input
ABS Diagnostic Link (UART)
Serial Data (Class 2)
Brake Warning lamp Control
Signal Ground
Not Used
Wire Color
LT BLU
12124662
4 Way F Metri-Pack 150 Series (BRN)
Circuit No.
Function
830
LF Wheel Speed Sensor High
Not Used
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C
D
E
DK GRN
YEL
TAN
872
873
833
Wire Color
RED
BLK
Step
1.
2.
3.
4.
12085030
2 Way F Metri-Pack 630 Series P2S (BLK)
Circuit No.
442
150
Function
Motor and Solenoid Power
Power Ground
Action
Value(s)
Verify that all of the EBCM
connectors are connected
properly.
Install the Scan Tool .
Turn the ignition to RUN.
Yes
No
Go to Step 2
Go
to
Step
4
Go
Go to Symptom and to
Diagnostic Trouble Step
Code Table
3
Go
System is operating to
normally. Go to Step
Diagnostic Aids.
11
Go
1015V
Go to Step 5
to
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harness connector.
3. Turn the ignition to RUN.
4. Measure the voltage between the
10-way EBCM harness connector
terminal A and ground using the J
39200 .
Step
9
0-2
Go to Step 6
Go
to
Step
12
Go to Step 7
Go to Step 1
Go
to
Step
8
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connection.
Is the repair complete?
Reconnect the EBCM connectors and the
battery cables.
8
12
Go to Step 10
Go
to
Step
13
0-2
OL
Go to Step 18
Go
to
Step
14
Go
to
Step
21
Go to Step 1
Go to Step 1
Go to Step 1
Go
to
Go to Step 15
Go to Step 16
Go to Data Link
Communications
System Check in
Wiring Systems
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Step
17
Go to Step 1
Go to Step 1
Go
to
Step
20
Go to Step 1
Go to Step 1
Go to Step 20
Go
to
Step
19
Go to Step 1
Definition
DTC C0221 or C021 RF Wheel Speed Sensor Circuit Open in
Antilock Brake System
DTC C0222 or C022 RF Wheel Speed Signal Missing in Antilock
Brake System
DTC C0223 or C023 RF Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0225 or C025 LF Wheel Speed Sensor Circuit Open in
Antilock Brake System
DTC C0226 or C026 LF Wheel Speed Signal Missing in Antilock
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DTC C0227
DTC C0229
DTC C0238
DTC C0241
DTC C0242
DTC C0243
DTC C0244
DTC C0245
DTC C0246
DTC C0247
DTC C0248
DTC C0251
DTC C0252
DTC C0253
DTC C0254
DTC C0265
DTC C0266
DTC C0235
(4.3L)
DTC C0235
(2.2L)
DTC C0236
(4.3L)
DTC C0236
(2.2L)
DTC C0237
(4.3L)
DTC C0237
(2.2L)
Brake System
DTC C0227 or C027 LF Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0229 or C029 Drop Out of Front Wheel Speed Signals in
Antilock Brake System
DTC C0235 or C035 Rear Wheel Speed Signal Circuit Open in
Antilock Brake System
DTC C0235 or C035 Rear Wheel Speed Signal Circuit Open in
Antilock Brake System
DTC C0236 or C036 Rear Wheel Speed Signal Circuit Missing in
Antilock Brake System
DTC C0236 or C036 Rear Wheel Speed Signal Circuit Missing in
Antilock Brake System
DTC C0237 or C037 Rear Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0237 or C037 Rear Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0238 or C038 Wheel Speed Mismatch in Antilock Brake
System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0265 or C0266 and C065 C066 EBCM Relay Circuit in
Antilock Brake System
DTC C0265 or C0266 and C065 C066 EBCM Relay Circuit in
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DTC C0267
DTC C0268
DTC C0271
DTC C0272
DTC C0274
DTC C0281
Application
Hold Down Spring Screw
Park Brake Cable Mounting Bracket Bolt
Park Brake Lever Mounting Bolts
Park Brake Lever Mounting Nut
Specification
Metric
English
4 N-m
35 lb in
17 N-m
12.6 lb ft
25 N-m
18 lb ft
25 N-m
18 lb ft
DTC C0273
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Disassembly Procedure
1. Drain all the brake fluid from the caliper.
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4. Remove the boot from the caliper bore. Do not scratch the housing bore.
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Assembly Procedure
Tools Required
J 26267 Piston Seal Installer
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1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake
fluid.
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5. Install the boot into the caliper housing bore using J 26267 .
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Tighten
Tighten the bleeder valve to 12 N-m (110 lb in).
Disassembly Procedure
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4. Remove the boot from the caliper bore. Do not scratch the housing bore.
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6. Remove the bleeder valve and bleeder valve cap from the caliper body.
7. Remove the guide pins and guide pin sleeves from the anchor bracket.
8. Clean the following components with denatured alcohol.
o The bleeder valve
o The caliper bore
o The caliper passages
o The piston
o The lining contact area on the anchor bracket.
9. Dry the parts and blow out the brake fluid passages. Use dry and filtered
compressed air.
10. Replace the piston or the caliper if any of the following conditions exist:
o Scoring on the piston surface or in the caliper bore
o Corrosion on the piston
o Chrome plating damage on the piston
o Corrosion in the caliper bore. Use crocus cloth in order to polish light
corrosion from the caliper bore. Replace the caliper if the corrosion
cannot be removed.
o Pitting in the caliper bore
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.
11. Replace the bleeder valve cap.
Tighten
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Assembly Procedure
1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake
fluid.
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4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by
hand.
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Installation Procedure
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1. Before installing the master cylinder, bench bleed the master cylinder. Refer to
Master Cylinder Bench Bleeding in Hydraulic Brakes .
2. Install the master cylinder.
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Tighten
Tighten the master cylinder nuts to 36 N-m (27 lb ft).
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1.
2.
3.
4.
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8. Caution: If air pressure is used to remove the secondary piston, place the open
end of the cylinder bore approximately 25 mm (1 in) from a padded workbench
or other surface to catch the piston when it comes out of the bore. Apply low air
pressure very carefully to ease the piston out of the bore. Never point the open
end of the bore at anyone when applying air pressure. The piston may come out
of the bore with considerable force and cause personal injury.
Remove the secondary piston from the master cylinder body.
Plug the rear port. Apply a small amount of air pressure to the front port.
9. Remove the seals.
10. Remove the spring retainer and the spring from the master cylinder body.
Notice: Use only approved solvents when cleaning or flushing the master
cylinder and related components. Solvents which contain traces of mineral oil or
other contaminants will damage the rubber parts in the system.
11. Clean all the parts using the following procedure:
o Clean the metal parts in denatured alcohol.
o Clean the rubber parts in clean brake fluid.
12. Inspect the diaphragm for cuts, cracks, or swelling.
13. Inspect the cylinder bore for scoring or corrosion.
o Replace the master cylinder if corrosion is present.
o Do not attempt to hone the cylinder bore.
14. Inspect the reservoir for cracks.
Assembly Procedure
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1. Lubricate the grommets, seals, and the cylinder bore with clean DOT 3 motor
vehicle brake fluid.
2. Use new seals when assembling the master cylinder.
3. Install the secondary piston spring.
4. Install the spring retainer.
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1.
2.
3.
4.
5. Important: Verify that the replacement combination valve has the same pin
punched identification code as the code found on the old part.
Remove two transfer tubes (13).
Installation Procedure
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1. Install two new transfer tubes (13) into the combination valve (12) until fully
seated.
2. Install combination valve (12) to BPMV (4).
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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Installation Procedure
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Installation Procedure
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Tools Required
Disassembly Procedure
Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or
deform the tube causing an imbalance or unsafe condition. Always clamp on one
of the yokes and support the shaft horizontally. Avoid damaging the slip yoke
sealing surface. Nicks may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft as to which end is the transmission end and which end
goes to the rear axle.
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4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on
the open horizontal bearing cups. Press the lower bearing cup out of the yoke
ear.
5. If you do not completely remove the bearing cup, lift the cross and insert J 95225 between the seal and the bearing cup you are removing. Continue to press the
bearing cup out of the yoke.
6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke.
7. Mark the orientation of the slip yoke to the tube for proper reassembly.
8. Remove the cross from the yoke.
9. Remove the remaining universal joint parts from the yoke. If you are replacing
the front universal joint, remove the bearing cups in the slip yoke in the same
manner.
10. Inspect the retaining ring grooves for plastic.
11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections.
12. Clean the remains of the sheared plastic bearing retainers from the grooves in
the yoke.
13. The sheared plastic may prevent the bearing cups from pressing into place and
thus prevent the bearing retainers from properly seating.
Assembly Procedure
1. Remove the bearing cups from the universal joint.
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13. It may be necessary to lubricate the snap ring with a slight amount of chassis
grease so the snap ring seats in the bearing cup groove.
Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform
the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes
and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks
may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft in order to show which end connects to the transmission
and which end goes to the rear axle.
3. Disassemble the snap rings by pinching the ends together with a pair of pliers.
4. If the ring does not readily snap out of the groove in the yoke, tap the end of the
cup lightly in order to relieve the pressure from the ring.
Disassembly Procedure
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6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup
out of the yoke ear.
7. If you do not completely remove the bearing cup, lift the cross and insert J 95225 between the seal and the bearing cup you are removing. Continue pressing the
bearing cup out of the yoke.
8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke.
9. Mark the orientation of the slip yoke to the tube for proper reassembly.
10. Remove the cross from the yoke.
11. Remove the remaining universal joint parts from the yoke.
12. If you are replacing the front universal joint, remove the bearing cups in the slip
yoke in the same manner.
13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring.
14. Inspect the bearing cup bores for burrs or imperfections.
15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old
retaining ring may prevent the bearing cups from pressing into place or prevent
the bearing retainers from properly seating.
Assembly Procedure
1. Remove the bearing cups from the universal joint.
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2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear
toward the bottom.
3. Assemble the cross into the yoke so that the trunnion seats freely into the
bearing cup.
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2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in
Instrument Panel.
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7. With the key installed, turn the key to the RUN position.
8. Gently lift the upper trim cover up so that you may install an allen wrench into
the hole on top of the lock cylinder housing.
Push down on the allen wrench to release the tab on the lock cylinder inside the
lock cylinder housing.
Installation Procedure
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7. Install the screws that retain the lower steering column trim cover to the steering
column.
Tighten
Tighten the lower steering column trim cover retaining screws to 6 N-m
(53 lb in).
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5. Remove the 2 wire harness straps from the steering column wire harness.
6. Remove the connector position assurance (CPA) retainer from the brake
transmission shift interlock (BTSI).
7. Disconnect the steering column bulkhead connector from the vehicle wire
harness.
8. Disconnect the gray and the black connectors of the switch from the column
bulkhead connector.
9. Remove the multifunction switch to the steering column mounting screws.
10. Remove the multifunction turn signal/hazard switch.
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.
2. Install the multifunction switch to steering column mounting screws.
Tighten
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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:
o
o
o
Tighten
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Important: Remove the SIR coil from the steering shaft and let the SIR coil
hang freely.
3. Remove the SIR coil. Refer to Steering Wheel Inflatable Restraint Module Coil
Replacement in SIR .
4. Install the J 23653-SIR to the steering shaft and compress the shaft lock shield
(2).
5. Remove the lock shield retainer from the steering column shaft.
6. Remove the J 23653-SIR from the steering shaft.
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9. Insert a small screwdriver into the slot on the electronic lock module and push
down on the park lock cable locking tab and remove park lock cable (1) from the
electronic lock module (column shift only).
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11. Unsnap the electric park lock (2) off of the electronic lock module (1)
(floorshift only).
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14. Disconnect the ignition switch (2) from the electronic lock module using the J42759.
15. Remove the ignition switch (2) from the electronic lock module (2).
16. Let the ignition switch (2) hang freely.
Installation Procedure
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1. Install the electronic lock module (1) to the steering column housing.
2. Install the electronic lock module(1) mounting screws (2).
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7. Connect the electric park lock (1) electrical connector (2) (floorshift only).
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3. Remove the air cleaner assembly. Refer to Intake Air Resonator Replacement in
Engine Controls 2.2L or Air Cleaner Assembly Replacement in Engine Controls
4.3L.
Note the relationship of the lower intermediate shaft to the upper intermediate
shaft and the lower intermediate shaft to the steering gear input shaft in order to
ensure proper installation.
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5. Remove the bolt that retains the lower intermediate shaft coupling to the steering
gear input shaft.
Installation Procedure
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the bolt that retains the lower intermediate shaft coupling to the steering
gear input shaft.
Tighten
Tighten the lower intermediate shaft coupling to the steering gear input shaft
bolt to 35 N-m (25 lb ft).
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2. Remove the wire harness assembly (1) from the wire harness strap (2).
3. Disconnect the turn signal and multifunction switch assembly connector from
the inflatable restraint steering wheel module coil connector.
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5. Remove the 2 pan head tapping screws (1) from the turn signal and
multifunction switch assembly (2).
6. Remove the turn signal and multifunction switch assembly (2) from the steering
column housing assembly.
Removal Procedure
1. Disconnect the negative battery cable. Refer to Engine Electrical.
Caution: Refer to SIR Caution in Cautions and Notices.
2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
3. Remove the hush and knee bolster. Refer to Knee Bolster Replacement in
Instrument Panel.
4. Remove the steering column trim covers. Refer to Trim Covers, Shift Lever Seal
- Disassemble - Off Vehicle in Steering Wheel and Column - Tilt .
5. With the key installed, turn the key to the RUN position.
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6. Install an allen wrench into the hole on top of the lock cylinder housing.
Push down on the allen wrench to release the tab on the lock cylinder inside the
lock cylinder housing.
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9. Insert J-42759 into the lock cylinder housing to release the tabs on the ignition
switch.
10. Pull the ignition switch out of the lock cylinder housing.
11. Disconnect the connector from the ignition switch.
Steering Column Accident Damage Inspection - Off Vehicle Document ID: 447635
Inspection Procedure
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Notice: Vehicles involved in accidents that result in any of the following kinds
of damage or situations, may also have a damaged or misaligned steering
column:
o Frame damage
o Major body damage
o Sheet metal damage
o If the steering column has been impacted
o If the supplemental inflatable restraints system was deployed
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. If measured
dimensions are not within specifications, a new jacket must be installed.
Check the capsules on the steering column bracket assembly: all must be
securely seated in the bracket slots and checked for any loose conditions when
pushed or pulled by hand. If not, the bracket should be replaced if bolted to the
jacket assembly. If the bracket is welded to the jacket assembly replace the
jacket assembly.
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Notice: Before the shaft is rotated, remove the inflatable restraint coil assembly
from the steering column and allow it to hang freely. Failure to do so may
damage the coil assembly.
Visually inspect steering shaft for sheared injected plastic. If steering shaft
shows sheared plastic, a new steering shaft must be installed.
Any frame damage that could cause a bent steering shaft must have the steering
shaft runout checked in the following manner. Using a dial indicator at the lower
end of the steering shaft, have the steering wheel rotated. Runout must not
exceed 1.60 MM.
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2. Remove the cotter pin from outer tie rod ball stud nut.
3. Remove the outer tie rod ball stud nut.
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Remove the outer tie rod ball stud from the steering knuckle using J 6627-A .
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Installation Procedure
Tools Required
J 29193 Steering Linkage Installer (12 mm)
J 29194 Steering Linkage Installer (14 mm)
Important: If the tie rod ends were removed, lubricate the tie rod ends with
chassis lubricant.
1. Connect the tie rod ends to the adjuster tube.
Ensure that the number of threads on both the inner and the outer tie rod ends
are equal within three threads.
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Seat the taper using J 29193 or J 29194 .
Tighten
Tighten J 29193 or J 29194 to 54 N-m(40 lb ft).
4. Remove J 29193 or J 29194 from inner tie rod ball stud.
5. Install the new nut to the inner tie rod ball stud.
Tighten the inner tie rod ball ball stud nut to 53 N-m (39 lb ft).
Tighten
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7. 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.
Seat the taper using J 29193 or J 29194 .
Tighten
Tighten J 29193 or J 29194 to 54 N-m(40 lb ft).
8. Remove J 29193 or J 29194 from outer tie rod ball stud.
9. Install the nut to the outer tie rod ball stud.
Tighten
Tighten the outer tie rod ball stud nut to 53 N-m (39 lb ft).
Important: Do not back the nut off in order to align the cotter pin hole.
Advance the nut in order to align the nut slot with the cotter pin hole.
10. Install the new cotter pin to the outer tie rod stud nut.
11. Spread the cotter pin ends.
12. Lower the vehicle.
13. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.
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14. Position the two clamps (2) between the locating dimples (1) at either end of the
adjuster tube.
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18. When clamps are tightened to specifications, the ends may touch.
19. Install the adjuster tube clamp bolts.
Tighten
Tighten the adjuster tube clamp bolts to 21 N-m (16 lb ft).
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4. Important: Use the proper tool in order to separate all ball joints.
Remove the relay rod stud nut.
Installation Procedure
Tools Required
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1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
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2. Important: Use the proper tool in order to remove the relay ball stud nut.
Remove the relay rod ball stud at the pitman arm.
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5.
6.
7.
8.
Remove the pitman arm from steering gear using J 6632-01 or J 29107-A .
Inspect the ball stud threads for damage.
Inspect the ball stud seals for excessive wear.
Clean the threads on the ball stud.
Installation Procedure
Tools Required
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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 pitman arm washer and nut to the pitman arm shaft.
Tighten the pitman arm shaft nut to 250 N-m (185 lb ft).
3. Install the relay rod ball stud to the pitman arm.
Ensure the seal is on the stud.
Tighten
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Ensure that the pilot bottoms in the pump shaft by turning the nut to the top of
the pilot bolt.
5. Hold the pilot bolt.
6. Turn the nut clockwise.
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13. Disconnect the power steering outlet hose from the power steering pump.
14. Cap the power steering pump hoses.
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Installation Procedure
Tools Required
J 25033-C Power Steering Pump Pulley Installer
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Tighten the power steering pump front mounting bolts to 50 N-m (37 lb ft).
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12. Place the power steering pump pulley on the end of the power steering pump
shaft.
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17. Install the pulley (1) flush against the end of the power steering pump shaft (2),
with an allowable variance of 0.25 mm (0.010 in).
18. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement
in Engine Cooling.
19. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical
4.3L.
20. Remove the upper fan shroud. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
21. Fill the power steering system.
22. Bleed the system. Refer to Power Steering System Bleeding in Power Steering
System .
23. Inspect the hoses for clearance.
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Installation Procedure
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Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering gear pressure hose to the vehicle.
2. 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.
Connect the power steering gear pressure hose to the power steering gear.
Tighten
Tighten the power steering gear pressure hose to the power steering gear to
30 N-m (22 lb ft).
3. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
4. Raise the vehicle.
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5. Connect the power steering gear pressure hose to the power steering pump.
Tighten
Tighten the power steering gear pressure hose to the power steering pump to
25 N-m (18 lb ft).
6. Remove the drain pan from under the vehicle.
7. Install the steering linkage shield, if equipped. Refer to Steering Linkage Shield
Replacement in Steering Linkage.
8. Lower the vehicle.
9. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
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3. Disconnect the power steering gear return hose from the power steering pump
(for vehicles without power steering cooler).
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5. Disconnect the power steering gear return hose from the power steering gear.
6. Remove the power steering gear return hose from the vehicle.
Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering gear return hose to the vehicle.
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3. Connect the power steering gear return hose to the power steering cooler, if
equipped.
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).
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4. Connect the power steering gear return hose to the power steering pump (for
vehicles without power steering cooler).
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).
5. Remove the drain pan from under the vehicle.
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
7. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
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7. Remove the following components from the power steering gear (1):
o The dust seal (5)
o The return ring (4)
o The washer (3)
o The pitman shaft oil seal (2)
8. Inspect the pitman shaft seal surfaces for roughness or pitting.
Replace the pitman shaft if the shaft is pitted.
9. Clean the pitman shaft and seal areas using a wire brush.
Installation Procedure
Tools Required
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7. Install the snap ring (6) to the pitman arm shaft using J 4245 .
8. Center the steering gear.
9. Line up steering gear to pitman arm.
10. Install the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.
11. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
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4. Disconnect the power steering cooler hose from the power steering cooler.
5. Remove the power steering cooler hose from the vehicle.
Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering cooler hose to the vehicle.
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3. Connect the power steering cooler hose to the power steering pump.
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).
4. Remove the drain pan from under the vehicle.
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
6. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
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Removal Procedure
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of components. Failure to
do so could result in contamination or loss of power steering fluid and damage to the
system.
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls 4.3L.
2. Install drain pan under vehicle.
3. Disconnect the power steering cooler hoses from the power steering cooler.
4. Remove the radiator air intake baffle. Refer to Air Intake Baffle Replacement Radiator in Body Front End.
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Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
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2. 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.
Install the power steering cooler retaining bolts.
Tighten
Tighten the power steering cooler retaining bolts to 10 N-m (90 lb in).
3. Install the radiator air intake baffle. Refer to Air Intake Baffle Replacement Radiator in Body Front End.
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4. Connect the power steering cooler hoses to the power steering cooler.
Tighten
Tighten the power steering cooler hoses to the power steering cooler clamps to
2 N-m (18 lb in).
5. Remove drain pan from under the vehicle.
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
7. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
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Installation Procedure
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7. Install the inlet and the outlet hoses to the power steering gear.
Tighten
Tighten the inlet hose to 25 N-m (18 lb ft) for the vehicle equipped with
the 2.2L engines.
o Tighten the inlet hose to 30 N-m (22 lb ft) for the vehicle equipped with
the 4.3L engines.
o Tighten the outlet hose to 25 N-m (18 lb ft).
8. Install the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement in
Engine Controls 2.2L.
9. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
o
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .
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2. Rotate the stub shaft back and forth in order to drain the power steering fluid.
3. Remove the coupling shield retainer and the lock nut from the steering gear
housing using the J 43435 and a torque wrench.
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Turn the adjuster nut assembly (1) clockwise using the J 42882 until the adjuster
nut assembly (1) and the thrust support assembly (2) are firmly bottomed in the
steering gear housing (3).
Tighten
Tighten the adjuster nut assembly (1) to 2831 N-m (2023 lb ft).
5. Place an index mark (1) on the steering gear housing (4) parallel with one of the
holes (3) in the adjuster nut assembly (2).
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8. Using the J 42882 and a torque wrench, turn the adjuster nut assembly (1)
counterclockwise 1525 degrees in order to align the hole (2) in the adjuster nut
assembly (1) with the second mark (4) on the steering gear housing (3).
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Tighten
Tighten the coupling shield retainer and the lock nut (2) to 109 N-m (80 lb ft).
12. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
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7. Use the following procedure in order to ensure that the gear is properly centered:
o Ensure that the flat on the stub shaft is facing upward.
o Ensure that the flat of the stub shaft is parallel with the side cover.
o Ensure that the master spline on the pitman shaft is aligned with the
adjuster screw.
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12. Ensure that the recorded preload is within the range of 0.70.17 N-m (6
15 lb in) with the worm and ballnut installed. If the torque is outside this range,
the gear assembly should be readjusted or repaired as necessary.
13. Adjust the over-center torque by turning the pitman shaft adjuster screw
clockwise until the correct preload torque is obtained.
14. Add 0.71.1 N-m (610 lb in) torque to the previously measured worm bearing
preload torque.
15. Prevent the adjuster screw from turning while tightening the adjuster lock nut.
Tighten
Tighten the adjuster lock nut to 49 N-m (36 lb ft).
16. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
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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Installation Procedure
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1. Screw the pitman shaft (4) to the side cover (8) until the shaft fully seats to the
side cover (8).
2. Install the adjuster lock nut (1). Do not tighten the adjuster lock nut (1) until the
pitman shaft adjustment is completed.
3. Install the gasket (3) to the side cover (8).
4. Bend the gasket tabs around the edges of the side cover (8).
5. Install the pitman shaft assembly (4) and the side cover (8) to the steering gear
housing (7).
6. Install the bolts (2).
Tighten
Tighten the bolts (2) to 60 N-m (45 lb ft).
7. Refer to Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off
Vehicle in order to adjust the pitman shaft (4).
8. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System orSteering Gear Replacement in Power Steering System .
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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3. Insert a punch into the housing access hole (1) in order to unseat the retaining
ring (3).
4. Remove the plug (3).
5. Remove the O-ring seal (3).
Installation Procedure
1. Lubricate the O-ring seal (5) with the power steering fluid.
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5. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
1. Remove the steering gear from the vehicle. Steering Gear Replacement in Power
Steering System or Steering Gear Replacement in Power Steering System .
Removal Procedure
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5. If the valve assembly needs repair, disassemble the valve in the following
manner:
1. Simultaneously pull and rotate the valve spool (5) from the valve
body (1).
2. Remove the valve spool O-ring seal (4).
3. Alternately remove the valve body Teflon rings (2) and the O-ring
seals (3).
Installation Procedure
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2. Lubricate the valve spool (5) and O-ring seal (4) using power steering
fluid.
3. Simultaneously push and rotate the valve spool (5) into the valve
body (1) until the hole in the valve spool for the stub shaft pin is
accessible from the opposite end of the valve body (1).
2. If necessary, install the stub shaft to the valve spool in the following manner:
1. Insert the stub shaft (3) into the valve spool.
2. Insert the pin.
3. Ensure that the notch in the stub shaft cap (1) fully engages the valve
body pin (2). Seat the stub shaft cap against the valve body shoulder.
4. Alternately install the O-ring seals and the Teflon rings to the valve
body.
5. Lubricate the O-ring seals and the Teflon rings using power steering
fluid.
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3. Install the stub shaft (7) and valve assembly (6) to the worm shaft (5). Ensure
the pin fits in the worm shaft to the slot in the valve assembly.
4. Install the thrust support assembly. Refer to Steering Gear Worm Gear Adjuster
Seal and Stub Shaft Bearing Replacement in Power Steering System .
5. Refer to Steering Gear Worm Gear Thrust Bearing Preload Adjustment - Off
Vehicle in order to adjust the thrust bearing preload.
6. Refer to Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off
Vehicle in order to adjust the pitman shaft over-center sector.
7. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
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2. Remove the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft
and Housing Cover Replacement - Off Vehicle in Power Steering System .
3. Remove the housing end plug (1). Refer to Steering Gear Housing Plug
Replacement - Off Vehicle in Power Steering System .
4. Turn the stub shaft counterclockwise until the rack piston (2) begins to come out
of the steering gear housing.
5. Remove the rack piston plug (1).
6. Insert the J 21552 into the bore of the rack piston (2).
7. Hold the J 21552 tightly against the worm shaft while turning the stub shaft
counterclockwise. Turning the stub shaft forces the race piston (2) onto the J
21552 . The rack piston balls remain in place.
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Installation Procedure
Tools Required
8. Remove the following items as an assembly from the steering gear housing (9):
o The rack piston (4)
o The rack piston balls (5)
o J 21552
9. Remove the valve. Refer to Steering Gear Valve Replacement - Off Vehicle in
Power Steering System .
10. Remove the worm shaft (14).
11. Remove the thrust bearing (12) and the flat races (11,13).
12. Remove the flat races (11).
13. Remove the J 21552 from the rack piston (4).
14. Remove the rack piston balls (5).
15. Remove the following items from the rack piston (4):
1. The screws (8)
2. The clamp (7)
3. The ball guide (6)
16. Remove the Teflon ring (2).
17. Remove the O-ring seal (3).
18. Clean all of the disassembled parts.
19. Inspect all of the disassembled parts for wear.
20. Replace the parts if necessary.
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3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear
housing (9).
Important: Reinstall all of the rack piston balls in the rack piston. Improper
rack piston ball installation may result in personal injury.
Fully seat the worm shaft to the rack piston.
4. Align the worm shaft spiral groove with the rack piston ball return guide
hole (1).
5. Lubricate the rack piston balls with power steering fluid.
Important: The black rack piston balls are smaller than the silver rack piston
balls. Install the black and the silver rack piston balls alternately into the rack
piston and the ball guide in order to maintain the rack piston to the worm shaft
preload.
6. Insert the rack piston balls through the ball return guide hole (1) while turning
worm shaft (2) counterclockwise in order to install the rack piston balls into the
rack piston.
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7. Install the remaining rack piston balls (3) into the ball guide (1) using grease at
each end (2) in order to retain the rack piston balls (3).
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
10. Install the screws (7).
Tighten
Tighten the screws (7) to 58 N-m (43 lb in).
11. Insert the J 21552 into the bore of the rack piston while turning the worm shaft
counterclockwise. The turning of the worm shaft forces the rack piston onto the
J 21552 . The rack piston balls remain in place.
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13. Install the worm shaft (4) to the steering gear housing (3).
14. Install the valve. Refer to Steering Gear Valve Replacement - Off Vehicle in
Power Steering System .
15. Install the rack piston (2) to the worm (4) from the J 21552 using the J 8947 in
order to compress the seals.
Important: Reinstall all of the rack piston balls into the rack piston. Improper
rack piston ball installation may result in personal injury.
16. Hold the J 21552 tightly against the worm shaft (4).
17. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm
shaft (4).
18. Install the rack piston plug.
Tighten
Tighten the rack piston plug to 150 N-m (111 lb ft).
19. Install the housing end plug (1). Refer to Steering Gear Housing Plug
Replacement - Off Vehicle in Power Steering System .
20. Install the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft and
Housing Cover Replacement - Off Vehicle in Power Steering System .
21. Adjust the steering gear. Refer to Steering Gear Adjustments in Power Steering
System .
22. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle
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Removal Procedure
Tools Required
J 6278 Pitman Shaft Bearing Remover and Installer
J 4245 Internal Snap Ring Pliers
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .
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15. Insert the J 6278 through the hole in the top of the steering gear housing (1).
16. Drive out the needle bearing (2).
Installation Procedure
Tools Required
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2. Install the needle bearing (2) to the steering gear housing (1) using the J 6278 .
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Installation Procedure
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .
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1. Install the check valve (1) using a 3/8 inch diameter piece of tubing 100 mm
(4 in) long in order to drive into the steering gear housing (2).
2. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .
Steering Gear Worm Gear Adjuster Seal and Stub Shaft Bearing
Replacement
Document ID: 598990
Removal Procedure
Tools Required
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1. Rotate the stub shaft back and forth in order to drain the power steering fluid.
2. Remove the coupling shield retainer and the lock nut from the steering gear
housing using the J 43435 and a torque wrench.
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4. Remove the thrust support assembly (2) from the steering gear housing (1).
5. Remove the O-ring seal (3) from the thrust support assembly (2).
Installation Procedure
Tools Required
J 42882 Adjuster Nut Socket
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4. Connect the adjuster nut assembly (2) to the steering gear housing (1) using the J
42882 .
5. Install the coupling shield retainer and the lock nut (1) to the adjuster nut
assembly.
6. Adjust the worm thrust bearing preload. Refer to Steering Gear Worm Gear
Thrust Bearing Preload Adjustment - Off Vehicle in Power Steering System .
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Tighten
Tighten the coupling shield retainer and the lock nut (2) to 109 N-m (80 lb ft).
10. Adjust the pitman shaft over-center preload. Refer to Steering Gear Pitman Shaft
Over-Center Preload Adjustment - Off Vehicle in Power Steering System .
9. Tighten the coupling shield retainer and the lock nut using the J 43435 and a
torque wrench.
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Installation Procedure
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1.
2.
3.
4.
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Tools Required
J 39400-A Halogen Leak Detector
Removal Procedure
1. Disconnect the underhood lamp electrical connector, if equipped.
2. Remove the hood. Refer toHood Replacement in Body Front End Hood
Replacement in Body End.
3. Remove the PCM. Refer to the appropriate procedure:
o Powertrain Control Module Replacement/Programming in Engine
Controls-2.2L.
o VCM Replacement/Programming in Engine Controls-4.3L.
4. Remove the coolant recovery tank. Refer toCoolant Recovery Reservoir
Replacement in Engine Cooling.
5. Disconnect the electrical connectors from the grille mounted lamps, if equipped.
6. Remove the right front headlamp assembly. Refer toHeadlamp Replacement in
Lighting Systems.
7. Remove the front bumper. Refer toFront Bumper Impact Bar Replacement in
Bumpers.
8. Remove the right wheelhouse panel. Refer toWheelhouse Panel Replacement in
Body Front End.
9. Disconnect the radio antenna cable.
10. Disconnect the electrical connector for the horn.
11. Remove the right fender. Refer toFront Fender Replacement in Body Front End.
12. Remove the blower motor resistor. Refer toBlower Motor Resistor Replacement
in Heating, Ventilation and Air Conditioning .
13. Remove the accumulator. Refer toAir Conditioning Accumulator Replacement
in HVAC Systems - Manual .
14. Remove the evaporator tube. Refer toEvaporator Tube Replacement in HVAC
Systems - Manual .
15. Remove the evaporator and blower module heat shield mounting screws.
16. Remove the evaporator and blower module heat shield.
Important: Retain the evaporator and blower module heat shield mounting
bracket for installation.
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17. Remove the evaporator and blower module mounting bolts and nuts.
18. Remove the evaporator and blower module from the vehicle.
19. Remove the 6 retaining screws holding the evaporator case section to the blower
case section.
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23. Remove the expansion (orifice) tube (2) from the evaporator (1).
Installation Procedure
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6. Important: Install the evaporator and blower module heat shield mounting
bracket with the evaporator and blower module mounting nuts.
Install the evaporator and blower module mounting fasteners.
Tighten
Tighten the bolts to 4.5 N-m (40 lb in).
7. Install the evaporator and blower module heat shield.
8. Install the evaporator and blower module heat shield mounting screws.
Tighten
Tighten the screws to 2.2 N-m (19 lb in).
9. Install the evaporator tube. Refer toEvaporator Tube Replacement in HVAC
Systems - Manual .
10. Install the accumulator. Refer toAir Conditioning Accumulator Replacement in
HVAC Systems - Manual .
11. Install the blower motor resistor. Refer to Blower Motor Resistor Replacement
in Heating, Ventilation and Air Conditioning .
12. Install the right fender. Refer to Front Fender Replacement in Body Front End.
13. Connect the electrical connector for the horn.
14. Install the radio antenna cable.
15. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in
Body Front End.
16. Install the front bumper. Refer to Front Bumper Impact Bar Replacement in
Body Front End.
17. Install the right front headlamp assembly. Refer to Headlamp Replacement in
Lighting Systems.
18. Connect the electrical connectors to the grille mounted lamps.
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19. Install the coolant recovery tank. Refer to Coolant Recovery Reservoir
Replacement in Engine Cooling.
20. Install the PCM. Refer to the appropriate procedure:
o Powertrain Control Module Replacement/Programming in Engine
Controls - 2.2L
o VCM Replacement/Programming in Engine Controls - 4.3L
21. Install the hood. Refer to Hood Replacement in Body Front End in Body Front
End.
22. Connect the underhood lamp electrical connector.
23. Evacuate and recharge the A/C system. Refer toRefrigerant Recovery and
Recharging in HVAC Systems - Manual
24. Leak test the fittings components using the J 39400-A
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4. Depress the retaining clip in order to remove the vacuum connectors from the
mode valve.
Installation Procedure
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3. 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.
Disconnect the battery negative cable.
4. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
5. Remove the right instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and
Console .
6. If the vehicle is equipped with a multiple CD changer located in the center
console, remove the center console. Refer to Front Floor Console Replacement
in Instrument Panel, Gauges, and Console .
7. Remove the center sound insulator. Refer to Closeout/Insulator Panel
Replacement - Center in Instrument Panel, Gauges, and Console .
8. Remove the lower left instrument panel mounting bolt.
9. Remove and retain the instrument panel storage compartment. Refer to
Instrument Panel Compartment Door Replacement in Instrument Panel, Gauges,
and Console .
10. Remove the lower right instrument panel mounting bolt.
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11. Remove and retain the left and right speakers and the speaker grilles. Refer to
Radio Front Speaker Replacement in Entertainment.
12. Use a flat-bladed tool in order to remove the windshield defroster grille. Retain
the grille and sunload sensor for use on the next IP carrier.
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17. Remove and retain the instrument cluster. Refer to Instrument Cluster
Replacement in Instrument Panel, Gauges, and Console .
18. Remove and retain the radio. Refer to Radio Replacement in Entertainment.
19. Remove the HVAC control assembly. Refer to the appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic
o
o
o
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23. Important: Label all of the connections in order to avoid improper installation.
Remove the top instrument panel screws.
24. Roll the instrument panel down.
25. Disconnect the electrical connections, as needed.
26. Remove the fastener that retains the radio antenna cable to the instrument panel.
27. Remove the instrument panel from the vehicle.
If replacing the instrument panel carrier, retain the parts for assembly of the new
instrument panel carrier.
Installation Procedure
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Tighten
Tighten the fastener to 1.9 N-m (17 lb in).
4. Connect the electrical connectors, as needed.
5. Roll the instrument panel up.
6. Install the top instrument panel screws.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).
3. Install the fastener that retains the radio antenna cable to the instrument panel.
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9. Enable the passenger side SIR system. Refer to Enabling the SIR System in SIR.
10. Install the HVAC control assembly to the instrument panel. Refer to the
appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic
11. Install the radio. Refer to Radio Replacement in Entertainment.
12. Install the instrument cluster. Refer to Instrument Cluster Replacement in
Instrument Panel, Gauges, and Console .
13. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel,
Gauges, and Console .
14. Connect the purple electrical connection to the body control module (BCM).
15. Connect the brown electrical connection to the body control module (BCM).
16. If equipped with a sun load temperature sensor, install the sensor to the defroster
grille by twisting the sensor turn clockwise.
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17. Install the windshield defroster grille by pressing carefully pressing the grille
into place.
18. Install the left and right speakers and the speaker grilles. Refer to Radio Front
Speaker Replacement in Entertainment.
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Tighten
Tighten the bolt to 11.5 N-m (102 lb in).
22. Install the center sound insulator. Refer toCloseout/Insulator Panel Replacement
- Center in Instrument Panel, Gauges, and Console .
23. Install the right sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges, and Console .
24. If the center console was removed, install the console to the vehicle. Refer to
Front Floor Console Replacement in Instrument Panel, Gauges, and Console .
25. Install the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
26. Connect the battery negative cable.
27. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Turn the ignition switch to the RUN position.
2. Depress the brake pedal and shift the transmission into the PARK
position.
3. Release the park brake.
28. On vehicles equipped with a manual transmission, install the shift lever.
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3. Disconnect the vacuum harness connectors from the vacuum electrical control
solenoid.
Installation Procedure
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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.
2. Install the vacuum electrical control solenoid retaining screws.
Tighten
Tighten the vacuum electrical control solenoid retaining screws to 1.9 N-m
(17 lb in).
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3. Disconnect the inside air temperature sensor from the door header panel to gain
access to the dome lamp wiring harness connection.
4. Remove the dome lamp wiring harness connection from the inside air
temperature sensor.
5. Remove the inside air temperature sensor from the vehicle.
Installation Procedure
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Installation Procedure
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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.
4. Install the rear seat upper seat belt anchor bolts (two-door models only).
Tighten
Tighten the bolts to 70 N-m (52 lb ft).
5. Install the body lock pillar trim panels (four-door models only).
6. Install the windshield garnish moldings. Refer to Windshield Pillar Garnish
Molding Replacement in Interior Trim .
7. Install the sunshades and the retainers. Refer to Sunshade Replacement in
Interior Trim .
8. Install the assist handles. Refer to Assist Handle Replacement in Interior Trim .
9. Install the coat hooks. Refer to Coat Hook Replacement in Interior Trim .
10. Install the sunroof opening trim (if equipped). Refer to Sunroof Replacement in
Roof.
11. Install the dome lamp (if equipped). Refer to Dome Lamp Replacement in
Lighting Systems .
12. Install the overhead or sunroof console (if equipped). Refer to Driver
Information Center Replacement in Instrument Panel, Gauges, and Console on
Instrument Panel, Gauges and Console.
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3. Remove the screws that retain the instrument panel accessory trim plate to the
instrument panel.
4. Remove the instrument panel accessory trim plate.
5. Disconnect the electrical connectors, as needed.
6. Remove and retain the control switches.
Installation Procedure
1. Install the control switches.
2. Connect the electrical connectors, as needed.
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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.
4. Install the screws that retain the instrument panel accessory trim plate to the
instrument panel.
Tighten
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3. Disconnect the electrical connector from the inside air temperature sensor.
4. Remove the inside air temperature sensor from the vehicle.
Installation Procedure
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1. To EVAP Canister
2. Positive Crankcase Ventilation (PCV)
3. To HVAC (When Used)
4. Throttle Body
5. Manifold Absolute Pressure (MAP) Sensor
6. Crankcase Vent (To Fresh Air)
7. EVAP Canister Purge Solenoid Valve
8. EVAP Service Port
9. EVAP Canister Purge Hose
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1. Crankshaft
2. Front Engine Cover
3. Crankshaft Position (CKP) Sensor
Bulletins
General Information
o
Cautions and Notices
o
General Information
o
Maintenance and Lubrication
o
Vibration Diagnosis and Correction
Specifications
Diagnostic Information and Procedures
Repair Instructions
General Service Precautions
Correcting Tire and Wheel Vibration
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HVAC
o
o
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Steering
o
Power Steering System
Specifications
Visual Identification
Diagnostic Information and Procedures
Repair Instructions
Power Steering Pump Replacement - 2.2L
Power Steering Pump Replacement - 4.3L
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o
o
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Automatic Transmission Shift Lock Control Assemble Off Vehicle - Column Shift
Turn Signal Cancel Cam and Upper Bearing Inner Race Disassemble - Off Vehicle - Column Shift
Turn Signal Cancel Cam and Upper Bearing Inner Race Disassemble - Off Vehicle - Floor Shift
Turn Signal Cancel Cam and Upper Bearing Inner Race Assemble - Off Vehicle - Column Shift
Turn Signal Cancel Cam and Upper Bearing Inner Race Assemble - Off Vehicle - Floor Shift
Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Column Shift
Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Floor Shift
Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Column Shift
Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Floor Shift
Steering Column Accident Damage Inspection - Off
Vehicle
Description and Operation
Special Tools and Equipment
Suspension
o
Suspension General Diagnosis
o
Wheel Alignment
o
Front Suspension
o
Rear Suspension
o
Tires and Wheels
o
Automatic Level Control
Driveline/Axle
o
Propeller Shaft
Specifications
Visual Identification
Diagnostic Information and Procedures
Repair Instructions
Front Propeller Shaft Replacement
One-Piece Propeller Shaft Replacement
Two-Piece Propeller Shaft Replacement
Double Cardan Universal Joints Replacement - Flange
Yoke Replacement
Double Cardan Universal Joints Replacement - Centering
Ball Replacement
Double Cardan Universal Joints Replacement - Ball Seat
Assembly
Center Bearing Replacement
Universal Joint Replacement - Nylon Injected Ring
Universal Joint Replacement - External Snap Ring
Description and Operation
Special Tools and Equipment
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Wheel Drive Shafts
Specifications
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Visual Identification
Diagnostic Information and Procedures
Repair Instructions
Wheel Drive Shaft Replacement
Wheel Drive Shaft Inner Joint and Boot Replacement
Wheel Drive Shaft Outer Joint and Boot Replacement
Special Tools and Equipment
Front Drive Axle
Specifications
Component Locator
Diagnostic Information and Procedures
Repair Instructions
Axle Lubricant Change
Shield Replacement
Four-Wheel Drive Indicator Switch Replacement
Vacuum Actuator Solenoid Valve Replacement
Vent Hose Replacement
Clutch Cable Replacement - Front Drive Axle
Clutch Cable Housing Replacement - Front Drive Axle
Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement - S4WD
Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement - A4WD
Front Drive Axle Clutch Fork Replacement
Front Drive Axle Clutch Fork Inspection
Front Drive Axle Clutch Shaft Bearing Replacement
Front Drive Axle Inner Shaft Seal and Inner Shaft
Bearing Replacement
Front Drive Axle Actuator Replacement
Front Differential Drive Pinion Flange/Yoke, Seal, and
Dust Deflector Replacement
Differential Carrier Assembly Bushing Replacement
Differential Carrier Assembly Replacement
Differential Carrier Assembly Disassemble - S4WD
Differential Carrier Assembly Disassemble - A4WD
Thrust Washers, Shims, and Adjuster Sleeves Inspection
Front Differential Case Disassemble
Differential Case Bearings Inspection
Differential Case and Gears Inspection
Pinion and Ring Gear Inspection
Front Differential Drive Pinion Gear Bearing Cup
Installation
Pinion Depth Adjustment
Front Differential Case Assemble
Differential Carrier Assembly Assemble
Backlash Inspection and Adjustment
Differential Carrier Assembly Final Assembly
Gear Tooth Contact Pattern Inspection
Description and Operation
Special Tools and Equipment
Rear Drive Axle
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Brakes
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Hydraulic Brakes
Specifications
Schematic and Routing Diagrams
Component Locator
Repair Instructions
Master Cylinder Reservoir Filling
Master Cylinder Replacement
Master Cylinder Overhaul
Master Cylinder Bench Bleeding
Brake Pedal Replacement
Combination Valve Replacement
Brake Pipe Replacement
Front Brake Hose Replacement - Dual Piston Caliper
Front Brake Hose Replacement - Single Piston Caliper
Rear Brake Hose Replacement
Hydraulic Brake System Bleeding
Hydraulic Brake System Flushing
Power Vacuum Brake Booster Replacement
Power Brake Booster Vacuum Hose Replacement
Stop Lamp Switch Replacement
Diagnostic Information and Procedures
Description and Operation
Special Tools and Equipment
Disc Brakes
Specifications
Diagnostic Information and Procedures
Repair Instructions
Brake Pad Inspection
Front Disc Brake Pads Replacement - Single Piston
Caliper
Front Disc Brake Pads Replacement - Dual Piston
Caliper
Rear Disc Brake Pads Replacement
Brake Pad and Rotor Burnishing
Brake Caliper Replacement - Front-Single Piston
Brake Caliper Replacement - Rear
Brake Caliper Replacement - Front-Dual Piston
Brake Caliper Inspection
Front Brake Caliper Overhaul - Single Piston
Front Brake Caliper Overhaul - Dual Piston
Rear Brake Caliper Overhaul
Brake Caliper Bracket Replacement - Rear
Brake Rotor Replacement - Front Wheel
Brake Rotor Replacement - Rear Wheel
Brake Rotor Refinishing
Description and Operation
Special Tools and Equipment
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Drum Brakes
Specifications
Repair Instructions
Brake Drum Inspection
Brake Drum Refinishing
Brake Shoe Replacement
Brake Shoe Inspection
Brake Backing Plate Replacement
Wheel Cylinder Replacement
Wheel Cylinder Overhaul
Drum Brake Adjustment
Description and Operation
Park Brake
Specifications
Fastener Tightening Specifications
GM SPO Group Numbers
Repair Instructions
Parking Brake Shoe Replacement
Parking Brake Shoe Adjustment
Park Brake Lubrication
Parking Brake Lever Replacement
Parking Brake Cable Replacement - Rear Cables for
RWD
Parking Brake Cable Replacement - Rear Cables for
4WD, Utilities
Parking Brake Cable Replacement - Front Cables
Parking Brake Cable Inspection
Park Brake Cable Service/Adjustment
Description and Operation
Antilock Brake System
Specifications
Schematic and Routing Diagrams
Component Locator
ABS Components
Antilock Brake System Component Views
Antilock Brake System Connector End Views
Diagnostic Information and Procedures
Self-Diagnostics
Displaying Diagnostic Trouble Codes (DTC)
Clearing DTCs
Intermittents and Poor Connections
Scan Tool Diagnostics
Diagnostic System Check
Diagnostic Trouble Code (DTC) List
DTC C0221 or C021 RF Wheel Speed Sensor Circuit
Open
DTC C0222 or C022 RF Wheel Speed Signal Missing
DTC C0223 or C023 RF Wheel Speed Signal Erratic
DTC C0225 or C025 LF Wheel Speed Sensor Circuit
Open
DTC C0226 or C026 LF Wheel Speed Signal Missing
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Engine
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{"DhtmlHistory_pageLoaded":tru
Reference on Schematic
Automatic Transmission Cell 21
Automatic Transmission Control Assembly Cell
138
Body Control Module (BCM) Cell 51
Camshaft Position Sensor Cell 21
Cigar Lighter Cell 19
Compass/Temperature Console Cell 86
Cruise Control Module Cell 34
Data Link Connector Cell 50
Driver Information Display Module Cell 86
Electronic Brake Control Module Cell 44
Engine Controls Cell 21
Engine Oil Pressure Guage Sensor Cell 21
Exhaust Gas Recirculation Valve Cell 21
Exterior Lights Cell 110
Front Axle Switch Cell 38
Fuel Level Sensor Cell 21
Fuel Pump Relay Cell 21
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Icon
Icon Definition
Notice: Electrostatic discharge (ESD) can damage many
solid-state electrical components. ESD susceptible
components may or may not be labeled with the ESD
symbol. Handle all electrical components carefully. Use
the following precautions in order to avoid ESD damage:
8 - Wiring Systems
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Name
Location
A/C Compressor
Clutch Diode (4.3
L Engine)
A/C Compressor
Clutch Relay (4.3L
Engine)
Locator View
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
HVAC Component
Views in HVAC
Systems with A/C
- Manual
Connector End
View
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
HVAC Connector
End Views in
HVAC Systems
with A/C - Manual
In engine harness
HVAC Component HVAC Connector
breakout, 7.5 cm from
Views in HVAC
End Views in
the breakout to the
Systems with A/C HVAC Systems
A/C Compressor and
- Manual
with A/C - Manual
high pressure switch
In the Underhood
Power and
Grounding
Bussed Electrical
Component Views
Center
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A/C Compressor
High Pressure Rear of A/C
Cutoff Switch Compressor
(4.3L Engine)
A/C Compressor
Cycling Switch At the Accumulator
(4.3L Engine)
Body Control
Module (BCM)
Connector C1,
Brown (24
Cavities)
Lower rear of IP on
the heater assembly
Body Control
Module (BCM) Lower rear of IP on
Connector C2, Blue the heater assembly
(24 Cavities)
Power and
Grounding
Component Views
in Wiring Systems
Engine Controls
Component Views
in Engine Controls
- 4.3L
Central Sequential
Engine Controls
Fuel Injection Top center of engine, Component Views
(CSFI) Connector forward of distributor in Engine Controls
(4.3L Engine)
- 4.3L
Engine Controls
Crankshaft Position Below RH front of
Component Views
(CKP) Sensor engine near harmonic
in Engine Controls
(4.3L Engine) balancer
- 4.3L
Camshaft Position
(CMP) Sensor Rear of Distributor
(4.3L Engine)
Cruise Control
Module
Cruise Control
LH rear of engine
Component Views
compartment on cowl
in Cruise Control
Antilock Brake
System
HVAC Connector
End Views in
HVAC Systems
with A/C - Manual
HVAC Connector
End Views in
HVAC Systems
with A/C - Manual
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Body Control
System Connector
End Views in
Body Control
System
Body Control
System Connector
End Views in
Body Control
System
Power and
Grounding
Connector End
Views in Wiring
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Cruise Control
Connector End
Views in Cruise
Control
Antilock Brake
System Connector
Automatic
Transmission Fluid
Inside the automatic
Pressure (TFP)
transmission
Manual Valve
Position Switch
in Wiring Systems
HVAC Component
Views in HVAC
Systems with A/C
- Manual
HVAC Component
Views in HVAC
Systems with A/C
- Manual
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Body Control
System
Component Views
in Body Control
System
Body Control
System
Component Views
in Body Control
System
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(EBCM)
(BPMV), LH rear
wheelwell
Component Views
in ABS/Traction
Control
End Views in
ABS/Traction
Control
Body harness
Antilock Brake
Antilock Brake
Electronic Brake connector on LH of
System
System Connector
Control Module Electronic Brake
Component Views
End Views in
(EBCM) Connector Control Module/Brake
in ABS/Traction
ABS/Traction
C1 (10 Cavities) Pressure Modulator
Control
Control
Valve
Body harness
Antilock Brake
Antilock Brake
Electronic Brake connector on LH of
System
System Connector
Control Module Electronic Brake
Component Views
End Views in
(EBCM) Connector Control Module/Brake
in ABS/Traction
ABS/Traction
C2 (2 Cavities) Pressure Modulator
Control
Control
Valve
HVAC Connector
Electronic Climate
HVAC Component
End Views in
Control (ECC) Center of Instrument
Views in HVAC
HVAC Systems
Module (W/ Auto Panel, below radio
Systems with A/C
with A/C A/C)
- Automatic
Automatic
Engine Coolant
Engine Controls
Engine Controls
Temperature (ECT) Front of engine near
Component Views Connector End
thermostat housing
Sensor (4.3L
in Engine Controls Views in Engine
- 4.3L
Engine)
Controls - 4.3L
Engine Oil
Engine Controls
Engine Controls
Top
rear
of
engine
Pressure Gauge
Component Views Connector End
below distributor
Sensor (4.3L
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Evaporative
Engine Controls
Engine Controls
(EVAP) Emission Top RH center of
Component Views Connector End
Canister Purge engine, near fuel
in Engine Controls Views in Engine
injector connector
Valve (4.3L
- 4.3L
Controls - 4.3L
Engine)
Engine Controls
Crossmember area of
Evaporative
fuel tank, to the rear
Connector End
Emission Canister
LH center of
Views in Engine
Vent Valve
crossmember
Controls - 4.3L
Exhaust Gas
Engine Controls
Engine Controls
Top front of engine
Recirculation
Component Views Connector End
near drive belt
Valve (4.3L
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Transfer Case
Transfer Case
Front axle, right of
Control
Control Connector
Front Axle Switch
differential
Component Views
End Views in
in Transfer Case
Transfer Case
Engine Controls
Engine Controls
Fuel Pump and Internal to the fuel
Component Views Connector End
Sender
tank
in Engine Controls Views in Engine
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- 4.3L
Controls - 4.3L
Power and
In the Underhood Fuse
Grounding
Fuel Pump Relay
Block
Component Views
in Wiring Systems
Engine Controls
Engine Controls
Fuel Tank Pressure Top of fuel tank, three Component Views Connector End
Sensor
wire connector
in Engine Controls Views in Engine
- 4.3L
Controls - 4.3L
Engine Controls
Engine Controls
Generator (4.3L
Component Views Connector End
RH front of engine
Engine)
in Engine Controls Views in Engine
Controls - 4.3L
- 4.3L
Heated Oxygen On the rear of the LH
Engine Controls
Sensor (HO2S) exhaust pipe on the
Component Views
in Engine Controls
Bank 1 Sensor 3
exhaust pipe
(4.3L Engine)
- 4.3L
Heated Oxygen
Engine Controls
Sensor (HO2S) RH rear of engine, in Component Views
in Engine Controls
Bank 2 Sensor 1 exhaust pipe
- 4.3L
(4.3L Engine)
Heater And A/C
HVAC Component HVAC Connector
Controller (W/
Bottom center
Views in HVAC
End Views in
Manual A/C)
Systems with A/C HVAC Systems
Connector C1 (10 connector
- Manual
with A/C - Manual
Cavities) (Heater
Control Lamp)
Heater And A/C
HVAC Component HVAC Connector
Controller (W/
Next to the vacuum
Views in HVAC
End Views in
Manual A/C)
Systems with A/C HVAC Systems
Connector C2 (3 harness connector
- Manual
with A/C - Manual
Cavities) (Heater
Control Lamp)
Engine Controls
Engine Controls
Idle Air Control
Top of the engine, on Component Views Connector End
(IAC) Valve (4.3L
the throttle body
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Engine Controls
Engine Controls
Ignition Coil (4.3L
Component Views Connector End
Top RH side of engine
Engine)
in Engine Controls Views in Engine
- 4.3L
Controls - 4.3L
Ignition Control
Engine Controls
Engine Controls
Module (ICM) Top RH side of engine Component Views Connector End
in Engine Controls Views in Engine
(4.3L Engine)
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IP Fuse Block
Power and
LH of the IP, near the
Grounding
door jamb switch, LF Component Views
in Wiring Systems
Engine Controls
Component Views
in Engine Controls
- 4.3L
Manifold Absolute
Engine Controls
Pressure (MAP)
Component Views
Top center of engine
in Engine Controls
Sensor (4.3L
- 4.3L
Engine)
Engine Controls
LH front of engine
Mass Air Flow
Component Views
compartment on air
(MAF) Sensor
in Engine Controls
intake duct
- 4.3L
Park/Neutral
Engine Controls
Position (PNP)
Component Views
LH of the transmission
Switch, Connector
in Engine Controls
C1 (7 Cavities)
- 4.3L
Park/Neutral
Engine Controls
Position (PNP)
Component Views
LH of the transmission
Switch, Connector
in Engine Controls
C2 (4 Cavities)
- 4.3L
Automatic
Transmission
Pressure Control
Inside the automatic
Electronic
Solenoid (PC SOL)
transmission
Component Views
Valve
in Automatic
Transmission
Radio (Except
Entertainment
Center of the
Bravada)
Component Views
Connector C1, (10 Instrument Panel
in Entertainment
Cavities)
Radio (Except LH rear of radio
Entertainment
Top rear of engine
Knock Sensor (KS)
above transmission
(4.3L Engine)
bell housing
Controls - 4.3L
Instrument Panel,
Gages, and
Console Connector
End Views in
Instrument Panel,
Gauges, and
Console
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Power and
Grounding
Connector End
Views in Wiring
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Entertainment
Connector End
Views in
Entertainment
Entertainment
- 4.3L
Instrument Panel,
Gages, and
Console
In the IP, ahead of the
Instrument Cluster
Component Views
steering column
in Instrument
Panel, Gauges, and
Console
Intake Air
Engine Controls
LH front of engine
Temperature (IAT)
Component Views
compartment in air
Sensor (4.3L
in Engine Controls
intake duct
Engine)
- 4.3L
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Bravada)
Connector C2 (10
Cavities)
Component Views
in Entertainment
Lighting Systems
Component Views
in Lighting
Systems
Engine Controls
Throttle Position Top LH side of
Component Views
(TP) Sensor (4.3L engine, on the throttle
in Engine Controls
Engine)
body
- 4.3L
Automatic
Torque Converter
Transmission
Clutch Pulse Width
Inside the automatic
Electronic
Modulation
transmission
Component Views
Solenoid (TCC
in Automatic
PWM SOL) Valve
Transmission
Automatic
Transmission
Torque Converter
Inside the automatic
Electronic
Clutch Solenoid
transmission
Component Views
(TCC SOL) Valve
in Automatic
Transmission
Transfer Case
Transfer Case Shift
Control
Control Module Behind Center of
Component Views
Connector C1 (32 Instrument Panel
in Transfer Case Cavities)
NV136
Transfer Case
Transfer Case Shift
Control
Control Module
Lower Connector
Component Views
Connector C2 (4
in Transfer Case Cavities)
NV136
Transfer Case
Transfer Case
Front center of
Select Switch (w/
Control
instrument panel
Push Button
Component Views
above and to the left of
Control) Connector
in Transfer Case the radio
C1 (8 Cavities)
NV233
Transfer Case
Transfer Case
Front center of
Select Switch (W/
Control
instrument panel
Electric Shift
Component Views
above and to the left of
4WD) Connector
in Transfer Case the radio
C2 (4 Cavities)
NV233
Transmission Fluid
Inside the automatic
Temperature (TFT)
transmission
Sensor
Underhood Fuse Over left front fender
Power and
Block
well
Grounding
TCC/Stop Lamp Mounted on brake
Switch
pedal
Connector End
Views in
Entertainment
Lighting Systems
Connector End
Views in Lighting
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Transfer Case
Control Connector
End Views in
Transfer Case NV136
Transfer Case
Control Connector
End Views in
Transfer Case NV136
Transfer Case
Control Connector
End Views in
Transfer Case NV233
Transfer Case
Control Connector
End Views in
Transfer Case NV233
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Component Views
in Wiring Systems
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C1 (68 Cavities) Fuse Block
Component Views
(Body)
in Wiring Systems
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C3 (32 Cavities) Fuse Block
Component Views
(Chassis)
in Wiring Systems
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C3 (32 Cavities) Fuse Block
Component Views
(Chassis)
in Wiring Systems
Vehicle Control
Module (VCM)
(4.3L Engine)
RH side of engine
compartment
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C1 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C2 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C3 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C4 (24
Cavities)
Vehicle Speed RH rear of automatic
Sensor (VSS) (4.3L transmission
Engine Controls
Component Views
in Engine Controls
- 4.3L
Engine Controls
Connector End
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C2 (68 Cavities) Fuse Block
Component Views
(Engine)
in Wiring Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
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Engine W/ A/T,
W/O 4WD)
Vehicle Speed
Sensor (VSS) (4.3L LH Rear of the auto
Engine W/ Auto 4WD Transfer Case
4WD) (Bravada)
C100 (Engine
Harness to Oxygen
Sensor Harness)
(4.3L Engine, 6
Cavities)
C101 (Engine
Harness to Body
Harness) (4.3L
Engine, 10
Cavities)
C104 (Chassis to
4.3L Engine
Harness) (6
Cavities)
C105 (Engine
Harness to LH
Front Heated
Oxygen Sensor
Pigtail Connector)
(4.3L Engine) (4
Cavities)
C108 (W/ Active
Transfer Case
Active Transfer
Case extension
harness to Body
Harness) (7
Cavities)
C114 (W/ Electric
Shift 4WD, Body
harness to front
axle switch
extension harness)
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
RH rear of engine
compartment, near the
accumulator
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
RH engine
compartment, near
VCM
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
LH side of
transmission
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
LH rear engine
compartment near
cowl penetration P100
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
LH center of engine
compartment, near the
electronic brake
control module)
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Vehicle Speed
Sensor (VSS) (4.3L To the left rear of the
Engine w/ M/T w/o M/T
Transfer Case)
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
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(2 Cavities)
C116 (M to M) (W/ Near the top rear of
A/T and Transfer the automatic
Case) (2 Cavities) transmission
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Automatic
Transmission
Harness Routing
Inline Harness
Views in Wiring
Connector End
Systems
View in Automatic
Transmission
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
C125 (Oxygen
Sensor Harness to
Post-Converter Chassis harness near
Heated Oxygen the Post-Converter
Sensor Pigtail (Bank 1, Sensor 3)
Connector) (4.3L Heated Oxygen Sensor
Engine) (4
Cavities)
C126 (Oxygen
Sensor Harness to
Chassis harness near
RH Front Heated
the RH Front (Bank 2,
Oxygen Sensor
Sensor 1) Heated
Pigtail Connector)
Oxygen Sensor
(4.3L Engine) (4
Cavities)
C175 (Engine
Harness to
Automatic
RH rear of the
Transmission
automatic transmission
Connector) (4.3L
Engine) (13
Cavities)
C203 (Body
Harness to IP
RH side of dash
Harness) (116
Cavities)
C209 (Pickup Body
Harness to Dome LH front of dash at LH
front side window
Harness) (16
Cavities)
C209 (Utility Body
Harness to Dome LH front of dash at LH
front side window
Harness) (16
Cavities)
G102 (Circuit 350,
LH rear of engine
4.3L Engine
block
Harness)
G103 (Circuit 351, LH rear of engine
4.3L Engine
block
Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
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Harness)
G104 (Circuit 450,
4.3L Engine
Harness)
G105 (Circuit 451,
4.3L Engine
Harness)
RH rear of engine
block
RH rear of engine
block
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
LH rear of engine
G117 (Circuit 850,
compartment, near
Body Harness)
cruise control module
G200 (Circuit LH front of dash
1850, Body
panel, above grommet
Harness)
P100
G201 (Circuit LH front of dash
1850, Body
panel, above grommet
Harness)
P100
G402 (Circuit
Inside rear of LH
1750, Pickup
Frame Rail
Chassis Harness)
Near top center of
G402 (Circuit 22,
second cross-member
1650 Four-Door
from rear, with fuel
Utility Chassis
filler neck ground
Harness)
strap
G402 (Circuit 22, LH rear crossmember
1650 Two-Door near LH frame rail,
Utility Chassis with fuel filler ground
Harness)
strap
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
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Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
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Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
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Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Wire Color
BRN/WHT
TAN
PNK/BLK
PPL
TAN/BLK
WHT
YEL/BLK
PPL/WHT
PPL
12129025
32 Pin VCM Connector C1 (BLU)
Circuit No.
633
1667
632
30
422
687
1827
1665
1666
Function
Not Used
1X CMP Signal
Not Used
HO2S Bank 2 Sensor 1 Low
CMP Sensor Ground
Fuel Level Output
TCC Solenoid Control
Not Used
32 Shift Solenoid Control
Not Used
VSS Output Signal (EBCM)
Not Used
HO2S Bank 1 Sensor 1 Signal
Not Used
HO2S Bank 2 Sensor 1 Signal
area
SP422 (Pickup On the LH frame rail
Chassis W/ 4.3L behind the
Engine, Circuit crossmember at the
470)
transmission
SP423 (Circuit 470,
On front of
1650, 2109 Splice
crossmember near LH
Pack, Chassis
frame rail, near
Harness) (Fourcanister vent valve
Door Utility)
SP423 (Circuit 470,
1650, 2109 Splice
On top of rear
Pack, Chassis
crossmember
Harness) (TwoDoor Utility)
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PPL/WHT
TAN/WHT
TAN/WHT
PPL
LT GRN/BLK
PPL/WHT
YEL
1668
1653
1669
574
822
821
573
Wire Color
WHT
YEL/BLK
LT GRN
BRN
BLK
YEL/BLK
BRN
LT GRN/WHT
LT BLU/WHT
LT GRN/BLK
PNK/BLK
DK BLU
12129025
32 Pin VCM Connector C2 (RED)
Circuit No.
1310
1223
1222
418
1744
846
1456
1749
1747
1745
1746
496
Function
Not Used
EVAP Canister Vent Solenoid Control
Not Used
2-3 Shift Solenoid Control
Not Used
1-2 Shift Solenoid Control
TCC PWM Solenoid Control
Fuel Injector #1 Control
Fuel Injector #6 Control
EGR Pintle Position Signal
Not Used
IAC Coil B High
IAC Coil A High
Fuel Injector #2 Control
Fuel Injector #3 Control
Not Used
KS Signal
22
23-24
25
26
27
28
29
30
31
32
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WHT
LT GRN
TAN
YEL
DK BLU
DK GRN
YEL/BLK
YEL
LT GRN/BLK
LT BLU/BLK
BLK/WHT
LT BLU/BLK
121
432
472
410
417
890
1227
492
444
1748
845
844
Tachometer Output
MAP Sensor Signal
IAT Sensor Signal
ECT Sensor Signal
TP Sensor Signal
Fuel Tank Pressure Sensor Signal
Not Used
TFT Sensor Signal
MAF Sensor Signal
IAC Coil B Low
IAC Coil A Low
Fuel Injector #5 Control
Fuel Injector #4 Control
12129025
32 Pin VCM Connector C3 (CLR)
BLK
452
RED
225
RED/BLK
1228
WHT
423
RED
1226
GRY
416
PPL
1589
Function
A/C Compressor Enable Relay Control
EVAP Canister Purge Solenoid Control
Not Used
ECT/TP Sensor Ground
Generator Control/Monitoring
PC Solenoid High
Not Used
IC Control
Not Used
Transmission Range C Signal
TP Sensor 5 V Reference
Fuel Level Sensor Signal
Not Used
20
21
22
23
24
25
26
27
28
29
30
31
32
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15
16
17
18
19
27
28
29
30
31
32
1229
PC Solenoid Low
351
351
VCM Ground
VCM Ground
IAT/MAP/EGR Pintle Position/Fuel Tank Pressure/TFT
BLK
470
Sensor Ground
Not Used
ORN
440
Battery Positive Voltage (B+)
DK BLU
1225
Transmission Range B Signal
PNK
1224
Transmission Range A Signal
Not Used
GRN/WHT GRN/WHT A/C Request Signal
WHT
776
PRNDL P Signal
Fuel Tank Pressure/EGR Pintle Position/MAP Sensor
GRY
474
5 V Reference
GRY
773
PRNDL C Signal
Not Used
GRN
603
A/C Pressure Signal
BLK/WHT
771
PRNDL A Signal
YEL
772
PRNDL B Signal
Wire Color
DK
GRN/WHT
DK
GRN/WHT
DK GRN
12129225
24 Pin VCM Connector C4 (BLK)
Circuit
Function
No.
465
Not Used
VSS Output (TCCM, Cruise Control Module,
Console,TBC Module
VSS Output Signal (Speedo, Radio)
817
389
20
21
22
23
24
25
26
LT BLU
WHT
BLK/WHT
BLK/WHT
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419
MIL Control
Not Used
420
1807
241
710
1676
1020
439
1695
257
379
1694
396
Brake Signal
Serial Data (Class II)
Not Used
Ignition Positive Voltage
Serial Data (Class II)
Not Used
EGR Valve Control
Ignition Positive Voltage
Ignition Positive Voltage
4WD Front Wheel Lock Input
EGR Valve Low
Not Used
CPP Switch Signal
4WD Low Signal
Cruise Engaged Signal
5 BRN/WHT
6
9
10
PPL
11
PPL
12
13
BRN
14
YEL
15
16
RED
17
PNK
18
PNK
19 BLK/WHT
20
WHT
21
22 BRN/WHT
23 GRY/BLK
24 LT BLU/BLK
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Ignition Coil, Ignition Control (IC) Module, MAP, Throttle Body, and Evaporative
(EVAP) Canister Purge Valve
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98 S/T 4.3L VSS 2WD M/T Comploc Graphic Document ID: 247972
Manual Transmission (4.3L w/2WD)
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Canister and Vent Valve Comp loc 1998 S/T 2DR Document ID: 406835
Canister and Vent Valve (2DR Utility)
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1. Vent Valve
2. Frame
3. Canister
4. Fuel Tank
5. Fuel Sender
98 S/T 4.3L FTPS and Sender Assm Comploc Figure Document ID: 247975
Fuel Tank Pressure Sensor and Fuel Level Sender Assembly
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1. Fuel Tank
2. Fuel Tank Pressure Sensor Connector
3. Fuel Level Sender Connector
4. Fuel Tank Sender Assembly
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Pin
12
3
46
7
8
9
10
1112
13
14
15
1618
19
20
21
22
23-24
25
26
27
28
29
30
31
32
Wire Color
BRN/WHT
TAN
PNK/BLK
PPL
TAN/BLK
WHT
YEL/BLK
PPL/WHT
PPL
PPL/WHT
TAN/WHT
TAN/WHT
PPL
LT GRN/BLK
PPL/WHT
YEL
12129025
32 Pin VCM Connector C1 (BLU)
Circuit No.
633
1667
632
30
422
687
1827
1665
1666
1668
1653
1669
574
822
821
573
Function
Not Used
1X CMP Signal
Not Used
HO2S Bank 2 Sensor 1 Low
CMP Sensor Ground
Fuel Level Output
TCC Solenoid Control
Not Used
32 Shift Solenoid Control
Not Used
VSS Output Signal (EBCM)
Not Used
HO2S Bank 1 Sensor 1 Signal
Not Used
HO2S Bank 2 Sensor 1 Signal
HO2S Bank 1 Sensor 3 Signal
Not Used
HO2S Bank 1 Sensor 1 Low
HO2S Bank 1 Sensor 3 Low
Not Used
CKP Sensor Ground
VSS Low
VSS High
3X CKP Sensor Signal
Not Used
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Pin
1
2
3
4
5
6
7
8
9
10
1112
13
14
15
16
1718
19
20
21
22
23
24
25
26
27
28
29
30
Wire Color
WHT
YEL/BLK
LT GRN
BRN
BLK
YEL/BLK
BRN
LT GRN/WHT
LT BLU/WHT
LT GRN/BLK
PNK/BLK
DK BLU
WHT
LT GRN
TAN
YEL
DK BLU
DK GRN
YEL/BLK
YEL
LT GRN/BLK
LT BLU/BLK
12129025
32 Pin VCM Connector C2 (RED)
Circuit No.
1310
1223
1222
418
1744
846
1456
1749
1747
1745
1746
496
121
432
472
410
417
890
1227
492
444
1748
Function
Not Used
EVAP Canister Vent Solenoid Control
Not Used
2-3 Shift Solenoid Control
Not Used
1-2 Shift Solenoid Control
TCC PWM Solenoid Control
Fuel Injector #1 Control
Fuel Injector #6 Control
EGR Pintle Position Signal
Not Used
IAC Coil B High
IAC Coil A High
Fuel Injector #2 Control
Fuel Injector #3 Control
Not Used
KS Signal
Tachometer Output
MAP Sensor Signal
IAT Sensor Signal
ECT Sensor Signal
TP Sensor Signal
Fuel Tank Pressure Sensor Signal
Not Used
TFT Sensor Signal
MAF Sensor Signal
IAC Coil B Low
IAC Coil A Low
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31
32
BLK/WHT
LT BLU/BLK
845
844
Connector Part
Information
Pin
1
2
3
4
5
6
78
9
10
11
12
13
14
15
12129025
32 Pin VCM Connector C3 (CLR)
BLK
452
RED
225
RED/BLK
1228
WHT
423
RED
1226
GRY
416
PPL
1589
17
18
LT BLU
WHT
BLK/WHT
BLK/WHT
19
BLK
470
20
21
ORN
440
16
Function
A/C Compressor Enable Relay Control
EVAP Canister Purge Solenoid Control
Not Used
ECT/TP Sensor Ground
Generator Control/Monitoring
PC Solenoid High
Not Used
IC Control
Not Used
Transmission Range C Signal
TP Sensor 5 V Reference
Fuel Level Sensor Signal
Not Used
1229
PC Solenoid Low
351
351
VCM Ground
VCM Ground
IAT/MAP/EGR Pintle Position/Fuel Tank Pressure/TFT
Sensor Ground
Not Used
Battery Positive Voltage (B+)
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22
23
24
25
26
27
Wire Color
DK
GRN/WHT
DK
GRN/WHT
DK GRN
BRN/WHT
12129225
24 Pin VCM Connector C4 (BLK)
Circuit
Function
No.
465
389
419
Not Used
VSS Output (TCCM, Cruise Control Module,
Console,TBC Module
VSS Output Signal (Speedo, Radio)
MIL Control
Not Used
PPL
PPL
BRN
420
1807
241
817
Brake Signal
Serial Data (Class II)
Not Used
Ignition Positive Voltage
28
29
30
31
32
DK BLU
1225
Transmission Range B Signal
PNK
1224
Transmission Range A Signal
Not Used
GRN/WHT GRN/WHT A/C Request Signal
WHT
776
PRNDL P Signal
Fuel Tank Pressure/EGR Pintle Position/MAP Sensor
GRY
474
5 V Reference
GRY
773
PRNDL C Signal
Not Used
GRN
603
A/C Pressure Signal
BLK/WHT
771
PRNDL A Signal
YEL
772
PRNDL B Signal
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710
1676
1020
439
1695
257
379
1694
396
Pin
A
B
C
Circuit No.
632
633
239
Wire Color
PNK/BLK
BRN/WHT
PNK
12110293
3-Way M Metri-Pack 150 Series, Sealed (BLK)
Function
Camshaft Position Sensor Return
Camshaft Position Sensor Signal
Fuse Output - Ignition 1
14
YEL
15
16
RED
17
PNK
18
PNK
19 BLK/WHT
20
WHT
21
22 BRN/WHT
23 GRY/BLK
24 LT BLU/BLK
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Connector Part
Information
Pin
A
B
C
D
E
F
G
H
J
K
L
M
Wire Color
BLK/WHT
PNK
PNK/BLK
PNK
PNK
BLK
LT GRN/BLK
PNK
PNK
LT BLU/BLK
PNK
YEL/BLK
12177083
12-Way F Micro-Pack 100 Series, Sealed
(BLK)
Circuit No.
845
439
1746
439
439
1744
1745
439
439
844
439
846
Function
Fuel Injector 5 Output
Fuse Output - Ignition 1
Fuel Injector 3 Output
Fuse Output - Ignition 1
Fuse Output - Ignition 1
Fuel Injector 1 Output
Fuel Injector 2 Output
Fuse Output - Ignition 1
Fuse Output - Ignition 1
Fuel Injector 4 Output
Fuse Output - Ignition 1
Fuel Injector 6 Output
12059595
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Pin
A
B
C
Wire Color
PNK
PPL
YEL
Circuit No.
Function
439
Fuse Output - Ignition 1
574
Crankshaft Position Sensor Return
573
Crankshaft Position Sensor Signal
Connector Part
Information
Pin
A
B
Wire Color
BLK
YEL
12162194
2-Way F Metri-Pack 150.2 Series, Pull-to-Seat
(BLK)
Circuit No.
Function
452
Sensor Return
410
Coolant Temperature Sensor Signal
12065299
1-Way F Metri-Pack 150 Series, Sealed (LT
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GRY)
Pin
A
Wire Color
TAN/WHT
Circuit No.
331
Function
Oil Pressure Sensor Signal
12052643
Connector Part Information
Pin
A
B
Wire Color
PNK
DK GRN/WHT
Wire Color
PNK
WHT
12052643
2-Way F Metri-Pack 150 Series, Sealed (RED)
Circuit No.
Function
239
Fuse Output - Ignition 1
1310
Canister Vent Valve Solenoid Output
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Wire Color
BLK/WHT
DK GRN
GRY
12059595
3-Way F Metri-Pack 150 Series, Sealed (BLK)
Circuit No.
Function
470
Sensor Return
890
Fuel Tank Pressure Sensor Signal
474
Reference Voltage Feed - 5 Volt
Wire Color
PPL
GRY
BLK
BLK/WHT
Generator Connector
12160482
4-Way M Metri-Pack 150 Series (BLK)
Circuit No.
1589
120
1650
470
Function
Fuel Gauge Sensor Signal
Fuel Pump Motor Feed
Ground
Sensor Return
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Connector Part
Information
12186566
1-Way F Metri-Pack 150 Series, Sealed (NAT)
Pin
A
Wire Color
Circuit
No.
RED
225
C-D
Function
Not Used
Alternator Output - Regulator Reference
Voltage
Not Used
12162144
4-Way M Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit
No.
TAN/WHT
1653
PPL/WHT
1665
BLK
450
Function
Oxygen Sensor Return - Left - Forward of
Catalytic Converter
Oxygen Sensor Signal - Left - Forward of
Catalytic Converter
Ground
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PNK
539
Fuse-Output-Ignition 1
Connector Part
Information
12162144
4-Way M Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit
No.
TAN/WHT
1669
PPL/WHT
1668
C
D
BLK
PNK
350
539
Function
Oxygen Sensor Return-Left-Rear of Catalytic
Converter
Oxygen Sensor Signal-Left-Rear of Catalytic
Converter
Ground
Fuse-Output-Ignition 1
12162144
4-Way M Metri-Pack 150 Series (BLK)
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Pin
Wire Color
Circuit
No.
TAN
1667
PPL
1666
C
D
BLK
PNK
350
539
Function
Oxygen Sensor Return-Right-Forward of
Catalytic Converter
Oxygen Sensor Signal-Right-Forward of
Catalytic Converter
Ground
Fuse-Output-Ignition 1
Connector Part
Information
12162190
4-Way M Metri-Pack 150.2 Series, Pull-to-Seat
(BLK)
Pin
Wire Color
Circuit
No.
LT GRN/BLK
444
LT GRN/WHT
1749
LT BLU/BLK
1748
LT BLU/WHT
1747
Function
Idle Air Control Valve Motor Feed - Coil B
Low
Idle Air Control Valve Motor Feed - Coil B
High
Idle Air Control Valve Motor Feed - Coil A
Low
Idle Air Control Valve Motor Feed - Coil A
High
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Wire Color
PNK
WHT/BLK
12146121
3-Way F Metri-Pack 150 Series, Sealed (BRN)
Circuit No.
Function
439
Fuse Output - Ignition 1
Not Used
1847
Ignition Coil Output - Bank A
Connector Part
Information
Pin
A
B
C
D
Wire Color
PNK
WHT
BLK/WHT
WHT/BLK
12162189
4-Way F Metri-Pack 150.2 Series, Pull-to-Seat
Sealed (BLK)
Circuit No.
439
423
451
1847
Function
Fuse Output - Ignition 1
Electronic Spark Timing Control Signal
Engine Control Module Ground
Ignition Coil Output - Bank A
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Connector Part
Information
Pin
A
B
Wire Color
TAN
BLK
12162198
2-Way F Metri-Pack 150.2 Series, Sealed, Pull-toSeat (GRY)
Circuit No.
Function
472
Manifold Absolute Temperature Sensor Signal
470
Sensor Return
Wire Color
DK BLU
12146549
1-Way F Weather Pack (BLK)
Circuit No.
496
Function
Knock Sensor Signal #1
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Connector Part
Information
Pin
A
B
C
Wire Color
BLK
LT GRN
GRY
12129946
3-Way Metri-Pack 150 Series Sealed (MD
GRY)
Circuit No.
Function
470
Sensor Return
432
Manifold Absolute Pressure Sensor Signal
474
Reference Voltage Feed-5 Volt Reference
Wire Color
YEL
BLK/WHT
PNK
12059595
3-Way F Metri-Pack Series, Sealed (BLK)
Circuit No.
Function
492
Mass Air Flow Sensor Signal
451
Engine Control Module Ground
239
Fuse Output - Ignition 1
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Connector Part
Information
Pin
A
B
C
Wire Color
GRY
BLK
DK BLU
12110192
3-Way F Micro-Pack 150 Series, Sealed, Pull-toSeat (BLK)
Circuit No.
Function
416
Reference Voltage Feed - 5 Volt Reference
452
Sensor Return
417
Throttle Position Sensor Signal
Wire Color
PPL/WHT
LT GRN/BLK
VCM Replacement/Programming
Document ID: 214937
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Notice: In order to prevent possible electrostatic discharge (ESD) damage to the VCM,
do not touch the connector pins or soldered components on the circuit board.
Important:
A shorted solenoid, relay coil, or harness will not damage the output driver module
(ODM) in the VCM. A shorted solenoid, relay coil, or harness will cause the circuit and
the controlled component to be inoperative.
When the circuit fault is not present or the technician has repaired the fault, the output
driver module (ODM) will again operate in a normal manner due to its fault protected
design.
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. Disconnect the negative battery cable.
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Installation Procedure
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Important: Ensure that the VCM being installed is the original VCM, or that the
replacement VCM service number is identical to the original VCM service number.
Steps 13 are only necessary for a replacement VCM installation:
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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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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
9. Install the VCM bracket bolts.
Tighten
Tighten the bolts to 10 N-m (89 lb in).
VCM Programming
1. Perform the following steps in order to prepare for programming the VCM
(EEPROM).
o Make sure that both the Tech 2 and the Techline terminal software are
updated to the most current level.
o Verify that the vehicle battery is properly charged prior to performing the
reprogramming process.
o Make sure the connection at the Data Link Connector (DLC) is secure.
o Turn ON the ignition.
o Turn OFF all the accessories (i.e., radio, HVAC controls, interior lamps,
etc.).
2. Refer to the Techline terminal and follow the user's instructions for VCM
programming.
3. If the VCM fails to program, perform the following functions:
o Check all the VCM connections.
o Try again to program the VCM. If the programming fails again, replace
the VCM.
4. Perform the VTD Password Learn Procedure. Refer to Password Learn in
Engine Controls - 4.3L .
5. Perform the CKP System Variation Learn Procedure. Refer to Crankshaft
Position System Variation Learn in Engine Controls - 4.3L .
6. For a functional check, perform the Powertrain On-Board Diagnostic (OBD)
System Check.
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4.
5.
6.
7.
8. Enable the Crankshaft Position System Variation Learn Procedure with the scan
tool.
Password Learn
Document ID: 247178
Important: Refer to Theft Deterrent System Check in Body and Accessories if the
Passlock Learn Procedure cannot be completed successfully.
Passlock Learn Procedure Using a Tech 2 Scan Tool (Seed and Key)
Important: In addition to the time involved in performing the specific steps, the Seed
and Key Procedure accomplishes the same task in 10 minutes as the Auto Learn
Procedure does in 30 minutes. Use either one of these two procedures.
The following is the Seed and Key Learn Procedure:
1. Clear all Vehicle Theft Deterrent (VTD), or (Passlock), module and VCM
DTCs.
2. Turn the ignition to the ON position.
3. With the scan tool (TECH 2) connected to the vehicle, select
'Programming/Request Info' from the menu, then follow the instructions.
Important: After the ignition switch is turned to the CRANK position, the
VCM must see a change in the state of brake switch (Released to Applied) to run
the learn procedure. Also, the service brakes, not the parking brake, must be held
throughout the duration of the learn procedure.
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4. Disconnect the scan tool from the vehicle and perform 'Service Programming
System/VTD Learn' with Techline terminal, then follow the instructions.
5. Reconnect the scan tool to the vehicle.
6. Follow the instructions on the scan tool to perform the VTD (Passlock)
password learn on the vehicle, this takes about 10 minutes.
7. After 10 minutes, the SECURITY indicator will turn OFF and the module will
learn the new component on the next ignition lock cylinder cycle from OFF-toCRANK-to-ON (start attempt).
1.
2.
3.
4.
5.
Important: While the VCM is in the Auto Learn Procedure, maintain the battery
voltage at all times. Follow the procedure exactly as indicated or the procedure will
have to be repeated from the beginning.
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Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will
affect the operation of the fuel control system.
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. Disconnect the negative battery cable.
2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct.
3. Move the air intake assembly aside.
Caution: Allow sufficient time for the engine to cool before removing the ECT
sensor. A hot engine may cause an excessive coolant loss or a personal injury.
4. Relieve the coolant pressure.
5. Drain the cooling system below the level of the sensor.
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Installation Procedure
1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent.
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2. 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.
Install the ECT sensor in the engine.
Tighten
Tighten the sensor to 20 N-m (15 lb ft).
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5. Install the air intake assembly and tighten the wing nuts.
6. Connect the negative battery cable.
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Disconnect the MAF sensor from the air cleaner cover and air cleaner outlet duct
by loosening the hose clamps.
Installation Procedure
1. Important: The embossed arrow on the MAF sensor indicates the proper air
flow direction. The arrow must point towards the engine.
Attach the MAF sensor to the air cleaner outlet duct and the air cleaner cover.
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. Secure the air cleaner cover and outlet duct to the MAF sensor.
Tighten
Tighten the clamps to 4 N-m (35 lb in)
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Installation Procedure
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Do not apply contact cleaner or other materials to the sensor or vehicle harness
connectors. These materials may get into the sensor causing poor performance.
Do not damage the sensor pigtail and harness wires in such a way that the wires
inside are exposed. This could provide a path for foreign materials to enter the
sensor and cause performance problems.
Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp
bends or kinks could block the reference air path through the lead wire.
Do not remove or defeat the oxygen sensor ground wire, where applicable.
Vehicles that utilize the ground wired sensor may rely on this ground as the only
ground contact to the sensor. Removal of the ground wire will cause poor engine
performance.
Ensure that the peripheral seal remains intact on the vehicle harness connector in
order to prevent damage due to water intrusion. The engine harness may be
repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no
circumstances should repairs be soldered since this could result in the air
reference being obstructed.
The Heated Oxygen Sensor (HO2S) may be difficult to remove when the engine
temperature is below 48C (120F). Excessive force may damage the threads in the
exhaust manifold or the exhaust pipe.
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. Disconnect the negative battery cable.
Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the
oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor
operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical
connector and the louvered end free of grease, dirt, or other contaminants. Do not use
cleaning solvents of any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the
pigtail wiring, connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors, or terminals could result in the
obstruction of the air reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
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4. Remove the HO2S electrical connector by releasing the locking tab. The
electrical connector may typically have either a 1x4 or 2x2 configuration.
Installation Procedure
Important: A special anti-seize compound is used on the Heated Oxygen Sensor
(HO2S) threads. The compound consists of liquid graphite and glass beads. The
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graphite tends to burn away, but the glass beads remain, making the sensor easier to
remove. New, or service replacement sensors already have the compound applied to the
threads. When installing a previously removed sensor, the threads must have anti-seize
compound applied before the installation.
1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N
5613695 or the equivalent if necessary.
2. 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.
Install the HO2S.
Tighten
Tighten the sensor to 42 N-m (31 lb ft).
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10. Notice: The TP sensor is an electrical component. Do not soak the TP sensor in
any liquid cleaner or solvent as damage may result.
Remove the TP sensor from the throttle body assembly.
Installation Procedure
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2. 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.
Important: The screws used to attach the TP sensor are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the TP sensor mounting screws.
Tighten
Tighten the screws to 2.0 N-m (18 lb in).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .
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deosits are excessive. Refer to Idle Air Control Valve Replacement in Engine Controls 4.3L
for IAC removal or
Throttle Position Sensor Replacement in Engine Controls - 4.3L
for TP sensor removal. After disassembly, clean the throttle body using a parts cleaning
brush. DO NOT immerse the throttle body in any cleaning solvent.
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.
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11. Remove the stud and nuts retaining the accelerator control cable bracket and
position bracket aside.
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Installation Procedure
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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.
Install the throttle body assembly retaining studs.
Tighten
Tighten the studs to 9 N-m (80 lb in).
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4. Install the accelerator control cable bracket using the mounting stud and nuts.
Tighten
Tighten the stud and nuts to 12 N-m (108 lb in).
5. Install the accelerator cable routing bracket using the mounting nuts.
Tighten
Tighten the accelerator cable routing bracket nuts to 9 N-m (75 lb in).
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14. Connect the breather tube from the air cleaner outlet duct.
15. Connect the negative battery cable.
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10. Notice: The TP sensor is an electrical component. Do not soak the TP sensor in
any liquid cleaner or solvent as damage may result.
Remove the TP sensor from the throttle body assembly.
Installation Procedure
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2. 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.
Important: The screws used to attach the TP sensor are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the TP sensor mounting screws.
Tighten
Tighten the screws to 2.0 N-m (18 lb in).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .
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1. Loosen the fuel filler cap to relieve vapor pressure in the fuel tank.
2. Remove the positive crankcase ventilation (PCV) clean air tube from air inlet
duct and set aside.
3. Remove the resonator and air inlet duct from throttle body.
4. Remove the brake booster vacuum hose and connector from intake manifold.
5. Remove the electrical connector from the central sequential fuel injection (CSFI)
fuel metering body.
6. Remove the spark plug wires from 1, 3 and 5 from the distributor cap.
7. Remove the fuel line bolt (4) at the rear of intake manifold.
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Important: Make sure that the fuel pipe O-rings, washers, and spacers are
present and in their proper position.
11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and
tighten.
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13. Obtain the J 41413 , close the valve (2) on the tank (3), and remove the regulator
assembly.
14. Install the J 44466-10 (5) to the J 41413 tank (3)
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25. Disconnect and remove the J 44466-10 (1) from the J 44466-12 (3) and the J
41413 .
26. Remove the J 39021-301 J 39021-210 and J 39021 from the metering body.
27. Install the vehicle electrical connector to the metering body.
28. Install brake booster vacuum hose and connector to the intake manifold.
29. Install ignition wires 1, 3, and 5 to the distributor cap.
30. Install the resonator and air intake duct to the throttle body and hand tighten
wing nut.
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32. Remove the canister top and add Top Engine Cleaner GM P/N 12346535 to the
canister.
33. Fill the remainder of the canister with regular unleaded gasoline and install the
canister top.
34. Suspend J 38500-A from a convenient underhood location.
35. Connect the hose from J 38500-A (1) to the service port on the J 44466-12 (3).
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47. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body.
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Important: Make sure that all of the O-rings (6 and 8), washers (7), and spacers
(5) are present and in proper position.
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Installation Procedure
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1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet
duct until seated.
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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. Disconnect the negative battery cable.
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4. Remove the wing nut retaining the air cleaner outlet duct.
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9. Remove the IAC valve and O-ring from the throttle body assembly.
Installation Procedure
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1. 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).
Important: Use an identical part when installing a new Idle Air Control (IAC)
valve. The IAC valve pintle shape and dimensions are designed for specific
applications.
On a new IAC valve, measure the distance between the IAC valve pintle and
mounting flange. Use finger pressure to slowly retract the pintle if the distance is
greater than 28 mm (11/8 in).
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5. 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.
Important: The screws used to attach the IAC valve are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the IAC valve mounting screws.
Tighten
Tighten the screws to 3 N-m (27 lb in).
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10. Remove the accelerator cable from the dash panel (1).
Installation Procedure
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Tighten
Tighten the air cleaner outlet duct clamp to 4 N-m (35 lb in).
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Installation Procedure
Important: The accelerator cable must not be kinked or damaged in any way during
installation.
Ensure that the mounting surface between the accelerator pedal assembly and the dash
panel is free of insulation. The carpet and padding in the pedal and tunnel area must be
positioned to lay flat and be free of wrinkles and bunches. Wire, hoses, cables, and other
flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any
point in their travel.
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1. Place the accelerator pedal assembly over the mounting studs and onto the
mounting surface.
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.
Tighten
Tighten the accelerator pedal mounting nuts to 9 N-m (84 lb in).
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Installation Procedure
1. Install the fuel pump relay. The location is indicated on the electrical center
cover.
2. Install the underhood electrical center cover.
3. Connect the negative battery cable.
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.
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2. Disconnect the spark plug wires and the ignition coil wire from the distributor.
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6. Important: A DTC P1345 will set if the rotor is not reinstalled in the exact
position the rotor was in prior to removal.
Observe the alignment of the rotor in relation to the distributor base (1).
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11. Remove the fuel pump and engine oil pressure sender with a J 35748 Oil
Pressure Sending Unit Socket.
Installation Procedure
Important: Do not use the old cap, CMP sensor, and rotor screws. Use replacement
screws that have been coated with a thread locking compound. Precoated replacement
cap and CMP sensor screws can be acquired using GM P/N 10475922 (pkg of
10 screws). Precoated replacement rotor screws can be acquired using GM
P/N 10475924 (pkg of 10 screws).
Tools Required
J 35748 Oil Pressure Sending Unit Socket
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1. 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.
Install the fuel pump and engine oil pressure sender with a J 35748 Oil Pressure
Sending Unit Socket.
Tighten
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3. Important: The proper CKP/CMP correlation will be lost if the rotor is not be
reinstalled in the same exact position. A DTC P1345 will result from improper
distributor shaft alignment.
Align the rotor in its original position in relation to the distributor base (1).
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9. Connect the spark plug wires and the ignition coil wire.
10. Connect the negative battery cable.
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Installation Procedure
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Installation Procedure
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Installation Procedure
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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.
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2. Loosen the fuel filler cap in order to relieve the tank vapor pressure.
3. Connect the J 34730-1A fuel pressure gauge or the equivalent to the fuel
pressure connection.
4. Wrap a shop towel around the fitting while connecting the gauge in order to
avoid spillage.
5. Install the bleed hose of the gauge into an approved container.
6. Open the valve on the gauge 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.
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2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each
direction to loosen any dirt within the fitting.
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4. Choose the correct tool from J 41769 Tool Set for the size of the fitting. Insert
the tool into the female connector, then push inward to release the locking tabs.
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Installation Procedure
1. 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.
Apply a few drops of clean engine oil to the male pipe end.
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3. Once installed, pull on both sides of the fitting to make sure the connection is
secure.
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1. Important: Relieve the fuel system pressure before servicing any fuel system
connection. Refer to the Fuel Pressure Relief Procedure .
Grasp both sides of the quick-connect fitting. Twist the female connector 1/4
turn in each direction in order to loosen any dirt within the quick-connect fitting.
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Installation Procedure
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1. 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.
Apply a few drops of clean engine oil to the male fuel pipe end.
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3. Once installed, pull on both sides of the quick-connect fitting in order to make
sure the connection is secure.
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3. Remove the fuel feed nut and plastic quick connect fitting from either side of the
filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
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Installation Procedure
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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.
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Installation Procedure
Important: When installing the CKP sensor, make sure the sensor is fully seated before
tightening the mounting bolt. A poorly seated CKP sensor may perform erratically;
possibly setting false DTCs.
Important: Do not reuse the original O-ring.
1. Replace the CKP sensor O-ring.
2. Lubricate the O-ring with clean engine oil before installing the CKP sensor.
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3. Important: Make sure the CKP sensor mounting surface is clean and free of
burrs.
Install the CKP sensor.
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2. Disconnect the spark plug wires and the ignition coil wire from the distributor.
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Installation Procedure
Important: Do not use the old cap, CMP sensor, and rotor screws. Use replacement
screws that have been coated with a thread locking compound. Precoated replacement
cap and CMP sensor screws can be acquired using GM P/N 10475922 (pkg of
10 screws). Precoated replacement rotor screws can be acquired using GM
P/N 10475924 (pkg of 10 screws).
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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 new CMP mounting screws.
Tighten
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Removal Procedure
Tools Required
J 35748 Oil Pressure Sending Unit Socket
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.
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10. Disconnect the fuel pump and engine oil pressure sensor harness connector.
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Installation Procedure
Tools Required
J 35748 Oil Pressure Sending Unit Socket
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Tighten
Tighten the sender to 30 N-m (22 lb ft)
4. Connect the fuel pump and engine oil pressure sensor harness connector.
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Caution: In order to reduce the risk of fire and personal injury that may result
from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel
sender assembly.
1. 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.
2. Remove the fuel tank. Refer to Fuel Tank Replacement in Engine Controls 4.3L .
Assembly Procedure
Notice: Do not fold or twist the strainer when installing the sending unit. This action
restricts fuel flow.
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1. Support the pump with one hand and position the new pump strainer on pump in
the same position as noted during disassembly.
2. Push on the outer edge of the ferrule until fully seated.
Installation Procedure
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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. Disconnect the negative battery cable.
2. Raise the vehicle.
3. Remove the fuel tank. Refer to Fuel Tank Replacement in Engine Controls 4.3L .
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Installation Procedure
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2.
3.
4.
5.
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2. Important: Note the orientation of the EGR valve at the BASE before
removing. Do not use the electrical connector as an indication of valve
orientation. It is possible to install this EGR valve backwards. An EGR valve
installed backwards may cause a rough idle and set DTCs.
Disconnect the EGR valve electrical connector.
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Installation Procedure
1. Clean any remaining gasket material from the EGR mounting surface.
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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.
Insert the retaining bolts through the EGR valve and gasket into the mounting
holes.
Tighten
First tighten the bolts to 10 N-m (89 lb in), and then tighten the bolts to 25 N-m
(18 lb ft).
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Installation Procedure
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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 EGR pipe fitting to the exhaust manifold.
Tighten
Tighten the EGR pipe fitting to exhaust manifold to 30 N-m (22 lb ft).
Tighten
Tighten the EGR pipe fitting to intake manifold to 25 N-m (18 lb ft).
5. Install the EGR pipe bracket retaining fastener.
Tighten
Tighten the fastener to 25 N-m (18 lb ft).
6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
in Engine Controls - 4.3L .
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Installation Procedure
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1. Assemble the new O-rings into the inlet and outlet of the fuel injector assembly.
Caution: Always apply a few drops of clean engine oil to the male pipe ends
before connecting the fuel pipe fittings in order to reduce the risk of fire and
personal injury. 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.
2. Apply a few drops of clean engine oil to the male tube ends.
3. Install the fuel feed and return pipes to the fuel assembly.
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Once installed, pull on both ends of each connection in order to make sure they
are secure.
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.
Tighten
1. Tighten the rear fuel line bracket bolt to 6.0 N-m (53 lb in).
2. Tighten the fuel pipe retainer nuts to 3.0 N-m (27 lb in).
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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. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
Removal Procedure
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4. Disconnect the fuel pipes (1) and the attaching hardware (2) at the transmission.
5. Remove the fuel tank.
6. Refer to Fuel Tank Replacement in Engine Controls - 4.3L .
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3. Inspect all the connectors for dirt and burrs. Clean or replace the
components/assemblies as required.
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. Install the new O-rings on the engine fuel feed and return pipes.
Installation Procedure
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4. 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.
Position the new fuel pipe harness (1) in the original location and the fuel pipe
harness attaching hardware (2), tighten to specification.
Tighten
Fuel pipe attaching nuts to 27 N-m (20 lb ft) using a back-up wrench.
5. Remove protective caps from one end of both fuel pipes.
Leave caps on other end of pipes to prevent dirt from entering.
6. Apply a few drops of clean engine oil to the male connector tube ends.
7. Connect the quick-connect fittings at the fuel feed and return pipe near the inline filter and at the fuel sender assembly. Refer to Quick Connect Fitting(s)
Service (Metal Collar) and Quick Connect Fitting(s) Service (Plastic Collar) .
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8. Install the fuel tank and attaching fuel pipe hardware. Refer to Fuel Tank
Replacement in Engine Controls - 4.3L .
9. Tighten the fuel filler cap.
10. Connect the negative battery cable.
11. Check for fuel leaks.
1. Turn the ignition switch to the ON position for 2 seconds.
2. Turn the ignition switch to the OFF position for 10 seconds.
3. Again, turn the ignition switch to the ON position.
4. Check for fuel leaks.
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1. 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.
Disconnect the negative battery cable.
2. Remove the fuel pressure connection valve cap (3).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
4. Use a standard valve core tool in order to remove the valve core (2).
Installation Procedure
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1. Use a standard valve core tool in order to install a new valve core (2).
2. Connect the negative battery cable.
3. Inspect for leaks.
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition for 2 seconds.
4. Inspect for fuel leaks.
4. Install the fuel pressure connection valve cap (3).
Disassembly Procedure
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Assembly Procedure
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3. Assemble the regulator with the vacuum tube pointing down into the snap ring
retainer.
Installation Procedure
1. Install the upper manifold assembly. Refer to Engine Mechanical.
2. Connect the negative battery cable.
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Before removal, the fuel meter body assembly may be cleaned with a spray type
engine cleaner, GM X-30A or the equivalent.
Follow the package instructions.
Do not soak fuel meter body assemblies in liquid cleaning solvent.
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.
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4. Remove the fuel feed and the return hoses from the engine fuel pipes.
5. Remove the engine fuel pipe retainer nuts and retainer.
6. Remove the engine fuel pipes by lifting straight up and away from the fuel meter
body.
7. Remove the upper manifold assembly.
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9. Remove the fuel meter body from the bracket by releasing the lock tabs on the
bracket.
Installation Procedure
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Install the fuel meter body retaining bracket in the intake manifold.
Tighten
Tighten the attaching bolts to 10 N-m (88 lb in).
2. Caution: Verify that the poppet nozzles are firmly seated and locked in their
casting sockets in order to reduce the risk of fire and personal injury. An
unlocked poppet nozzle could work loose from its socket and produce a fuel
leak.
Push the fuel meter body into the bracket.
3. Make sure all of the tabs are locked into place.
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4. Important: The fuel meter body assemblies are numbered to indicate poppet
nozzle order.
Push the poppet nozzles into the casting sockets.
5. Inspect the poppet nozzles in order to ensure they are firmly seated and locked in
the casting sockets.
6. Install the upper manifold assembly. Refer to Engine Mechanical.
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Tighten the fuel feed and return pipe retainer nuts to the fuel meter body to
3.0 N-m(27 lb in).
9. Install the fuel feed and the return hoses to the engine fuel pipes.
Tighten
Tighten the fuel pipe nuts to 30.0 N-m (22 lb ft).
Disassembly Procedure
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1. Disassemble the lower hold down plate and the nuts (1).
2. While pulling the poppet nozzle tube downward, push with a small tip punch
down between the injector terminals until the injector is removed.
Assembly Procedure
Important: Each injector is calibrated for a specific flow rate. Order the correct injector
for the application being serviced when replacing the fuel injectors.
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Installation Procedure
1. Install the fuel meter body assembly. Refer to Fuel Meter Body Assembly
Replacement in Engine Controls - 4.3L .
2. Install the upper manifold assembly. Refer to Engine Mechanical.
3. Connect the negative battery cable.
4. Turn the ignition On for 2 seconds.
5. Turn the ignition Off for 2 seconds.
6. Turn the ignition On for 2 seconds.
7. Inspect for fuel leaks.
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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The above DTCs contain a table in order to check for sensor resistance values that are
relative to temperature.
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The mass air flow (MAF) sensor measures the amount of air entering the engine.
The VCM uses this information to determine the operating condition of the
engine in order to control the fuel delivery. A large quantity of air indicates an
acceleration. A small quantity of air indicates a deceleration or an idle.
The scan tool reads the MAF value and displays the MAF value in grams per
second (gm/Sec). At idle, the MAF value should read between 5 gm/sec
7 gm/sec on a fully warmed up engine. The values should change rather quickly
on acceleration, but values should remain fairly stable at any given RPM. When
the VCM detects a malfunction in the MAF sensor circuit, the following DTCs
will set:
o
o
o
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The manifold absolute pressure (MAP) sensor responds to any changes in the intake
manifold pressure. The pressure any changes as a result of the engine load and speed.
The MAP sensor converts this to a voltage output.
A closed throttle on the engine coast down would produce a relatively low MAP output
voltage. A wide open throttle would produce a high MAP output voltage. This high
output voltage is produced because the pressure inside of the manifold is the same as
outside the manifold. The MAP is inversely proportional to what is measured on a
vacuum gauge. The MAP sensor is used for the following:
Altitude determination
Ignition timing control
EGR diagnostic
Speed density fuel management default
When the VCM detects a malfunction in the MAP sensor circuit, the following DTCs
will set:
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9. Inner Electrode
10. Zirconia Element
11. Insulator
12. Clip Ring
13. Gripper
When the VCM detects an HO2S signal circuit that is low, the VCM will set the
following DTCs:
When the VCM detects an HO2S signal circuit that is high, the VCM will set the
following DTCs:
When the VCM detects no HO2S activity, the VCM will set the following DTCs:
A fault in the heated oxygen sensor heater element or its ignition feed or ground will
result in an increase in time to Closed Loop fuel control. This may cause increased
emissions, especially during startup. When the VCM detects a malfunction in the
HO2S heater circuits, the following DTCs will set:
The Heated Oxygen Sensors are mounted in the exhaust system where they can monitor
the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas
reacts with the sensor to produce a voltage output. This voltage should constantly
fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV
(low oxygen content rich mixture). The heated oxygen sensor voltage can be
monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the
VCM calculates what fuel mixture command to give to the injectors (lean mixture
low HO2S voltage = rich command, rich mixture high HO2S voltage = lean
command).
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The VCM also has the ability to detect HO2S response, switching, transition time, and
incorrect ratio voltage problems. If an HO2S response switching, transition time, or
ratio problem is detected, the VCM will store a DTC which indicates degraded an
HO2S performance.
The HO2S sensors which are used in order to monitor the catalyst function are the same
as the HO2S sensors which are used in order to control the fuel. Bank 1 Sensor 1 and
Bank 1 Sensor 3 are used primarily for catalyst monitoring. These sensors also play a
limited role in fuel control. If a sensor output indicates a voltage either above or below
the 450 millivolt bias voltage for an extended period of time, the VCM will make a
slight adjustment to the fuel trim in order to ensure that the fuel delivery is correct for
catalyst monitoring.
In order to control the emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx), a three-way catalytic converter is used. The catalyst within
the converter promotes a chemical reaction which oxidizes the HC and CO present in
the exhaust gas, converting them into harmless water vapor and carbon dioxide. The
catalyst also reduces NOx, converting it to nitrogen. The VCM has the ability to
monitor this process by using the Bank 1 Sensor 1 and the Bank 1 Sensor 3 heated
oxygen sensors. The Bank 1 Sensor 1 sensor produces an output signal which indicates
the amount of oxygen present in the exhaust gas entering the three-way catalytic
converter. The Bank 1 Sensor 3 sensor produces an output signal which indicates the
oxygen storage capacity of the catalyst; this in turn indicates the ability of the catalyst to
convert the exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 1
Sensor 1 sensor will produce a far more active signal than that produced by the Bank 1
Sensor 3 sensor.
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When the VCM detects a malfunction with the TP sensor circuits, the following DTCs
will set:
The VCM calculates the fuel delivery based on the throttle valve angle (driver demand).
A broken or loose TP sensor may cause intermittent bursts of fuel from an injector. This
may cause an unstable idle because the VCM detects the throttle is moving.
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The Evaporative Canister Vent Valve replaces the fresh air vent used on past EVAP
canisters. The vent valve now not only allows the fresh outside air to the EVAP canister
during the purge modes, but also allows the diagnostic to pull a vacuum on the fuel tank
by closing the vent valve. This valve is normally open.
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The Evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP
canister to the engine when active. The normally closed valve is pulse width modulated
by the VCM in order to control vapor flow.
The Fuel Tank Pressure Sensor is similar to the MAP sensor; however, the sensor is
calibrated to different tolerances. The sensor measures the air pressure differences
between the fuel tank and outside air.
The sensor uses a 5 volt reference voltage to send an output signal to the VCM.
Depending upon the atmospheric pressure, the output voltage with the fuel cap removed
will vary between 1.31.7 volts. A high voltage output (near 5 volts) indicates a very
negative pressure (vacuum below 4 Kpa).
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The knock sensor (KS) system is used in order to detect the engine detonation. The
VCM will retard the spark timing based on the signals from the KS module. The knock
sensors produce an AC voltage that is sent to the KS module. The amount of the AC
voltage produced is proportional to the amount of knock.
An operating engine produces a normal amount of engine mechanical vibration (Noise).
The knock sensors will produce an AC voltage signal from this Noise. When an engine
is operating, the VCM will learn the minimum and maximum frequency of the noise
that the engine produces. When the VCM determines that this frequency is less than or
greater than the expected amount, a knock sensor DTC will set.
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The vehicle speed sensor (VSS) is a pulse counter type input that informs the VCM how
fast the vehicle is being driven. The VSS system uses an inductive sensor mounted in
the tail housing of the transmission and a toothed reluctor wheel on the tail shaft. As the
reluctor rotates, the teeth alternately interfere with the magnetic field of the sensor
creating an induced voltage pulse.
The VSS produces an AC voltage signal that increases with the vehicle speed. The
VCM processes this signal and sends it to the following components:
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The crankshaft position sensor provides the VCM with the crankshaft speed and the
crankshaft position. The VCM utilizes this information in order to determine if an
engine Misfire is present. The VCM monitors the CKP sensor for a momentary drop in
the crankshaft speed in order to determine if a misfire is occurring. When the VCM
detects a misfire, a DTC P0300 will set.
The VCM also monitors the CKP sensor signal circuit for malfunctions. The VCM
monitors CKP signal and the High and Low resolution signals. The VCM calculates
these signals in order to determine a ratio. When the VCM detects that the ratio is out of
normal operating range, the VCM will set a DTC P0337 or a DTC P0338.
The Camshaft Position (CMP) sensor is located within the distributor. The operation of
the CMP sensor is very similar to the Crankshaft Position (CKP) sensor. The CMP
sensor will provide one pulse per camshaft revolution (1x signal). This signal will not
affect the driveability of the vehicle. The VCM utilizes this signal in conjunction with
the crankshaft position in order to determine which cylinder(s) are misfiring.
The Central Sequential Fuel Injection (Central SFI) (4.3L, 5.0L, 5.7L)
The Sequential Fuel Injection (SFI) (7.4L only)
The main control sensor is the heated oxygen sensor (HO2S). The HO2S is located in
the exhaust manifold. The HO2S tells the control module the amount of oxygen in the
exhaust gas. The control module changes the air to fuel ratio to the engine by
controlling the fuel injector. Efficient catalytic converter operation requires a 14.7:1 air
to fuel ratio. Because the constant measuring and adjusting of the air to fuel ratio, the
fuel injection system is called a Closed Loop system.
Several other important engine operation parameters include the following items:
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The Central Sequential Fuel Injection (Central SFI) (4.3L, 5.0L, 5.7L)
The Sequential Fuel Injection (MFI) (7.4L)
The fuel supply system
Modes of Operation
Starting Mode
When the ignition switch is turned to the ON position, before engaging the starter, the
control module energizes the fuel pump relay for 2 seconds allowing the fuel pump to
build up pressure. The control module then checks the engine coolant temperature
(ECT) sensor and the throttle position (TP) sensor in order to determine the proper air
and fuel ratio for starting. The control module controls the amount of fuel delivered in
the starting mode by changing how long the injectors are energized. This is done by
pulsing the injectors for very short times.
Run Mode
The Run Mode is the mode under which the engine operates most of the time. In this
mode, the engine operates in either Open Loop or Closed Loop.
Open Loop
When the engine is first started and it is above 400 RPM, the system goes into the open
loop operation. In the open loop, the control module ignores the signal from the HO2S,
and the control module calculates the air to fuel ratio based on the inputs from the
engine coolant temperature (ECT) sensor and manifold absolute pressure (MAP) sensor.
The system stays in open loop until the following conditions are met:
1. The HO2S has varying voltage output, showing that it is hot enough to operate
properly. This depends on engine temperature.
The control module monitors the voltages from several sensors in order to determine
how much fuel to give the engine. The fuel is delivered under one of several conditions
called modes. The control module controls all of the modes.
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Acceleration Mode
When the control module senses rapid changes in the throttle position and the manifold
pressure, the system enters the acceleration mode. The system provides the extra fuel
needed for smooth acceleration.
Deceleration Mode
When the driver releases the accelerator pedal, the air flow into the engine is reduced.
The corresponding changes in the throttle position and the manifold air pressure are
relayed to the control module, which reduces the injector pulse width, in order to reduce
the fuel flow. If the decel is very rapid, or for long periods (such as long closed throttle
coast-down), the control module shuts OFF the fuel completely in order to protect the
catalytic converter.
The specific values for the above conditions vary with different engines. When these
conditions are met, the systems goes into a closed loop operation. In a closed loop, the
control module calculates the air to fuel ratio (injector on-time) based on the signal from
the HO2S. This allows the air to fuel ratio to stay very close to 14.7:1.
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Engine
Gear
IAC
(Drive/Neutral) Idle Speed Counts
Transmission
(1)
(RPM)
(2)
Automatic
Drive
60025
Varies
Open/Closed
Loop (3)
Closed Loop
Manual
Automatic
Neutral
Drive
70025
70025
Varies
Varies
Closed Loop
Closed Loop
Manual
Automatic
Manual
Drive
70025
55025
Varies
Varies
Closed Loop
Closed Loop
Manual
Automatic
Manual
Drive
67525
55025
Varies
Varies
Closed Loop
Closed Loop
Manual
Automatic
Manual
Drive
67525
60025
Varies
Varies
Closed Loop
Closed Loop
5.0L
5.7L (Under
8500 GVW)
5.7L (Over
8500 GVW)
7.4L
Manual
Manual
72525
Varies
Closed Loop
Important: The engine should be at operating temperature 92C to 104C (196F
to 222F).
(1) On manual transmission vehicles, the scan tool will display RDL in neutral
(2) Add 2 counts for engines with less than 500 miles. Add 2 counts for every
1000 ft. above sea level (4.3L and V8).
(3) Let the engine idle until the engine reaches proper fuel control status
(Open/Closed Loop).
4.3L
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1. Fuel Inlet
2. Bleed Hose
3. J 347301A Fuel Pressure Gage Assembly
4. Fuel Pressure Connection
5. In-Line Fuel Filter
6. Fuel Line Pressure Side
7. Fuel Pump Feed Hose
8. In-Tank Fuel Pump
9. Fuel Pump Strainer
10. Return Line
11. Flexible Hose
12. Fuel Return Line
The fuel supply system consists of the following components:
The fuel tank(s) (fuel balance control system when equipped with dual tanks.
The fuel sender assembly (fuel sender, fuel pump and fuel pump strainer).
The fuel filter
The fuel feed and return pipes
The fuel pump electrical circuit
The accelerator control components
Fuel Tank
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The fuel tank, at the rear of the underbody, is held in place by 2 metal straps. Antisqueak pieces are used on top of the tank to reduce rattles.
Filler Neck
In order to help prevent refueling with leaded gasoline, the fuel filler neck on a gasoline
engine vehicles has a built-in restrictor and deflector. The opening in the restrictor will
only admit the smaller unleaded gas nozzle spout, which must be fully inserted to
bypass the deflector.
Fuel Pump
The fuel pump is a high pressure rollervane type, electric pump, which mounts in the
fuel tank. Fuel is pumped, at a specified flow and pressure from the fuel pump, through
the in-line filter to the pressure regulator in the fuel injection unit. Excess fuel is
returned to the fuel tank through the fuel return line.
The fuel pump attaches to the fuel sender assembly. A fuel strainer attaches to the fuel
pump inlet line. The strainer prevents dirt particles from entering the fuel line and tends
to separate water from the fuel. A ceramic resistor card for the fuel level sensor is also
attached to the outside of the sender assembly. The function of the ceramic resistor card
is to vary the resistance, depending on the position of the float and to send a signal to
the fuel gage via the BCM. The modular fuel sender assembly is serviced as a complete
assembly. The only serviceable components on the modular unit are the strainer, fuel
level sensor, and the OBD II fuel tank pressure sensor.
Attempted refueling with a leaded gas nozzle or failure to fully insert the unleaded gas
nozzle results in gasoline splashing back out of the filler neck.
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A steel in-line fuel filter is used in the fuel feed pipe ahead of the fuel injection system.
The filter element is made of paper and is designed to trap particles in the fuel that may
cause damage to the injection system. The filter housing is constructed to withstand
maximum fuel system pressure, exposure to fuel additives and changes in temperature.
If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not
attempt to repair the sections of the nylon fuel pipes. Replace them.
When installing new fuel pipes, Do Not hammer directly on the fuel harness
body clips as it may damage the nylon pipes resulting in a possible 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 115C (239F)
for more than one hour, or more than 90C (194F) for any extended period.
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.)
Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel tubes
they replace. Nylon pipes are constructed to withstand maximum fuel system pressure,
exposure to fuel additives and changes in temperature. There are two sizes used: 3/8 in.
ID for the fuel feed and 5/16 in. ID for the fuel return.
The fuel feed and return pipes are assembled as a harness. Retaining clips hold the pipes
together and provide a means for attaching the pipes to the vehicle. Quick-connect type
fittings are used at the fuel tank ends of the fuel feed/return pipes and at the in-line fuel
filter. They are described below. Sections of the pipes that are exposed to chafing, high
temperature or vibration are protected with a heat resistant rubber hose and/or
corrugated plastic conduit.
Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under
the vehicle. However, if forced into sharp bends, nylon pipes will kink and restrict fuel
flow. Once exposed to fuel, nylon pipes may become stiffer and are more likely to kink
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if bent too far. Special care should be taken when working on a vehicle with nylon fuel
pipes.
Quick-Connect Fittings
Quick-connect type fittings provide a simplified means of installing and connecting the
fuel system components. The quick-connect fittings consists of a female socket and a
compatible male connector. O-rings, located inside the female socket, provide the fuel
seal. Integral locking tabs or fingers hold the fittings together. The metal collar quickconnect fittings have locking tabs that require a special tool to release. Refer to Quick
Connect Fitting(s) Service (Metal Collar) .
If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not
attempt to repair the sections of the nylon fuel pipes. Replace them.
When installing new fuel pipes, Do Not hammer directly on the fuel harness
body clips as it may damage the nylon pipes resulting in a possible 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 115C (239F)
for more than one hour, or more than 90C (194F) for any extended period.
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.)
The vapor pipe extends from the fuel sender assembly to the charcoal canister. It is
made up of nylon pipe and is connected to the fuel sender assembly and the EVAP
canister with the fuel resistant rubber hoses.
Accelerator Control
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The accelerator control system is a control cable type attached at one end to an
accelerator pedal assembly. On the other end is the throttle valve.
The function of the fuel metering system is to deliver the correct amount of fuel to the
engine under all operating conditions.
Fuel is delivered to the engine by individual fuel injectors and poppet nozzles mounted
in the intake manifold near each cylinder.
Purpose
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If a problem occurs in the fuel metering system, it usually results in either a rich or lean
exhaust condition. This condition is sensed by the HO2S. This condition causes the
VCM to change the fuel calculation (injector pulse width). The change made to the fuel
calculation is indicated by a change in the short and long term fuel trim values which
can be monitored by a scan tool. A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a prolonged change is indicated by the
long term fuel trim value. Average fuel trim values will measure around 128. The
averages may vary slightly from engine to engine.
Important: When using a scan tool to observe fuel trim values, remember that if the
system is in control, no action is required unless a driveability symptom is present.
A momentary lean HO2S signal (system is in control) will appear on the scan
tool as the following items:
o Short term fuel trim value above 128 (adding fuel).
o Long term fuel trim value around 128.
A prolonged lean HO2S signal (system is in control) will appear on the scan tool
as the following items:
o Short term fuel trim value around 128.
o Long term fuel trim value above 128 (added fuel).
A prolonged lean HO2S signal (system is out of control) will appear on the scan
tool as the following items:
o Short term fuel trim value well above 128 (adding fuel).
o Long term fuel trim value well above 128 (added fuel).
If both fuel trim values are fixed well above 128, see DTC P0131 for items which can
cause a lean system. Refer to DTC DTC P0131 HO2S Circuit Low Voltage Bank 1
Sensor 1 in Engine Controls - 4.3L .
A momentary rich HO2S signal (system is in control) will appear on the scan
tool as the following items:
o Short term fuel trim value less than 128 (reducing fuel).
o Long term fuel trim value around 128.
A prolonged rich HO2S signal (system is in control) will appear on the scan tool
as the following items:
o Short term fuel trim value around 128.
o Long term fuel trim value less than 128 (reduced fuel).
A prolonged rich HO2S signal (system is out of control) will appear on the scan
tool as the following items:
o Short term fuel trim value much less than 128 (reducing fuel).
o Long term fuel trim value much less than 128 (reduced fuel).
If the fuel trim values are fixed well below 128, see DTC P0132 for items which can
cause the system to run rich. Refer to DTC P0132 HO2S Circuit High Voltage Bank 1
Sensor 1 in Engine Controls - 4.3L .
If a driveability symptom exists, refer to the particular symptom in Symptoms, for
additional items to check.
Listed below are examples of lean and rich HO2S signals with the system in control and
out of control.
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Fuel Control
Fuel delivery is controlled by the control module system.
The diagnosis of fuel control starts with Engine Cranks But Will Not Run. This table
will test the fuel system to determine if there is a problem. Refer to Engine Cranks But
Does Not Run in Engine Controls - 4.3L .
Fuel Injector
A fuel injector which does not open may cause a nostart condition. An injector which
is stuck partially open could cause loss of pressure after sitting, resulting in extended
crank times on some engines. Also, dieseling could occur because some fuel could be
delivered to the engine after the key is turned OFF.
Testing of the fuel injector circuit is located in theFuel Injector Circuit Diagnosis in
Engine Controls - 4.3L table.
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The scan tool displays engine coolant temperature in degrees. After engine startup, the
temperature should rise steadily to about 90C (194F) then stabilize when thermostat
opens. If the engine has not been run for several hours (overnight), the engine coolant
temperature and intake air temperature displays should be close to each other. A fault in
the engine coolant sensor circuit should set DTC P0117 or DTC P0118.
The VCM supplies a 5 volt signal to the engine coolant temperature sensor through a
resistor in the VCM and measures the voltage. The voltage will be high when the engine
is cold, and low when the engine is hot. By measuring the voltage, the VCM calculates
the engine coolant temperature. Engine coolant temperature affects most systems the
VCM controls.
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lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen
sensor voltage can be monitored with a Scan tool.
By monitoring the voltage output of the heated oxygen sensor, the VCM calculates what
fuel mixture command to give to the injector (lean mixturelow HO2S 1 voltage=rich
command, rich mixturehigh HO2S 1 voltage=lean command).
The heated oxygen sensor circuit, if open, should set a DTC P0134 and the Scan tool
will display a constant voltage between 350-550 mV. A constant voltage below 250 mV
in the sensor circuit should set DTC P0131, while a constant voltage above 750 mV in
the circuit should set DTC P0132. DTC P0131 and DTC P0132 could also be set as a
result of fuel system problems.
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TP Sensor Output
This check should be performed when TP sensor attaching parts have been replaced. A
scan tool can be used to read the TP signal output voltage.
Idle Speed
When there is a problem with the idle refer toIdle Air Control (IAC) System Diagnosis
in Engine Controls - 4.3L .
System too lean (High air/fuel ratio) - Idle speed may be too high or too low.
Engine speed may vary up and down, disconnecting the IAC valve has no effect.
System too rich (Low air/fuel ratio) - Idle speed too low. Scan counts usually
above 80. System obviously rich and may exhibit black exhaust smoke. Scan
tool and/or voltmeter will read a Heated Oxygen Sensor (HO2S) signal fixed
above 800 mV (.8 volt).
Cam Signal
The VCM uses this signal to determine the position of the #1 piston during its power
stroke. This signal is used by the VCM to calculate fuel injection mode of operation. A
loss of this signal will set DTC P0340.
If the cam signal is lost while the engine is running, the fuel injection system will shift
to a calculated fuel injection mode based on the last fuel injection pulse, and the engine
1. Connect the DMM from TP sensor connector terminal B (BLK wire) to terminal
C (DK Blue wire). Jumpers for terminal access can be made using terminals
1214836 and 12014837.
2. With ignition ON, engine stopped, the TP signal voltage should be less than
1.25V if more than 1.25V verify free throttle movement. If still more than
1.25V, replace TP sensor.
3. Remove the voltmeter and jumpers, reconnect the TP sensor connector to the
sensor.
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will continue to run. The engine can be restarted and will run in the calculated mode as
long as the fault is present .
The pump provides fuel at a pressure greater than is needed by the injectors. The fuel
pressure regulator, part of the fuel meter body assembly, keeps the fuel to the injectors
at a regulated pressure. The unused fuel is returned to the fuel tank via a separate line.
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Each fuel injector assembly is a solenoid-operated device, controlled by the VCM. The
fuel injector assembly meters the pressurized fuel through a poppet nozzle (5) to a
single engine cylinder.
The VCM energizes the injector solenoid, which opens an armature valve (3), allowing
fuel to flow past the ball valve and through a fuel tube (1) to the poppet nozzle.
An increase in fuel pressure causes the poppet nozzle ball to open from its seat against
the extension spring force. This allows the fuel to flow from the nozzle (at
approximately 280 kPa (40 psi)).
De-energizing the injector solenoid (4) closes the armature. De-energizing also reduces
the fuel pressure acting on the poppet nozzle ball. The extension spring closes the ball
to the seat. The extension spring also checks the pressure between the ball and seat and
the injector armature and fuel tube shutoff. The flow control solenoid assembly (2) is
electrically activated to allow fuel to flow from the injector to the flexible fuel line to
the poppet nozzle.
An injector poppet nozzle that is stuck partly open would cause a loss of pressure after
the engine shut down. Consequently, the driver would notice long cranking times on
some engines. Dieseling could also occur because the fuel injector could deliver some
fuel to the engine after the driver turns the ignition to OFF. These components are
diagnosed in The Injector Balance Test and The Injector Coil Test. Refer to Fuel
Injector Solenoid Coil Test in Engine Controls - 4.3L and to Fuel Injector Balance Test
in Engine Controls - 4.3L .
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The fuel pressure regulator (1) is a diaphragm-operated cartridge relief valve with the
fuel pump pressure on one side and the regulator spring pressure and intake manifold
vacuum on the other. A retainer (2) holds the fuel pressure regulator.
The regulator's function is to maintain a constant pressure differential across the
injectors at all times. The pressure regulator compensates for engine load by increasing
the fuel pressure as engine vacuum drops.
With the ignition ON leaving the engine off (zero vacuum), the fuel pressure at the
pressure test connection should be 415455 kPa (6066 psi). If the pressure is too low,
poor performance could result. If the pressure is too high, excessive odor may result.
The Fuel System Diagnosis has information on diagnosing fuel pressure conditions.
Refer to Fuel System Diagnosis in Engine Controls - 4.3L .
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The throttle body also provides the location for mounting the throttle position (TP)
sensor. The throttle body also senses changes in the engine vacuum due to the throttle
valve position. The vacuum ports are located at, above, or below the throttle valve in
order to generate the vacuum signals that are needed by the various components.
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The IAC valve affects the idle characteristics of the vehicle. A fully retracted valve
allows too much air into the manifold causing a high idle speed. A valve which is stuck
closed allows too little air in the manifold, causing a low idle speed. If the valve is stuck
part way open, the idle may be rough, and the idle will not respond to the engine load
changes.
The non-adjustable TP sensor is mounted on the throttle body assembly opposite the
throttle lever. The TP sensor senses the throttle valve angle and relays that information
to the VCM. Throttle angle is one of the inputs needed by the VCM to generate the
required injector control signals (injector on time). It also is an important input for
transmission shift scheduling.
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When the engine is able to use the extra fuel vapor, the intake air flow purges the fuel
vapor from the carbon element, and then the normal combustion process consumes the
fuel vapor.
The system is designed to detect the evaporative fuel system leaks as small as 0.040 of
an inch between the fuel filler cap and the purge solenoid. The system can test the
evaporative system integrity by applying a vacuum to the fuel tank in order to create a
small vacuum. The vehicle control module (VCM) then used the fuel tank pressure
sensor to determine system integrity.
Operation
The control module monitors the ability of the system to maintain the vacuum. If the
vacuum remains for a specified period of time, then there are no evaporative leaks, and
a PASS report is made by the control module. If there is a leak, the system either will
not achieve a vacuum, or a vacuum cannot be maintained. Usually a fault can only be
detected after a cold start with a trip of sufficient length and driving conditions to run
the needed tests. The enhanced evaporative system diagnostic conducts up to 8 specific
sub-tests in order to detect the fault conditions. If the diagnostic fails a sub-test, the
control module stores a diagnostic trouble code (DTC) in order to indicate the type of
fault detected.
The purpose of the evaporative emission (EVAP) control system is to prevent the fuel
vapors from escaping into the atmosphere. The EVAP transfers the fuel vapor from the
sealed fuel tank to an activated carbon, or charcoal, storage device, or EVAP canister.
The EVAP canister stores the vapors until the engine is able to use the extra fuel vapor.
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If the control module determines that sufficient vacuum is not achieved, the control
module will perform the following steps:
If the control module determines that sufficient vacuum is achieved, the control module
will perform the following steps:
While the EVAP vent valve is ON or closed, turn the EVAP purge solenoid OFF
or closed, and run the Small EVAP Leak Test.
Run the Purge Solenoid Leak Test if the first Weak Vacuum Test passes.
Turn OFF the MIL, if the MIL is ON because of a previous failed Weak
Vacuum Test.
Clear the data stored in the Freeze Frame for the DTC P0440.
The Weak Vacuum Tests will not run unless the Loaded Canister Test has run and
failed.
The Weak Vacuum Test is performed by the control module in order to determine if the
EVAP control system is capable of achieving a sufficient vacuum in the system. During
the normal purging of the EVAP control system, the control module will perform the
following:
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The Small EVAP Leak Test does not test the EVAP purge solenoid for leaks.
In order to run the Small EVAP Leak Test the control module performs the following
steps:
The control module monitors the vacuum trapped in the system. If the control module
detects an excessive decrease in the vacuum that is trapped in the system, a DTC P0442
is set.
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1. Purge Line
2. Vapor From Fuel Tank
3. Air
The evaporative system canister, filled with activated carbon pellets, stores the fuel
vapors from the fuel tank. The engine vacuum purges the vapor canister during normal
driving.
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The fuel tank pressure (FTP) sensor is a 3 wire strain gauge sensor much like that of the
manifold absolute pressure (MAP) sensor, however this sensor has a very different
electrical characteristic due to its pressure differential design. The sensor measures the
difference between the air pressure, or vacuum in the fuel tank and the outside air
pressure.
The sensor mounts at the top of the fuel tank sending unit. A three wire electrical
harness connects it to the control module. The control module supplies a 5 volt
reference voltage and ground to the sensor. The sensor varies a voltage between 0.14.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such
as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3
1.7 volts.
When the air pressure in the tank is 4.5 inches Hg (1.25 kPa), the sensor output voltage
should measure 0.30.7 volts.
The sensor voltage will be approximately 1.5 volts when the fuel tank pressure is
equalized with ambient pressure. The sensor voltage increases to approximately
4.5 volts when a vacuum of 14 inches Hg (3.75 kPa) is detected.
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When energized, the evaporative canister purge solenoid allows the fuel vapor to flow
from the EVAP canister to the engine. The normally closed valve is pulse width
modulated by the control module in order to precisely control the vapor flow. The valve
opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in
the fuel tank and then closes in order to seal the system.
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The ignition system uses a primary and secondary sub system in order to accomplish the
timed spark distribution. The primary system consists of a low voltage trigger device
which determines the base timing. This signal is modified by the ignition control driver
(ICD) module. The signal travels to either or both the engine and transmission processor
(control module) for base timing reference. Another signal is sent back to the ignition
control driver (ICD) module, which has been adjusted by the control module (advanced
or retarded) in order to trigger the coil, according to the requirements of the engine.
The secondary system consists of the ignition coil which has primary, or low voltage,
windings and secondary, or high voltage, windings. The secondary side of the ignition
coil generates a high voltage which high tension spark plug wires deliver to the spark
plugs.
The control module controller now controls the ignition control (IC) and bypass
functions.
In order to properly control the ignition and combustion timing, the control module
needs to know the following things:
System Operation
The enhanced ignition system used on all OBD II engines somewhat resembles the
current distributor ignition (DI) system described in the ignition systems. However, the
system has been greatly enhanced in order to make it compatible with the new OBD II
regulations. The enhanced ignition system provides a spark at precisely the correct time
in order to ignite the air and fuel mixture for optimum performance and fuel economy.
The system consists of the following components:
The ignition system initiates combustion by providing a spark to ignite the compressed
air and fuel mixture at the correct time. In order to provide an improved engine
performance, fuel economy, and control of exhaust emissions, the control module
controls the distributor spark advance, or timing, with the ignition control (IC) system.
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Distributor
Ignition coil driver module
Ignition coil
Crankshaft position (CKP) sensor
This system does not use the ignition module used on the DI systems in the past. The
VCM controller now controls the ignition control (IC) and bypass functions.
The VCM then utilizes this 3x (V6) or 4x (V8) signal in order to provide the correct
spark to the engine by way of the single coil driver module. The single coil driver
module is basically an electronic switch that when commanded by the VCM, causes the
primary coil voltage to breakdown, energizing the secondary coil and providing a spark
via the coil wire to the distributor cap. The distributor consists of the following
components:
The camshaft drives the distributor shaft which rotates providing a spark to the correct
cylinder by way of the cap and rotor. The camshaft position sensor functions much like
the crankshaft sensor previously described but provides only a 1x signal to the VCM.
That is, for every 2 rotations of the crankshaft, there is 1 rotation of the camshaft. Note
that the CMP sensor will not affect driveability. The sole purpose of the CMP sensor is
to provide the VCM with the necessary information for the misfire DTCs.
System Components
Crankshaft Position Sensor
The crankshaft sensor, located in the front engine cover, is perpendicular to a target
wheel attached to the crankshaft. The target wheel is equipped with slots situated
60 degrees apart. As the crankshaft rotates, the target wheel rotates past the crankshaft
position sensor. The rising and falling edges created by the slots cause a signal to be
sent back to the VCM. This signal occurs three times per crankshaft revolution and is
referred to as the 3x signal for V6 applications. The signal occurs four times per
crankshaft revolution and is referred to as the 4x signal for V8 applications.
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The crankshaft position (CKP) sensor is located in the front engine cover and is
perpendicular to the crankshaft target wheel. The air gap between the sensor and the
wheel is preset and not adjustable. The target wheel has four slots 60 degrees apart and
is keyed to the crankshaft. As the target wheel rotates, the slots passing by the sensor
create a change in the magnetic field of the sensor which results in an induced voltage
pulse. One revolution of the crankshaft results in four pulses (4x signal). Based on these
pulses, the VCM is able to determine crankshaft position and engine speed. The VCM
then activates the fuel injector and provides a spark to the distributor. The relation
between the CKP sensor and the target wheel is crucial. The sensor must be exactly
perpendicular to the target wheel with the correct air gap.
Distributor
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The distributor is actually an assembly that contains the camshaft position (CMP)
sensor, cap, rotor, and shaft. The distributor is splined by a helical gear to the camshaft
and rotates providing a spark to each spark plug wire. When servicing the distributor, it
is critical to ensure proper cap sealing to the distributor body and correct installation to
the camshaft. If the distributor is installed a tooth off in relation to the camshaft, a DTC
sets. The distributor is repairable.
Camshaft Position Sensor
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The camshaft position (CMP) sensor is located within the distributor. The operation is
very similar to the crankshaft position (CKP) sensor however it provides one pulse per
camshaft revolution (1x signal). This signal is not detrimental to the driveability of the
vehicle. The VCM utilizes this signal in conjunction with the crankshaft position to
determine which cylinders are misfiring.
Ignition Coil Driver Module and Ignition Coil
The ignition coil driver module is mounted on a bracket next to the coil. The VCM
signals the ICD to turn ON primary current to the ignition coil by pulling the IC line
high (4 volts). The ICD turns the primary current ON and OFF by applying and
removing the ground to the primary winding at the appropriate time. This module is of
minimum function. The module does not contain backup calibrations that allows the
engine to continue to run if the IC signal is lost.
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Purpose
Varying octane levels in gasoline can cause a detonation in an engine. This detonation is
sometimes called a spark knock.
All of the engines use a knock sensor (KS) system with a knock sensor. The KS system
reduces the spark knock in the engine. This allows the engine to have maximum spark
advance for improved driveability and fuel economy.
Operation
A vehicle control module (VCM) is used in conjunction with one knock sensor in order
to control detonation. On a VCM application no KS module will be found as it is
internal to the control module.
A 5 volt reference is applied to the knock sensor which has an internal resistance of
about 100,000 ohms. This resistance will lower the applied voltage to about half or
2.5 volts. When a knock is present, a small AC voltage is produced by the knock sensor
and transmitted to the control module riding on top of the already existing 2.5 volts. An
AC voltage monitor inside the control module will detect the knock and trigger the
control module to start retarding the spark incrementally.
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The exhaust gas recirculation (EGR) system lowers the NOx (Oxides of Nitrogen)
emission levels created by the high combustion temperatures.
Operation
The EGR valve will open when the conditions of operation have been met. This allows
the exhaust gasses to re-enter the combustion chamber. When too much exhaust gas is
allowed to enter the chamber, the proper combustion will not occur. For this reason,
only very little exhaust gas is allowed to re-enter the combustion chamber.
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The control module command exclusively operates the linear EGR valve (1). The
control module monitors the following various engine parameters:
Output messages are then sent to the EGR system indicating the proper amount of
exhaust gas (2) recirculation [with intake air (3)] necessary in order to lower the
combustion temperatures. This electronic metering of exhaust gas is ten times faster
than the vacuum-operated models as well as an improved diagnostic capabilities.
Positioned at the top of the linear EGR assembly are 5 terminals.
A is the pulse width modulated negative signal from the control module.
B is the sensor ground.
C is the sensor output.
D is the +5 volts supply.
E is the positive from ignition.
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A 12 volt current which enters the valve through an electrical connector (terminal E)
energizes the solenoid (bobbin and coil) assembly (3). The 12 volt current then flows
through the solenoid assembly to the control module and creates an electromagnetic
field. This field causes the armature assembly (4, 6) to be pulled upward, lifting the
pintle (5) a variable amount off the base.
The exhaust gas then flows from the exhaust manifold through the orifice into the intake
manifold. The pintle position sensor (2,1sensor cap) reads the height of the pintle, and
the control module closes the loop on a desired position versus the actual position read.
This changes the pulse width modulated command to the solenoid accordingly, until the
actual pintle position equals the desired pintle position.
The linear EGR valve is unique in that the control module continuously monitors the
pintle position. The control module adjusts the pintle position in order to obtain accurate
flow, making linear EGR a Closed Loop system.
When the solenoid is de-energized (the control module breaks the circuit), the pintle
seals against the orifice, blocking the exhaust flow to the intake manifold.
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5. If the ohmmeter reads above 30,000 ohms, no matter how long the wire is, or
fluctuates from infinity to any value, replace the wire.
Generator Usage
Document ID: 236953
Engine
2.2L
4.3L
Model
CS-130D
CS-130D
Rated Output
100 A
100 A
Load Test
70 A
70 A
1998 Dom S/T Cell 30 Figure 3 Component Location View Document ID: 255078
4.3 L Engine Generator And Starter
Generator Specifications
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12. G107
1998 Dom. S/T Cell 30 Figure 5 Component Location View Document ID: 255084
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9. LR PRK (10 A)
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Generator
Wire Color
RED
12186566
ASM 1F M/P 150 Sealed (BLK)
Circuit No.
Function
225
Charge Indicator Lamp Output
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Connector Part
Information
Pin
A
B
C
PPL
PPL
PPL/WHT
Circuit
No.
806
420
1035
BRN/WHT
379
Wire Color
Function
Fuse Output - Crank - Type III Fuse
Stoplamp Switch Output
Starter Relay Feed - Coil
Cruise Control Clutch Pedal Position Switch
Output
Action
Normal Result(s)
Move the ignition switch from the Battery indicator lamp
OFF position to the RUN
turns ON, voltmeter
position.
gage reads between
12-14 volts.
Abnormal
Result(s)*
Refer to
Charge
Indicator
Inoperative
in Engine
Electrical .
Refer to
Voltmeter
Displaying
High or Low
in Engine
Electrical .
Refer to Charge
Indicator Always
On in Engine
Electrical .
Refer to Generator
Not Operating
Properly in Engine
Electrical .
Refer to Generator
Not Operating
12129136
CONN 4F M/P 280 FLXLK (BLK)
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Headlamps
volts and the battery Properly in Engine
Rear defogger
indicator lamp is OFF. Electrical .
Heater blower
motor to HI
2. Increase the engine speed
to 2500 RPM for
2 minutes and observe the
voltmeter gage.
o
o
o
* Refer to the appropriate symptom diagnostic table for the applicable abnormal
result.
Action
Turn all electrical loads OFF. Start the engine and
allow it to idle briefly. Use a DMM to check the
1 voltage across the battery terminals.
Value(s)
13.0
16.0 V
Yes
No
Go to
Go to Step
Step 2
5
2V
Go to
Go to Step
Step 3
6
13-16 V
Go to
Go to Step
Step 4
5
2V
Go to
System Step
OK
6
Go to Go to
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Electrical .
Step
8
Go to
Step 1
Go to
Step 1
Go to
Step 1
Step 7
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7. Remove the starter mounting bolts by accessing them below the right wheel
house panel.
Installation Procedure
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1. Install the starter and the inboard starter mounting bolt. Do not tighten.
2. Install the starter shims, if equipped.
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Tighten
Tighten the starter mounting bolts to 50 N-m (37 lb ft).
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Tighten
Tighten the differential carrier bolts to 25 N-m (18 lb ft).
7. Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
8. Lower the vehicle.
9. Connect the negative battery cable.
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probe is placed on the armature core shaft, the armature is grounded. Replace the
armature.
8. Inspect the brushes for wear. If the brushes are worn to half the size of a new
brush, replace the assembly.
9. Inspect the brush holders for dirt or damage. Make sure that the brushes are not
binding in the holders.
10. Inspect the brush springs for distortion or discoloring. If the springs are weak,
bent, or discolored, replace the frame and field assembly.
11. Inspect the field coils.
o Look for burned or damaged insulation, damaged connections or loose
poles.
o If the conditions of the coils is doubtful, replace the field and frame
assembly.
12. Inspect the field coils for grounds.
o Connect a self-powered test lamp between the field frame and the field
connector. Make sure the brush ends do not contact the field frame.
o If the test lamp lights, the field coils are grounded. Replace the field and
frame assembly.
13. Inspect the field coils for opens.
o Connect a self-powered lamp between the field connector and each of the
brushes.
o If the test lamp does not light at both brushes, the field coils are open.
Replace the frame and field assembly
14. Inspect for field coils for shorts.
o Shorts are indicated by poor motor performance after everything else has
been checked out.
o The coils cannot be replaced separately because of the integral frame
construction. The frame and field assembly must be replaced.
15. Inspect the drive assembly (clutch) by turning the drive pinion in the cranking
direction. If the drive pinion turns or slips in the cranking direction, replace the
over-running clutch assembly.
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16. Inspect the solenoid for grounds using a self-powered 12 volt test lamp.
1. Connect the test lamp between the BAT terminal and the case. The lamp
should not light (terminal should not be grounded).
2. Connect the test lamp between the S terminal and the case. Then connect
the test lamp between the M terminal and the S terminal or between the
M terminal and the case. The lamp should turn on.
3. If the solenoid does not pass these checks, replace it.
Notice: To prevent overheating of the solenoid pull-in winding, do not leave the
winding energized for more than 15 seconds. The current draw will decrease as
the winding temperature increases.
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Caution: Before servicing any electrical component, the ignition and start
switch must be in the OFF or LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these procedures. If a tool or equipment
could easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions may
cause personal injury and/or damage to the vehicle or its components.
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6. Loosen the bolts that secure the electrical connectors to the bottom of the
underhood electrical center.
Installation Procedure
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1. 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.
Connect the electrical connectors.
Tighten
Tighten the electrical connector bolts to 7 N-m (62 lb in).
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2. Install the bolts that attach the underhood electrical center to the underhood
electrical center support bracket.
Tighten
Tighten the electrical connector bolts to 7 N-m (62 lb in).
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The use of a waterless, GM approved coolant recycling system on the vehicle eliminates
the need for evacuation. This system is available through the GM Dealer Equipment
program (or the equivalent). This method removes the used coolant and replaces the
used coolant with approved new or with recycled coolant. When this equipment is not
available use the following procedure.
Draining Procedure
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and steam under
pressure if radiator cap or surge tank cap is removed while the engine and radiator are
still hot.
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.
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9. Remove the drain plugs from each side of the engine block, 4.3L shown.
o There may be more drainage from the radiator at this time.
o Allow the engine block to drain until the flow stops.
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.
10. Apply a sealer (GM P/N 12346004) to the threads and then tighten the engine
block drain plug(s).
Tighten
o
o
Tighten the engine block drain plugs (2.2L) to 15 N-m (11 lb ft).
Tighten the engine block drain plugs (4.3L) to 18 N-m (13 lb ft).
Important: Dispose of the used engine coolant properly. Store the used coolant in a
used coolant Holding Tank awaiting proper disposal or recycling. Do not pour used
coolant down the drain. DexCool antifreeze is a very toxic chemical. Disposal into
the sewer system or into the ground water is both environmentally irresponsible and
illegal.
If the drained coolant is discolored, flush the cooling system. Refer to Flushing
in Engine Cooling .
If the drained coolant appears normal, continue with the filling procedure.
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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 -22C (-8F).
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11. Inspect the level in the coolant recovery reservoir, add coolant if needed.
12. Test the cooling system for leaks. Refer to Cooling System Leak Testing in
Engine Cooling .
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2. Remove the fan clutch from the coolant pump using J 41240 .
1. Install J 41240-1 into the water pump access holes.
2. With J 41240-2 secure on the fan clutch nut, hold J 41240-1 firmly in
place while turning J 41240-2 counter-clockwise.
3. Remove the fan and the fan clutch as an assembly.
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5. Remove the fan-to-fan clutch mounting screws (2.2L, RWD w/o AC).
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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 fan to the fan clutch mounting (4.3L all and 2.2L w/AC).
Tighten
Tighten the screws to 33 N-m (24 lb ft).
2. Install the fan to the fan clutch mounting (2.2L w/o AC).
Tighten
Tighten the screws to 33 N-m (24 lb ft).
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Tighten
Tighten the screws to 33 N-m (24 lb ft).
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Removal Procedure
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Installation Procedure
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1. Important: In order to prevent leakage, thoroughly clean all parts and sealing
surfaces.
Install the coolant thermostat in the lower intake manifold.
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4. 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.
Install the attaching bolts.
Tighten
Tighten coolant outlet bolts to 19 N-m (14 lb ft).
5. Install the radiator inlet hose.
6. Fill the cooling system with specified coolant and concentration. Refer to
Cooling System Draining and Filling in Engine Cooling .
7. Inspect all sealing surfaces for leaks after starting the engine. Refer to Cooling
System Leak Testing in Engine Cooling .
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Installation Procedure
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Installation Procedure
1. Install the upper fan shroud to the vehicle.
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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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Installation Procedure
1. Apply a coating of lubricant to the O-ring seal and the cleaned surface of the
plug opening in the block. Use a water spray resistant, high-temperature grease
lubricant (GM P/N 9985164 or equivalent).
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2. Important: Install the heater element. Avoid element contact to the inner walls
of the engine block.
Install the engine coolant heater and push tight to the block.
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.
Tighten the bolt until both locking wings draw tight against the inner wall of the
engine block.
Tighten
Tighten the bolt to 1.9 N-m (17 lb in).
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4. Important: The heater cord must not touch the following components:
o The engine
o The hot pipes
o The manifold
o Any moving components
Install the heater cord to the coolant heater.
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Intake Manifold
Leaks
Coolant
Consumption
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Oil Consumption
Abnormal Internal
Engine Noises
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piston
No Abnormal
Internal Engine
Noise
Ensure that the vehicle batteries are in good condition, and fully charged.
Operate the vehicle until the engine is at normal operating temperature.
Disconnect the positive ignition coil wire plug from the ignition coil.
Disconnect the fuel injector electrical connector.
Remove all of the spark plugs.
Notice: Do not insert objects into the throttle plate opening. Damage to the
throttle body can result, requiring replacement of the throttle body assembly.
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Valves leaking
15. If one or more cylinders fails to meet the minimum specified compression,
repair or replace all damaged or worn components and test the engine again.
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1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
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2. Important: Do not remove the oil pump screen from the pipe. The pipe and oil
pump screen are serviced as a complete assembly.
Remove the oil pump pipe, if necessary. The oil pump pipe has a press fit into
the oil pump cover.
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5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
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5. During oil pump installation, install a NEW oil pump driveshaft retainer.
Tools Required
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3. Apply clean engine oil to the oil pump drive gear, the oil pump driven gear, and
the oil pump body internal surfaces.
4. Install the oil pump drive gear and the oil pump driven gear into the oil pump
body.
1. Align the matchmarks on the oil pump drive and driven gears.
2. Install the smooth side of the oil pump drive and driven gears toward the
oil pump cover.
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6. 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.
Install the oil pump cover bolts.
Tighten
Tighten the bolts to 12 N-m (106 lb in).
7. Inspect the oil pump for smoothness of operation by turning the oil pump
driveshaft by hand.
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1. Remove the nuts, the studs, and the accelerator control cable bracket.
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9. Important: Note the position and direction of the exhaust gas recirculation
(EGR) valve before removal. It is possible to improperly install the EGR valve
180 degrees from the original position.
Remove the exhaust gas recirculation (EGR) valve bolts.
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12. Remove the engine coolant temperature (ECT) sensor from the front of the
lower intake manifold (if equipped).
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25. Remove the studs and the evaporative emission (EVAP) canister purge solenoid
valve.
26. Remove the nut and the engine wiring harness bracket.
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31. Remove the TBI fuel meter body seal and discard.
32. Remove the 6 poppet nozzles from the lower intake manifold bores.
33. Remove the TBI fuel meter body.
34. Remove the bolt and the TBI fuel meter body bracket.
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Tighten the TBI fuel meter bracket bolt to 10 N-m (88 lb in).
3. Install the TBI fuel meter body into the TBI fuel meter body bracket.
4. Install the 6 poppet nozzles into the proper lower intake manifold bores.
5. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly
seated and locked in the lower intake manifold bores.
6. Install a NEW TBI fuel meter body seal into the groove of the TBI fuel meter
body.
7. Install a NEW upper intake manifold to lower intake manifold gasket into the
groove of the upper intake manifold.
8. Install the upper intake manifold onto the lower intake manifold.
9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the upper intake manifold attaching studs.
10. Install the upper intake manifold attaching studs.
Tighten
1. Tighten the upper intake manifold attaching studs on the first pass to
5 N-m (44 lb in).
2. Tighten the upper intake manifold attaching studs on the final pass to
9 N-m (80 lb in).
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11. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
12. Install the EVAP canister purge solenoid valve and studs.
Tighten
Tighten the EVAP canister purge solenoid valve studs to 10 N-m (88 lb in).
13. Install the engine wiring harness bracket and nut.
Tighten
Tighten the engine wiring harness bracket nut to 12 N-m (106 lb in).
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14. Install the NEW fuel seals (8) (black O-rings) into the TBI fuel meter body.
15. Install the NEW spacer rings (7) (flat washers) into the TBI fuel meter body.
16. Install the NEW fuel seals (6) (yellow O-rings) into the TBI fuel meter body.
17. Install the NEW fuel seal retainers (5) into the TBI fuel meter body.
18. Install the fuel pipe (3) into the TBI fuel meter body.
19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
20. Install the fuel pipe retainer bracket nuts (1).
21. If reusing the fastener, apply threadlock GM P/N 12345382 or equivalent to the
threads of the fuel pipe bolt.
22. Install the fuel pipe bolt (4).
Tighten
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29. Important: The exhaust gas recirculation (EGR) valve must be installed in the
original orientation.
Install a NEW EGR valve gasket and the EGR valve.
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36. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the throttle body attaching studs.
37. Install the throttle body attaching studs.
Tighten
Tighten the throttle body attaching studs to 9 N-m (80 lb in).
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2. Tighten the accelerator control cable bracket nuts to 12 N-m (106 lb in).
3. Tighten the accelerator control cable bracket stud to the throttle body to
12 N-m (106 lb in).
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TREN DELANTERO
Wheel Alignment Specifications
Document ID: 162608
Cross Caster
Camber
Crosss Camber
Steering Angle
Toe (Total)
ZR2/Z85/ZM6/G51
Caster
Cross Caster
Camber
Cross Camber
Steering Angle
Toe (Total)
Operation
Exc ZR2/Z85/ZM6/G51
Service Allowable
Service Preferred
2 to 4
1
-1 to 1
1
-0.5 to 0.5
-.10 to .10
0.1
1 to 3
1
-1 to 1
1
-0.5 to 0.5
-.10 to .10
0.1
Service Allowable
Service Preferred
Operation
Exc ZR2/Z85/ZM6/G51
Caster
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Caster
Cross Caster
Camber
Crosss Camber
Steering Angle
Toe (Total)
2 to 4
1
-1 to 1
Cross Caster
Camber
Cross Camber
Steering Angle
Toe (Total)
ZR2/Z85/ZM6/G51
Caster
-0.5 to 0.5
-.10 to .10
0.1
1 to 3
1
-1 to 1
1
-0.5 to 0.5
-.10 to .10
0.1
Specification
Metric
English
21 N-m
16 lb ft
75 N-m
55 lb ft
115 N-m 85 lb ft
Application
Tie Rod Adjuster Sleeve Nuts
Upper Control Arm Bolts to Frame Nuts (RWD)
Upper Control Arm Bolts to Frame Nuts (4WD)
Application
Steering Knuckle Upper Control Arm Bolt and Cam Kit
Drive Type/Model
Z Trim Height
RWD (except ZQ8)
RWD (ZQ8)
4WD (ZR2)
D Trim Height
Service Allowed
Service Preferred
73 mm (2.9 in)
64 mm (2.5 in)
64 mm (2.5 in)
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Utility
Pickup (ZQ8)
Checks
Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving
conditions.
Tire and wheel are Balance the wheels. Refer to Tire and Wheel Balancing in
out of balance
Vibration Diagnosis and Correction.
Tire and wheel are Replace the tire. Refer to Tire Description in Tires and
out of round
Wheels.
Blister or bump on Replace the tire. Refer to Tire Description in Tires and
the tire
Wheels.
Improper shock
Replace the shock absorber.
absorber action
For RWD, refer to Shock Absorber Replacement in
Front Suspension.
For 4WD, refer to Shock Absorber Replacement in
Front Suspension.
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Front Suspension or
Shock Absorber Replacement in Front
Suspension.
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4. CamberChange the shims at the front and the rear of the cross shaft. Add an
equal number of shims at the front and the rear of the cross shaft. This decreases
positive camber.
5. A normal shim pack will leave at least two threads of the bolt exposed beyond
the nut (1). The difference between the front shim pack and the rear shim pack
must not exceed 10 mm (0.40 in). If you cannot meet these requirements, check
for damage to the control arms and to related parts.
6. Tighten the nut on the thinner shim pack first. This improves the shaft-to-frame
clamping force. This also improves torque retention.
4x4
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Use the cams on the upper control arm frame attaching bolts to adjust the caster and the
camber.
To adjust the caster and the camber, loosen the upper control arm-to-frame attaching
nuts. Rotate the cam by rotating the bolt head.
CasterTo increase positive caster, move the front cam lobe inboard and move
the rear cam lobe outboard.
CamberTo increase positive camber, move the front and the rear cam lobes
inboard.
Tighten the nuts after you select the proper cam position. Refer to Fastener Tightening
Specifications .
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| Repair Instructions
Prev. Page
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Bulletins
General Information
HVAC
Steering
Suspension
o
Suspension General Diagnosis
Specifications
Trim Height Specifications
Diagnostic Information and Procedures
Suspension General Diagnosis
Ride
Vehicle Leads/Pulls
Body Leans or Sways in Corners
Suspension Bottoms
Dog Tracking
Trim Height
Wheel Tramp
Noisy Front Suspension
Poor Directional Stability
Struts or Shock Absorbers Weak
Struts or Shock Absorbers Noisy
Struts or Shock Absorbers Leak
Wheel Bearings Diagnosis - Utility and 4WD Pickup
Wheel Bearings Diagnosis - RWD Pickup
Special Tools and Equipment
o
Wheel Alignment
Specifications
Wheel Alignment Specifications
Fastener Tightening Specifications
GM SPO Group Numbers
Repair Instructions
Wheel Alignment Measurement
Front Caster and Camber Adjustment - RWD
Front Caster and Camber Adjustment - 4WD
Front Toe Adjustment
Rear Axle Housing Alignment
Description and Operation
o
Front Suspension
o
Rear Suspension
o
Tires and Wheels
o
Automatic Level Control
Driveline/Axle
Brakes
Engine
Transmission/Transaxle
Body and Accessories
Restraints
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{"DhtmlHistory_pageLoaded":tru
Cross Caster
Camber
Crosss Camber
Steering Angle
Toe (Total)
Service Allowable
Service Preferred
2 to 4
1
-1 to 1
1
ZR2/Z85/ZM6/G51
Caster
Cross Caster
Camber
Cross Camber
Steering Angle
Toe (Total)
-0.5 to 0.5
-.10 to .10
0.1
1 to 3
1
-1 to 1
1
-0.5 to 0.5
-.10 to .10
0.1
Application
Tie Rod Adjuster Sleeve Nuts
Upper Control Arm Bolts to Frame Nuts (RWD)
Upper Control Arm Bolts to Frame Nuts (4WD)
Application
Steering Knuckle Upper Control Arm Bolt and Cam Kit
Drive Type/Model
Z Trim Height
Service Allowed
Specification
Metric
English
21 N-m
16 lb ft
75 N-m
55 lb ft
115 N-m 85 lb ft
GM SPO Group Number
6
Service Preferred
Operation
Exc ZR2/Z85/ZM6/G51
Caster
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RWD (ZQ8)
4WD (ZR2)
73 mm (2.9 in)
64 mm (2.5 in)
64 mm (2.5 in)
D Trim Height
Pickup (ZQ8)
Checks
Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving
conditions.
Tire and wheel are Balance the wheels. Refer to Tire and Wheel Balancing in
out of balance
Vibration Diagnosis and Correction.
Tire and wheel are Replace the tire. Refer to Tire Description in Tires and
out of round
Wheels.
Blister or bump on Replace the tire. Refer to Tire Description in Tires and
the tire
Wheels.
Improper shock
Replace the shock absorber.
absorber action
For RWD, refer to Shock Absorber Replacement in
Front Suspension.
For 4WD, refer to Shock Absorber Replacement in
Front Suspension.
Excessive wheel or Refer to Tire and Wheel Runout Measurement in Vibration
tire runout
Diagnosis and Correction Vibration Diagnosis and Correction.
Checks
Action
Lack of lubrication of the ball Lubricate the ball joints and the linkage. Refer to
joints and the steering linkage Fluid and Lubricant Recommendations in
Maintenance and Lubrication.
Low or uneven front or rear Inflate the tires to the recommended pressure. Refer
tire pressure
to Tire Inflation Description in Tires and Wheels.
Worn or loose hub and wheel Replace the hub and wheel bearing assembly.
bearing
Refer to Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension or
Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension.
Utility
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1. Loosen the clamp bolts at each end of the adjustable sleeves of the steering tie
rod.
2. Set the steering wheel in the straight ahead position.
3. Turn the tie rod adjusting sleeves in order to obtain the proper toe-in
specification.
4. Check the number of threads inside the adjuster sleeve. These must be equal to
within three threads. Refer to Tie Rod Replacement (RWD) or Tie Rod
Replacement (4WD) in Steering Linkage.
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If a tram gauge is used for checking toe, perform steps 1 and 2 to check
camber.
You can not align the rear wheels by regular means. Replace bent or damaged axle
housing and springs. The frame often is not straight. You can straighten the frame using
frame straightening equipment, or by relocating the spring to the axle without removing
the axle housing from the vehicle. In this way you can determine when the axle and
spring assemblies are within the correct limits during the straightening operation.
If the frame and the springs are within specification, then the rear axle assembly is not
straight, and you must replace the rear axle.
er Description
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Camber Description
Document ID: 382974
Camber is the tilting of the wheels from the vertical when viewed from the front of the
vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the
wheel tilts inward at the top, the camber is negative (). The amount of tilt is measured
in degrees from the vertical. Camber settings influence the directional control and the
tire wear.
Too much positive camber will result in premature wear on the outside of the tire and
cause excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and
cause excessive wear on the suspension parts.
Unequal side-to-side camber, of 1 degree or more, will cause the vehicle to pull or lead
to the side with the most positive camber.
Toe Description
Document ID: 382972
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Toe is a measurement of how much the front wheels are turned in or out from a straightahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (). The actual amount of toe is normally only a fraction of a
degree. The purpose of toe is to ensure that the wheels roll parallel.
Toe also serves to offset the small deflections of the wheel support system that occur
when the vehicle is rolling forward. In other words, with the vehicle standing still and
the wheels set with toe-in, they tend to roll parallel on the road when the vehicle is
moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.
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1. Important:
o The vehicle must rest on a level surface.
o The vehicle must be stable. Do not rock the vehicle on the floor stands.
o The upper control arm bumper must not contact the frame.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
2. Support the lower control arm with a floor stand or jack, as far outboard as
possible, under the stabilizer bar bracket.
Important: If a seal is cut or torn, replace the ball joint.
3. Clean and inspect the ball joints seals for cuts or tears. If the ball joint seals are
damaged, replace the ball joint. Refer to Upper Control Arm Ball Joint
Replacement in Front Suspension or Lower Control Arm Ball Joint Replacement
in Front Suspension.
4. Check the wheel bearing for looseness. If looseness in the wheel bearing is
present, refer to Wheel Bearings Diagnosis in Suspension General Diagnosis.
5. Check the ball joints for horizontal looseness.
1. Position the J 8001 dial indicator against the lowest outboard point on the
wheel rim.
2. Rock the wheel in and out while reading the dial indicator. This shows
horizontal looseness in both joints.
3. The dial indicator reading should be no more than 2.00 mm (0.080 in). If
the reading is too high, check the lower ball joints for vertical looseness.
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6. Important: Do not support the lower control arm with a jack stand for a RWD
vehicle, this will unload or cause compression on the wear indicator and will
cause the wear indicator to give a false reading.
For RWD vehicles, check the lower ball joints for wear and for vertical
looseness using the following procedure:
0. Remove the safety stand from under the lower control arm.
1. Inspect by sight the lower ball joint for wear. The position of the housing
into which the grease fitting is threaded indicates wear. This round
housing projects 1.27 mm (0.050 in) beyond the surface of the ball joint
cover on a new lower ball joint. Under normal wear, the surface of the
ball joint housing retreats inward very slowly.
2. First observe, then scrape a scale, a screwdriver, or a fingernail across the
cover. If the round housing is flush with or inside of the cover surface,
replace the lower ball joint.
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7. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in
such a manner that the ball joint seal is contacted. Damage to the wheel drive
shaft boot will result (4WD).
For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order
to show vertical movement.
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9. If the dial indicator reading is more than 3.18 mm (0.125 in), replace the lower
ball joint. Refer to Lower Control Arm Ball Joint Replacement in Front
Suspension .
10. If the lower ball joint is within specifications, and there is too much horizontal
looseness, check the upper ball joint for wear.
0. Disconnect the upper ball joint from the steering knuckle. Refer to Upper
Control Arm Ball Joint Replacement in Front Suspension .
1. If you find any looseness or can twist the stud with your fingers, replace
the upper ball joint. Refer to Upper Control Arm Ball Joint Replacement
in Front Suspension .
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1. Raise and suitably support lower control arm with safety stands. Refer to Lifting
and Jacking the Vehicle in General Information.
2. Because the weight of the vehicle is used to relieve spring tension on the upper
control arm, position the floor stands between the spring seats and the ball joints
of the lower control arms.
3. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.
Notice: Support the caliper with a piece of wire to prevent damage to the brake
line.
4.
5.
6.
7.
8.
Remove the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
Disconnect the wheel speed sensor electrical connector from upper control arm.
Disconnect wheel speed sensor electrical connector.
Remove the cotter pin.
Remove the upper ball joint stud nut.
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9. Seperate the ball joint from the steering knuckle using J 23742 .
10. Apply pressure on the tool until the stud breaks loose.
11. Remove J 23742 .
12. Pull the ball joint stud away from the steering knuckle.
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15. Drill away the rivet heads. Use a 12.7 mm ( in) drill.
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Installation Procedure
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the upper ball joint retaining bolts and nuts.
Tighten
Tighten the upper ball joint retaining nuts to 23 N-m (17 lb ft).
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Caution: Floor jack must remain under the lower control arm during removal
and installation to retain the lower control arm in position. Failure to do so could
result in personal injury.
3. Place a floor jack under the control arm spring seat. Raise the jack in order to
support the control arm.
Notice: Support the caliper with a piece of wire to prevent damage to the brake
line.
4. Remove the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.
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6. Break the ball joint loose from the steering knuckle using the J 23742 .
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8. Remove the lower ball joint from the lower control arm using the J 95197, the
J 951928 and the J 951930 as shown.
9. Inspect the tapered hole in the steering knuckle and remove any dirt. If the
tapered hole is out of round, deformed, or damaged, replace the steering
knuckle.
Installation Procedure
Tools Required
J 9519-D Ball Joint Remover and Installer Set
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1. Press in the ball joint using the tools as shown. The ball joint will bottom
on the control arm.
2. Locate the grease fitting facing inboard.
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1. Raise the front of the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
o Support the lower control arm with floor stands.
o Place floor stands under the lower control arms as far outboard as
possible (between spring seats and ball joint) to maintain maxium
leverage.
2. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.
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3. Remove the wheel speed sensor harness and the brake hose bracket from the
upper control arm.
4. Remove the upper ball joint stud from the steering knuckle. Refer to Upper
Control Arm Ball Joint Replacement in Front Suspension .
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Installation Procedure
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Tighten
Tighten the upper control arm shaft nuts to 115 N-m (85 lb ft).
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7. Install the ABS wire and the brake hose bracket to the upper control arm.
8. Install the ABS wire and the brake hose bracket to the upper control arm
mounting bolts and nuts.
Tighten
Tighten the ABS wire and the brake hose bracket to the upper control arm nuts
to 24 N-m (18 lb ft).
9. Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
10. Lower the vehicle.
11. Check the front wheel alignment. Refer to Wheel Alignment Specifications in
Wheel Alignment.
1. Remove the upper control arm from the vehicle. Refer to Upper Control Arm
Replacement in Front Suspension .
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3. Remove the washers and the nuts from upper control arm shaft.
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5. Remove the upper control arm shaft from the upper control arm.
Installation Procedure
Tools Required
J 22269-1 Tie Rod End Installer
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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.
Tighten J 22269-1 until the bushing is positioned on the shaft and the upper
control arm as shown. The measurement should be 12.813.8 mm (0.480.52 in)
on both ends.
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4. Install the washers and the nuts to the upper control arm shaft. Do not tigten the
nuts.
5. Remove the upper control arm from the vise.
6. Install the upper control arm to the vehicle. Refer to Upper Control Arm
Replacement in Front Suspension .
Removal Procedure
Tools Required
J 23028-A Coil Spring Remover and Installer
1. Remove the front coil spring. Refer to Front Coil Springs Replacement in Front
Suspension .
2. Remove the lower ball joint from the steering knuckle. Refer to Lower Control
Arm Ball Joint Replacement in Front Suspension .
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4. Guide the lower control arm out of the splash shield opening.
Installation Procedure
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1. Remove the lower control arm from the vehicle. Refer to Lower Control Arm
Replacement in Front Suspension .
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4. Using a blunt chisel, drive the front bushing flare down flush with the rubber
part of the bushing.
5. Prior to removing or installing the front bushing, place a wedge or spacer
between the control arm bushing housing. This keeps the control arm bushing
housing from bending while removing or installing the bushing.
6. Remove the front bushing.
1. Install J 21474-3, 4, 5, 6. Tighten until the bushing is partially removed.
2. Then, reverse J 21474-6 and tighten until the front bushing becomes free.
Installation Procedure
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5. Important: The chain is not to take place for safety, but to retain the coil spring
to the upper control arm.
Secure the upper control arm with a chain around the spring and through the
upper control arm.
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10. Remove the coil spring and the insulators. While removing the coil spring, do
not apply force to the lower control arm and ball joint.
Position the coil spring properly for easy removal.
Installation Procedure
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
5. Install the lower control arm front pivot bolt and the new nut.
6. Install the lower control arm rear pivot bolt and the new nut.
Tighten
1. Tighten the lower control arm pivot bolts nuts with the front suspension
loaded.
2. Tighten the lower control arm front bolt to 115 N-m (85 lb ft).
3. Tighten the lower control arm rear bolt to 98 N-m (72 lb ft).
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1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
2. Remove the following parts from the stabilizer links:
o The lower nuts
o The washers
o The bolts
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Installation Procedure
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Removal Procedure
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5.
6.
7.
8.
Installation Procedure
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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 screws that retain the front of the console.
Tighten
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1. Remove the front ashtray from the console by gently prying out the ashtray with
a flat-bladed tool.
2. Carefully lift up on the wood shifter assembly close-out in order to remove the
assembly from the console. Rotate the closeout panel in order to fit the panel
over the shift handle.
3. Remove the passenger side toe-panel by gently prying out the panel with a flatbladed tool.
4. Disconnect the instrument panel to console wiring harness connection.
5. Open the armrest in order to expose and remove the convenience tray from the
storage compartment.
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7. Remove the console from the vehicle by lifting the console over the floor studs.
8. If replacing the center console, remove the compact disc player from the
console. Refer to Remote CD Changer Replacement in Entertainment.
9. Remove the amplifier from the console. Refer toRadio Speaker Amplifier
Replacement in Entertainment.
10. Remove the rear seat audio control from the console. Refer toRear Seat Audio
Control Replacement in Entertainment.
11. Remove and retain the console wiring harness for use on the new console.
Installation Procedure
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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
6. Install the fasteners (2) that retain the console to the vehicle.
Tighten
Tighten the console to the vehicle retainers to 10 N-m (88 lb in).
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10. Carefully press the wood shifter assembly close-out into place. Rotate the
closeout panel in order to fit the panel over the shift handle.
11. Install the front ashtray to the console by firmly pressing the ashtray into place.
Removal Procedure
1. On vehicles equipped with a manual transmission, remove the shift lever.
2. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Apply the park brake.
2. Insert the ignition key and turn the ignition switch to the RUN position.
3. Depress the brake pedal and shift the transmission to the 1 position.
4. Turn the ignition switch to the OFF position.
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4. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
5. Remove the right instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and
Console .
6. If the vehicle is equipped with a multiple CD changer located in the center
console, remove the center console. Refer to Front Floor Console Replacement
in Instrument Panel, Gauges, and Console .
7. Remove the center sound insulator. Refer to Closeout/Insulator Panel
Replacement - Center in Instrument Panel, Gauges, and Console .
8. Remove the lower left instrument panel mounting bolt.
9. Remove and retain the instrument panel storage compartment. Refer to
Instrument Panel Compartment Door Replacement in Instrument Panel, Gauges,
and Console .
10. Remove the lower right instrument panel mounting bolt.
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13. If equipped with a sun load temperature sensor, twist the sensor turn
counterclockwise in order to disengage.
14. Disconnect the brown electrical connection from the body control module
(BCM).
15. Disconnect the purple electrical connection from the body control module
(BCM).
16. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console .
17. Remove and retain the instrument cluster. Refer to Instrument Cluster
Replacement in Instrument Panel, Gauges, and Console .
18. Remove and retain the radio. Refer to Radio Replacement in Entertainment.
19. Remove the HVAC control assembly. Refer to the appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint
(SIR) System. Failure to follow the correct procedure could cause the following
conditions:
o
o
o
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20. Disable the passenger side SIR system. Refer to Disabling the SIR System in
SIR.
21. Remove the left and right instrument panel driver knee bolster brackets.
22. Lower the steering column for clearance. Refer to Steering Column Replacement
in Steering Wheel and Column.
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Installation Procedure
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7. Raise the steering column into position. Refer to Steering Column Replacement
in Steering Wheel and Column.
8. Install the left and right instrument panel driver knee bolster brackets.
Tighten
Tighten the screws/bolts to 6.3 N-m (56 lb in).
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17. Install the windshield defroster grille by pressing carefully pressing the grille
into place.
18. Install the left and right speakers and the speaker grilles. Refer to Radio Front
Speaker Replacement in Entertainment.
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Installation Procedure
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1. Install the brake pedal to the upper steering column support bracket. Refer to
Brake Pedal Replacement in Hydraulic Brakes.
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 upper steering column support bracket fasteners.
Tighten
Tighten the nuts to 25 N-m (18 lb ft).
Tighten the bolts to 25 N-m (18 lb ft).
3. Install the brake switch. Refer to Stop Lamp Switch Replacement in Hydraulic
Brakes.
4. Install the brake booster pushrod to the brake pedal. Refer to Power Vacuum
Brake Booster Replacement in Hydraulic Brakes.
5. Install the instrument panel. Refer to Instrument Panel Carrier Replacement in
Instrument Panel, Gauges, and Console .
o
o
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Removal Procedure
1. Remove the screws that retain the instrument panel sound insulator to the
following components:
o The instrument panel
o The cowl
2. Remove the instrument panel sound insulator from the vehicle.
Installation Procedure
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Tighten
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3. Disconnect the electrical connectors from the remote control door lock receiver
module.
4. Remove the remote control door lock receiver module from the instrument panel
sound insulator.
Installation Procedure
1. Install the remote control door lock receiver module to the instrument panel
sound insulator.
2. Connect the electrical connector to the remote door lock receiver module.
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.
Install the screw that retains the instrument panel sound insulator to the cowl
panel.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).
4. Install the screws that retain the instrument panel sound insulator to the knee
bolster.
Tighten
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Installation
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1. Install each wire and terminal in the new junction block. Refer to Electrical
Center Identification Views in Wiring Systems.
2. Rewrap the wrapping (3) on the wiring harness.
3. Install the junction block (2) to the instrument panel with the screw (1).
4. Install the left insulator/closeout panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
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1. Remove the screw at the front of the console that retains the console to the roof.
2. Pull downward at the rear of the console in order to remove the console from the
roof.
3. Disconnect the electrical connections as needed.
Installation Procedure
1. Connect the electrical connections as needed.
2. Insert the mounting tabs into the roof panel and push upward on the rear of the
console in order to install the console to the roof.
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.
3. Install the screw at the front of the console that retains the console to the roof.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).
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Removal Procedure
1. Remove the screw at the front of the console that retains the sunroof console to
the roof.
2. Pull downward on the rear of the console in order to expose the electrical
connections (1,4,5 and 6) and remove the sunroof console from the roof.
Installation Procedure
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1. Important: Ensure that the Flux Gate wire (4) is not trapped between the
retainer and the roof steel.
Install the sunroof console bracket to the roof.
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 screw that retains the sunroof console mounting bracket to the roof.
Tighten
Tighten the screw to 1.9 N-m (17 lb ft).
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1. Using a flat-bladed tool, carefully pry the display lens (1) from the console (3).
2. Remove the electronic display module (2) from the console (3).
3. Disconnect the electrical connection.
Installation Procedure
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Installation Procedure
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The calibration procedures that are described in this section establish a base direction
for the compass to work from. Once the compass is properly calibrated, the electronic
display indicates the direction that the vehicle is facing. Under normal circumstances,
no further attention to the compass should be required for a period of 2 years.
Calibration may be necessary under the following conditions:
Calibration
The compass is self-calibrating. This eliminates the need to manually set the compass.
For a short time when the vehicle is new, the compass may appear to operate erratically
and the CAL symbol or the letter C will display. Correct this by driving the vehicle in a
complete circle 3 consecutive times. The symbol will turn off and the compass will
function normally. If the compass displays a C at all times, the compass needs to be
calibrated.
Fast Calibration
The compass module is shipped to the assembly plant in the fast calibration mode. In
this mode, a C shows in the portion of the display that typically shows the compass
heading. When is vehicle is calibrated outside the assembly plant, drive the vehicle in an
area that is free from metal objects. Reset the compass by cycling the ignition (Off and
ON). Drive the vehicle in a circle, oval or square until the C is replaced by the display
heading.
Slow Calibration
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If the compass is displaying a heading, then the compass is in the slow calibration
mode. In this mode, the compass automatically calibrates for changes in the vehicle
magnetism over the life of the vehicle. This autocalibration assures that the compass
heading is always accurate and does not require manual calibration.
Important: Remove the Driver Information Center (DIC) before you degauss the
vehicle.
If you install a new compass, use the following procedure in order to calibrate the
compass:
1. Turn the ignition switch to the RUN position.
2. Depress and hold both the US/MET and the ON/OFF or the MODE buttons for
approximately 10 seconds, or until the display reads CAL or C.
3. Drive the vehicle in a complete circle 3 consecutive times. The symbol turns off
when the compass is calibrated. The compass will then function normally.
Variance
Variance is the difference between magnetic North and geographic North. In some areas
of the world, the difference between magnetic and geographic North is great enough to
cause false readings.
Use the following procedure in order to set the variance for the vehicle's particular
locations. On vehicles with a MODE switch, the display must be in the COMP/TEMP
mode before setting the variance.
World Magnetic Variation Map
Excessive magnetism in or near the vehicle may cause the compass display to go blank.
In order to distinguish between vehicle magnetics and surrounding magnetics, drive the
vehicle to an area that is free from large metal objects. Rest the compass by cycling the
ignition (OFF and ON). If the compass display goes blank within 20 seconds after the
reset of power, then the vehicle magnetism is too high and the vehicle should be
degaussed.
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When these circumstances arise, a malfunction may be suspected when, in fact, the
system is operating normally.
An approximate 15 degree deviation (declination) from true NORTH occurs between
the east and west coasts. This declination is the result of the earth's curvature. Various
other deviations throughout the country are the result of differences in the magnetic
fields.
The filters function by taking into account that vehicle directional changes ordinarily do
not occur as quickly at higher speeds as at lower speeds. The filters help avoid false
readings caused by large steel structures, such as the following objects:
Skyscrapers
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Bridges
Roads with steel reinforcement
Railroad tracks
Sometimes, the field projected by these structures leads to a reading that represents too
drastic a change of direction for the prevailing driving conditions. When this happens,
the filters intervene in order to prevent changes in the directional display. However,
under borderline conditions, as in large cities with slow driving, the compass may give
false readings and appear to be malfunctioning. If this occurs, test the compass in an
open area, free from magnetic disturbances.
When travelling on winding roads, the compass readings may oscillate between
2 neighboring directions, such as NORTH and NORTHWEST. This occurs when the
road coordinates coincidentally border the coordinates used by the system for the
2 different directions.
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Installation Procedure
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The overhead console is a convenience package which contains some or all of the
following features:
A multi-function electronic display (4) that indicates the outside temperature and
the direction that the vehicle is facing
On some models, the display is also used for the driver information system.
A compartment for a garage door opener transmitter that can be adapted to many
brands of transmitters
The transmitter can be activated by pressing the button on the compartment
door.
Button Operation
The two button user interface consists of the following switches:
US/MET
MODE
The US/MET switch allows the user to toggle the display readout between the English
and the metric systems.
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The MODE switch serves the function of toggling the display between the following
modes of operation:
OFF
COMP/TEMP
TRIP
Once in the TRIP mode of operation, the MODE switch served to step the user through
the TRIP functions. Refer to the following table for information about the applicable
states and the sequencing order of the MODE switch.
Function
Display Off
Compass and Outside Temperature
Average Fuel Economy
Instantaneous Fuel Economy
Trip Range
Fuel Used
Average Speed
Display Dimming
Display dimming follows the radio dimming characteristics. Upon activation of the park
lamp, the display dims to the maximum brightness in the dim mode. Further dimming is
controlled by the analog dimming signal of the IP dimming control. The display goes
blank when the IP dimming control is at the lowest setting.
Sequence
1
2
3
4
5
6
7
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The outside temperature is displayed on the electronic display (2). The electronic
display is located at the front of the console. Temperature readings may be displayed in
either degrees Fahrenheit (F) or degrees Celsius (C). Pushing the US/MET switch (4)
that is located on the left side of the display alternates the temperature readings between
Fahrenheit and Celsius. If the outside temperature is 3C (37F) or lower, the display
toggles between the word ICE and the current temperature every eight seconds in order
to warn the driver of the possibility of icy road conditions.
When the vehicle is first started, the electronic module uses an internal timer in order to
determine how long the vehicle has been turned off. If the vehicle has been turned off
for less than four hours, the sensor may be warmer than the actual ambient because the
engine and the radiator may not have cooled down yet. In order to prevent a false
temperature from being displayed, the electronic module displays the same temperature
as when the vehicle was last turned off. A new sensor reading is not displayed until the
vehicle speed meets the above mentioned criteria. If the vehicle has been off for more
than 4 hours, the module takes an immediate temperature reading from the sensor and
displays that temperature. Further updates then must meet the vehicle speed criteria.
The outside temperature is measured from a sensor that is located behind the front
grille. In this location, heat from the radiator may warm the sensor above the actual
ambient temperature if there is insufficient airflow across the sensor. In order to prevent
false temperature displays, the electronic module monitors the vehicle speed. The
vehicle speed must meet certain conditions before the module displays a new reading
from the sensor. If the vehicle speed is less that 29 km/h (18 mph), the temperature
display is not updated. If the vehicle speed is between 2958 km/h (1836 mph), the
temperature display is updated at a slow rate. If the vehicle speed is over 58 km/h
(35 mph) for longer than 2 minutes, the sensor will be at the correct ambient
temperature. The display then updates continuously in order to reflect the ambient
temperature more accurately.
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Installation Procedure
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2. Remove the bolt that retains the horn assembly to the fender.
3. Remove the horn assembly from the fender.
Installation Procedure
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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 bolt that retains the horn assembly to the fender.
Tighten
Tighten the bolt to 17 N-m (13 lb ft).
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Installation Procedure
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PUERTAS, ACCESORIOS Y
ESPEJOS
Front Side Door Replacement
Document ID: 299143
Tools Required
J 36604 Door Hinge Spring Compressor
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement
in Doors .
2. Disconnect the electrical connectors as needed.
3. Remove the rubber conduit from the door and the body hinge pillar.
4. Apply cloth-backed tape to the door and the body hinge pillar in order to protect
the door and the body hinge pillar from scratches.
Removal Procedure
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7. Use a soft-faced hammer and locking pliers in order to remove the lower hinge
pins.
8. Temporarily install a bolt through the lower hinge in order to hold the door in
place.
9. Remove the upper hinge pin.
10. Remove the temporary bolt from the lower hinge.
11. Remove the door from the vehicle.
12. Remove and discard the door hinge pin bushings.
Installation Procedure
1. Install the new door hinge pin bushings.
2. Install the door to the vehicle.
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Installation Procedure
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3.
4.
5.
6.
Remove the nuts and the bolts that retain the bracket to the bumper.
Remove the nuts and the bolts that retain the brace to the bumper.
Remove the bumper impact bar from the vehicle.
Remove the following components that retain the brace to the frame:
o The nuts
o The washers
o The bolts
7. Remove the brace.
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Installation Procedure
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7. Install the nuts and the bolts that retain the bracket to the bumper.
Tighten
Tighten the bolts to 40 N-m (30 lb ft).
8. Install the license plate lamps. Refer to Rear License Plate Lamp Replacement in
Lighting Systems.
9. Install the rear bumper step pads. Refer to Rear Bumper Step Pad Replacement
in Bumpers .
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Installation Procedure
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Installation Procedure
1. 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.
Install the nuts that retain the extension to the rear quarter panels.
Tighten
Tighten the nuts to 3 N-m (27 lb in).
2. Install the bolt that retains the brace to the extension.
Tighten
Tighten the bolt to 40 N-m (30 lb ft).
3. Install the screws to the wheel opening trim ring.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).
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Removal Procedure
1. Use a flat-bladed tool in order to remove the wire cover (if equipped).
2. Disconnect the electrical connector (if equipped).
Installation Procedure
1. Slide the mirror on to the mirror support.
2. Connect the electrical connector (if equipped).
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Installation Procedure
1. Draw a centerline on the outside of the glass from the roof panel to the
windshield base with a wax pencil.
2. Draw a line intersecting the centerline 53.4 cm (21 in) from the top of the
bottom black-out strip of the glass. Locate the base of the support at the
intersection of these lines.
3. Use a razor blade in order to remove old adhesive from the windshield
and the support.
2. Use the following procedure in order to clean the inside glass surface within
75 mm (3 in) of the intersecting lines:
1. Rub the area with a paper towel and glass cleaning solution until the
glass is completely clean and dry.
2. Remove all the traces of the cleaning solution from the glass with an
alcohol saturated paper towel.
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1. 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.
Disconnect the battery negative cable.
2. Disconnect the cruise control cable. Refer to Cruise Control Cable Replacement
in Cruise Control .
3. Disconnect the electrical connectors, as necessary.
4. Remove the 3 nuts that retain the cruise control module to the mounting bracket
studs.
5. Remove the cruise control module from the mounting bracket.
6. Remove the 3 screws that retain the mounting bracket to the cowl panel.
Installation Procedure
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1. 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.
Install the mounting bracket to the cowl panel with the 3 screws.
Tighten
Tighten the screws to 4.5 N-m (40 lb in).
2. Install the cruise control module to the vehicle.
3. Install the 3 nuts that retain the cruise control module to the mounting bracket.
Tighten
Tighten the nuts to 9.0 N-m (6.6 lb ft).
4. Connect the electrical connectors, as necessary.
5. Install the cruise control cable. Refer to Cruise Control Cable Replacement in
Cruise Control .
6. Connect the battery negative cable.
7. Test the systems operation.
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1. Disconnect the electrical connector from the cruise control servo module.
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5. Disconnect the cruise control cable fitting from the cruise control module.
Installation Procedure
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7. Snap the cruise control cable engine-end fitting over the nail head stud on the
throttle cam lever.
8. Connect the cruise control cable conduit fitting to the round hole in the engine
cable bracket.
Ensure that the tabs snap securely into the hole.
9. Connect the cruise control cable locator clip to the outboard rectangular hole in
the routing bracket at the left front corner of the engine.
1. Route the cruise control cable above the accelerator cable.
2. Ensure that the clip snaps securely into place.
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Push the cable adjuster plunger into the locked position (2). Ensure that the
white paint area is no longer visible.
o
o
11. Connect the electrical connection to the cruise control servo module.
12. Test the systems operation.
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Passlock sensor
Body control module
Powertrain control module
Vehicle control module
30 Minute Procedure
1. Ensure that the battery is fully charged.
2. Use a scan tool in order to clear the Passlock DTCs.
3. Turn the ignition switch from the OFF position to the CRANK position, and
then to the RUN position.
The vehicle will start and then stall.
4.
5.
6.
7.
Leave the ignition ON until the security telltale turns OFF in 10 minutes.
Repeat Steps 35 for 2 more times (3 times total)
The Passlock controller will learn the new data on the next start attempt.
Use a scan tool in order to clear all DTCs.
Both of the above modules except for the Passlock sensor must be programmed using
their own vehicle configuration. See the individual module service manual section.
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3.
4.
5.
6.
Installation Procedure
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1. Important: Push the washer pump as far into the container seal as possible.
Connect the washer pump to the container.
2. Insert the solvent container legs into the holes in the inner fender.
3. Install the mounting screw retaining the solvent container to the vehicle.
Tighten
Tighten the screw to 3 N-m (27 lb in)
4. Connect the washer hose assembly from the washer pump.
5. Connect the electrical connector to the washer pump.
6. Replace the washer solvent.
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.
7. Connect the negative battery cable.
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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5. Remove the left body side trim panel. Refer to Body Side Trim Panel
Replacement in Interior Trim.
6. Remove the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel
Replacement - Left Side in Interior Trim.
7. Fold over the left side of the carpet to allow access to the body harness. Refer to
Front Floor Mat/Carpet Replacement in Interior Trim and Rear Floor Panel
Carpet Replacement in Interior Trim.
8. Disconnect the washer hose connection (1) from the body harness (2) at the
endgate.
9. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.
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13. Pull the washer hose (1) into the vehicle though the bulkhead.
14. Cut the old washer hose off where it enters the body wiring harness (2).
15. Remove the hose from the vehicle.
Installation Procedure
1. Install the hose to the vehicle.
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13. Install the endgate/liftgate door sill plate. Refer to Rear Floor Rear Trim Plate
Replacement in Interior Trim or Liftgate Door Sill Plate Replacement in Interior
Trim.
14. Install the rear seat. Refer to Rear Seat Replacement in Seats.
15. Install the left front seat. Refer to Driver or Passenger Seat Replacement in
Seats.
Installation Procedure
Removal Procedure
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1.
2.
3.
4.
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8. Disconnect the driver yellow 2-way connector located at the base of the steering
column.
9. Open the IP compartment door, lift stop and allow door to fully open.
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Removal Procedure
1. Remove the screws that retain the data link connector (DLC) to the instrument
panel sound insulator.
Feed the DLC lines through the hole in the sound insulator.
2. Remove the screws that retain the instrument panel sound insulator to the knee
bolster and the cowl panel.
3. Disconnect the electrical connectors from the remote control door lock receiver
module.
4. Remove the remote control door lock receiver module from the instrument panel
sound insulator.
Installation Procedure
1. Install the remote control door lock receiver module to the instrument panel
sound insulator.
2. Connect the electrical connector to the remote door lock receiver module.
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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.
Install the screw that retains the instrument panel sound insulator to the cowl
panel.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).
4. Install the screws that retain the instrument panel sound insulator to the knee
bolster.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).
5. Feed the DLC through the hole in the instrument panel sound insulator.
6. Install the screws that retain the DLC to the instrument panel sound insulator.
Tighten
Tighten the screws to 2.4 N-m (21 lb in).
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2. Connect the passenger yellow 2-way connector located behind the glove box.
3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way
connector located behind the glove box.
4. Close the IP compartment door.
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6. Install the Connector Position Assurance (CPA) to the driver yellow 2-way
connector located at the base of the steering column.
7. Install the knee bolster (if equipped). Refer to Knee Bolster Replacement in
Instrument Panel, Gauges and Console.
8. Install the sound insulator-LH. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
9. Install the SIR Fuse to the IP fuse block.
10. Staying well away from both air bags, turn the ignition switch to the RUN
position.
1. The AIR BAG warning lamp will flash seven times.
2. The AIR BAG warning lamp will then turn OFF.
11. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does
not operate as described.
Failure to follow the correct procedure could cause air bag deployment, personal injury,
or unnecessary SIR system repairs.
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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:
Remove all water.
Repair the water damage.
Replace the SDM harness connector.
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
1. Disable the SIR system. Refer to Disabling the SIR System in SIR .
2. Remove the drivers seat. Refer to Driver or Passenger Seat Replacement in
Seats.
3. Remove driver seat belt from floor. Refer to the Seat Belt Replacement - Driver
in Seat Belts.
4. Remove the carpet retaining sill trim molding - LH. Refer to Sill Trim Plate
Replacement in Interior Trim.
5. Remove the floor console (if equipped). Refer to Front Floor Console
Replacement in Instrumenet Panel, Gauges and Console.
Important: Remove the left body side trim panel for extended cab pickup.
6. Remove the LH Kick Panel.
7. Fold back the carpet to access the inflatable restraint Sensing and Diagnostic
Module (SDM).
8. Remove the Connector Position Assurance (CPA) from the SDM harness
connector.
9. Disconnect the SDM harness connector from the SDM.
1.
2.
3.
4.
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Installation Procedure
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Important: Install the left body side trim panel for extended cab pickup.
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Installation Procedure
1. Install the inflatable restraint IP module (2) to the instrument panel (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 fasteners (4) (5) that retain inflatable restraint IP module (2) to the
instrument panel (3).
Tighten
Tighten the fasteners to 8.0 N-m (70 lb in).
3. Install the instrument panel. Refer to Instrument Panel Carrier Replacement in
Instrument Panel, Gauges and Console.
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Failure to follow the correct procedure could cause air bag deployment, personal injury,
or unnecessary SIR system repairs.
Removal Procedure
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Installation Procedure
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2. Install the inflatable restraint front end discriminating sensor mounting rivets
(P/N 15715058).
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Disable the SIR system. Refer to Disabling the SIR System in SIR .
2. Use a flat-bladed tool in order to pry the switch from the instrument panel.
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Installation Procedure
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TABLA DE CONVESION DE
MEDIDAS
US English/Metric Conversion
In order to convert English units to metric units, multiply the English units by the
conversion factor shown in the conversion table.
In order to convert metric units to English units, divide the metric units by the
conversion factor shown in the conversion table.
English
in
ft
yd
mi
sq in
sq ft
sq yd
cu in
qt
gal
cu yd
lb
ton
kg
oz
lb
Multiply/ Divide by
LENGTH
25
0.3048
1
2
AREA
645
6
0.0929
1
VOLUME
16387
16
0.0164
1
4
1
MASS
0.4536
907
1
FORCE
10
0.2780
4
Metric
mm
m
km
sq mm
sq cm
sq m
cu mm
cu cm
L
cu m
kg
tonne (t)
newtons (N)
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ft/s
in/s
lb in
lb ft
hp
Foot Candle
mph
F
C
mpg
m/s
N-m
kW
kPa
kPa
lm/m
km/h
C
F
L/km
Decimal (in)
0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.125
0.140625
0.15625
0.171875
0.1875
0.203125
Metric (mm)
0.39688
1
1
2
2
2
3
3
4
4
4
5
5
inches of Mercury
inches of H2O
lb/sq in
ACCELERATION
0.3048
0.0254
TORQUE
0.11298
1
POWER
1
PRESSURE (STRESS)
3
0.2491
7
LIGHT
11
VELOCITY
2
TEMPERATURE
5/9(F-32)
9/5(C+32)
FUEL PERFORMANCE
2
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0.21875
0.234375
0.25
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.375
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
6
7
7
8
8
8
9
9
10
10
10
11
11
12
12
12
13
13
13
14
14
15
15
15
16
16
17
17
17
18
18
19
19
19
20
20
21
21
21
22
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
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7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
1
1
1
1
1
1
1
1
1
22
23
23
23
24
24
25
25
25
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2. View Detail
3. Ambient Air Mixed With Another Gas or Indicate Temperature Change
4. Motion or Direction
5. View Angle
6. Dimension (1:2)
7. Ambient/Clean Air Flow or Cool Air Flow
9. Task Related
10. Sectioning (1:3)
11. Gas Other Than Ambient Air or Hot Air Flow
12. Lubrication Point Grease or Jelly
13. Multidirectional Arrow
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All engines and transmissions, as well as removable roof panels are stamped or
laser etched with a partial Vehicle Identification Number (VIN), which was
derived from the complete VIN. A VIN derivative contains the following nine
positions:
o
v = 1997
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The 6-speed manual transmission, the Borg Warner T-56 (RPO MM6), is
stamped with a VIN derivative on the LH side of the transmission case.
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6. Model
7. Transmission ID Location
8. Hydra-Matic 4L60-E
9. Julian Date (or Day of the Year)
10. Serial No.
11. Shift Built (A, B, j = First Shift; C, H, w = Second Shift)
13. (8 = 1998)
14. Transmission ID Location
12. Model
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5. Model
6. Serial Number in Base Code 31
7. Plant
8. Broadcast Date
9. Transaxle
10. Transaxle I.D. Tag Location
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15. Model
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The location for the Semi-Automatic VIN derivative (1) is on the transmission housing.
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1. Transaxle
1. Transaxle
2. Calendar Year
2. Calendar Year
3. Julian Date or Day of the Year
3. Julian Date or Day of the Year
4. Shift (a=First Shift, b=Second Shift, c=Third Shift)
5. Model
6. Serial Number in Base Code 31
7. Plant
8. Hydramatic 4T40 E
9. Serial Number
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10. Model
10. Model
11. Model Year
11. Model Year
12. Control Number
13. Line Built (1=Line 1, 2=Line 2, 3=Line 3, 4=Line 4)
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SFI
CSFI
LN2
LF6
4L60E / NV1500
4L60E / NV3500
M30 / MW2
M30 / M50
4.3L V6
CSFI
L35
4L60E / NV3500
M30 / M50
2.2L L4
SFI
LN2
3L30
MD2
4.3L V6
CSFI
LF6
4L60E / NV3500
M30 / M50
4.3L V6
CSFI
L35
4L60E / NV3500
M30 / M50
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CSFI
LF6
4L60E / NV3500
M30 / M50
CSFI
L35
4L60E / NV3500
M30 / M50
CSFI
L35
4L60E
M30
Chevrolet / 4.3L V6
GMC
GMT325
4WD
T
Blazer / 4.3L V6
Jimmy
Sport
Utility
Oldsmobile
GMT325
OLDS
4WD
4.3L V6
T
Bravada
Sport
Utility
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An identification tag is attached to the rear half of the transfer case. The tag provides the
following information:
The information on this tag is necessary for servicing the transfer case. If the tag is
removed or becomes dislodged during service operations, keep the identification tag
with the unit.
Abbreviations Table
Abbreviation
Meaning
A
A
ABS
A/C
AC
Ampere(s)
Antilock Brake System
Air Conditioning
Alternating Current
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B+
BBARO
batt
BBV
BCM
BHP
BLK
BLU
BP
BPM
BPMV
BPP
BRN
BTDC
BTSI
Btu
ACC
ACL
ACR4
A/D
ADL
A/F
AIR
ALC
AM/FM
Ant
AP
API
APP
APT
ARS
ASR
A/T
ATC
ATDC
Auto
avg
AWD
AWG
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Degrees Celsius
Charge Air Cooler
Corporate Average Fuel Economy
Calibration
Camshaft
California Air Resources Board
cubic centimeters
Central Control Module
Cycling Clutch Orifice Tube
Climate Control Panel
Compact Disc
Commutator End
Cold Engine Air Bleed
Counter Electromotive Force
cubic feet per minute
center of gravity
Cubic Inch Displacement
Crankshaft Position
Circuit
Closed Loop
Cigar Lighter
Camshaft Position
Compressed Natural Gas
Carbon Monoxide
Carbon Dioxide
Coaxial
Communication
Connector
Connector Position Assurance
Clutch Pedal Position
Central Power Supply
Central Processing Unit
Cathode Ray Tube
Cathode Ray Tube Controller
Charging System
Closed Throttle Position
cubic foot/feet
cubic inch/inches
Contant Velocity (joint)
Continuously Variable Road Sensing Suspension
Cylinder(s)
D
C
CAC
CAFE
Cal
Cam
CARB
cc
CCM
CCOT
CCP
CD
CE
CEAB
CEMF
cfm
cg
CID
CKP
CKT
CL
C/Ltr
CMP
CNG
CO
CO2
Coax
COMM
Conn
CPA
CPP
CPS
CPU
CRT
CRTC
CS
CTP
cu ft
cu in
CV
CVRSS
Cyl
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DAB
dB
dBA
DC
DCM
DE
DEC
DERM
DI
dia
DIC
Diff
DK
DLC
DMM
DOHC
DR
DRL
DTC
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F
FC
FDC
FED
FEDS
FF
FI
FMVSS
F/P
ft
FT
F4WD
4WAL
4WD
FW
FWD
g
GA
gal
gas
GCW
Gen
GL
GM
GM SPO
gnd
gpm
GRN
GRY
EPA
EPR
EPROM
ESC
ESD
ETC
ETCC
ETR
EVAP
EVO
Exh
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GVWR
IAC
IAT
IC
ICM
ID
IDI
ign
ILC
in
INJ
inst
I/P
IPC
I/PEC
ISC
ISO
ISS
H
H2O
Harn
HC
H/CMPR
HD
HDC
hex
Hg
Hi Alt
HO2S
hp
HPL
HPS
HPV
Htd
HTR
HUD
HVAC
HVACM
HVM
Hz
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K
Keep Alive Memory
Keyboard Display Driver
kilogram
kilohertz
kilometer
kilometers per hour
kilometers per liter
kilopascals
Knock Sensor
kilovolts
L
L
L4
L6
lb
lb ft
lb in
LCD
LDCL
LDCM
LED
LF
LH
lm
LR
lt
LT
MAF
Man
MAP
MAT
max
M/C
MDP
MFI
mi
MIL
min
ml
mm
Liter
Four Cylinder Engine, In-line
Six Cylinder Engine, In-Line
pound
pound feet (torque)
pound inch (torque)
Liquid Crystal Display
Left Door Closed Locking
Left Door Control Module
Light Emitting Diode
Left Front
Left Hand
lumens
Left Rear
left
Light
M
Mass Air Flow
Manual
Manifold Absolute Pressure
Manifold Absolute Temperature
maximum
Mixture Control
Manifold Differential Pressure
Multiport Fuel Injection
miles
Malfunction Indicator Lamp
minimum
milliliter
millimeter
KAM
KDD
kg
kHz
km
km/h
km/l
kPa
KS
kV
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mpg
mph
ms
MST
M/T
MV
mV
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qt
R-12
R-134a
RAM
RAP
RAV
RCDLR
RDCM
Ref
Rev
RF
RFA
RFI
RH
RKE
Rly
ROM
RPM
PCV
PM
P/N
PNK
PNP
PRNDL
POA
POS
POT
PPL
ppm
PROM
P/S
PSD
PSP
psi
psia
psig
pt
PWM
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RPO
RR
rt
RTD
RTV
RWAL
RWD
Tach
TBI
TC
TCC
TCS
TDC
TEMP
Term
TFP
TFT
s
SAE
SC
SCB
SCM
SDM
SEO
SFI
SI
SIR
SLA
sol
SO2
SP
SPO
sq ft
sq in
SRC
SRI
ST
S4WD
Sw
syn
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UART
U/H
U/HEC
U-joint
UTD
UV
V
V6
V8
Vac
VAC
VATS
VCM
VDOT
VDV
vel
VES
VF
VIO
VIN
VMV
VR
V ref
VSS
w/
W/B
WHL
TOC
TP
TPA
TPM
TR
TRANS
TV
TVRS
TVV
TWC
TWC+OC
TXV
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WHT
w/o
WOT
W/P
W/S
WSS
WU-OC
WU-TWC
yd
YEL
X-valve
White
without
Wide Open Throttle
Water Pump
Windshield
Wheel Speed Sensor
Warm Up Oxidation Converter (Catalytic)
Warm Up Three Way Converter (Catalytic)
X
Expansion valve
Y
yard(s)
Yellow
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TRANSMISION AUTOMATICA
4L60
Fastener Tightening Specifications Document ID: 191229
Application
Accumulator Cover to Case Bolt
Case Extension to Case Bolt
Case Extension to Case Bolt (4WD Shipping)
Converter Housing to Case Screw
Cooler Pipe Connector
Detent Spring to Valve Body Bolt
Forward Accumulator Cover to Valve Body Bolt
Line Pressure Plug
Manual Shaft to Inside Detent Lever Nut
Oil Passage Cover to Case Bolt
Park Brake Bracket to Case Bolt
Plate to Case Bolt (Shipping)
Plate to Converter Bolt (Shipping)
Pressure Control Solenoid Bracket to Valve Body Bolt
Pump Assembly to Case Bolt
Pump Cover to Pump Body Bolt
Specification
Metric
English
8.014.0 N610 lb ft
m
42.0
35.0
48.0 N-m
39.4 lb ft
11.2
8.3
22.6 N-m
16.7 lb ft
65.0
4855 lb ft
75.0 N-m
35.0
2630 lb ft
41.0 N-m
20.0
1520 lb ft
27.0 N-m
8.014.0 N610 lb ft
m
8.014.0 N610 lb ft
m
27.0
2025 lb ft
34.0 N-m
814.0 N-m 610 lb ft
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
8.014.0 N610 lb ft
m
26.0
1924 lb ft
32.0 N-m
20.0
1520 lb ft
27.0 N-m
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Fluid Capacity
Document ID: 6951
Fluid Capacity
Specification
Application
Metric
4.7 liters
10.6 liters
Pan Removal
Overhaul
English
5 quarts
11 quarts
8.014.0 N610 lb ft
m
10.5
7.710 lb ft
13.5 N-m
8.014.0 N610 lb ft
m
35.0
2630 lb ft
41.0 N-m
9.513.8 N710 lb ft
m
8.014.0 N610 lb ft
m
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Identification
None
0
1
Selective Plate
Thickness
1.6841.829 mm (0.066
0.072 in)
1.3141.168 mm (0.052
0.046 in)
2.1982.344 mm (0.087
0.092 in)
Identification
A
B
C
D
E
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Thickness (in)
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
Plate Thickness
7.2497.409 mm (0.2850.292 in)
6.6786.519 mm (0.2630.257 in)
5.9475.787 mm (0.2340.228 in)
Backing Plate Travel: 1.021.94 mm (0.0400.076 in)
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TRANSAXLE/ TRANSAXLE/
BODY CAR LINE ENGINE FUEL ENGINE
TRANSMISSION TRANSMISSION
TYPE (DIVISION) SIZE SYSTEM RPO
USED
RPO
Prism
S
1.6L L4
MFI
L01
A131 / M5
MB3 / MB5
(Chevrolet)
Prism
S
1.8L L4
SFI
LV6
A245E / M5
M57 / MB4
(Chevrolet)
Metro /
Firefly
M (Chevrolet) / 1.0L L3
TBI
LP2
M5
M58
(GM Of
Canada)
Metro /
Firefly
M (Chevrolet) / 1.3L L4
MFI
L72
A3 / M5
M60 / M42
(GM Of
Canada)
Cavalier
3T40 / 4T40E /
MD9 / MN4 /
J
2.2L L4
SFI
LN2
(Chevrolet)
M5
MK7
Cavalier
J
2.4L L4
SFI
LD9
4T40E / M5
MN4 / MJ1
(Chevrolet)
Sunfire
3T40 / 4T40E /
MD9 / MN4 /
J
2.2L L4
SFI
LN2
(Pontiac)
M5
MK7
Sunfire
J
2.4L L4
SFI
LD9
4T40E / M5
MN4 / MJ1
(Pontiac)
Malibu
N
2.4L L4
SFI
LD9
4T40E
MN4
(Chevrolet)
Malibu
N
3.1L V6
SFI
L82
4T40E
MN4
(Chevrolet)
Skylark
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Buick)
Skylark
N
3.1L V6
SFI
L82
4T60E
M13
(Buick)
Achieva
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Oldsmobile)
Achieva
N
3.1L V6
SFI
L82
4T60E
M13
(Oldsmobile)
Cutlass
N
3.1L V6
SFI
L82
4T40E
MN4
(Oldsmobile)
Grand Am
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Pontiac)
Grand Am
N
3.1L V6
SFI
L82
4T60E
M13
(Pontiac)
Venture
U
3.4L V6
SFI
LA1
4T60E
M13
(Chevrolet)
U
Trans Sport 3.4L V6
SFI
LA1
4T60E
M13
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U
W
W
W
W
W
W
W
F
F
F
F
G
G
C
V
P
H
3.4L V6
SFI
LA1
4T60E
M13
3.8L V6
SFI
L36
4T65E
M15
3.5L V6
SFI
LX5
4T65E ADV.
CONTROL
MN3
3.1L V6
SFI
L82
4T60E
M13
3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.1L V6
SFI
L82
4T60E
M13
3.1L V6
SFI
L82
4T60E
M13
3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.1L V6
SFI
L82
4T60E
M13
3.8L V6
SFI
L36
4T65E
M15
3.8L V6
SFI
L36
4L60E / M5
M30 / M49
5.7L V8
SFI
LS1
4L60E / M6
M30 / MM6
3.8L V6
SFI
L36
4L60E / M5
M30 / M49
5.7L V8
SFI
LS1
4L60E / M6
M30 / MM6
4.0L V8
SFI
L47
4T80E
MH1
3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.0L V6
SFI
L81
4L30E
ML4
EV
N/A
LN1
N/A
N/A
3.8LV6
SFI
L36
4T65E
M15
(Pontiac)
Silhouette
(Oldsmobile)
Intrigue
(Oldsmobile)
Intrigue
(Oldsmobile)
Grand Prix
(Pontiac)
Grand Prix
(Pontiac)
Century
(Buick)
Regal
(Buick)
Regal
(Buick)
Monte Carlo
/ Lumina
(Chevrolet)
Monte Carlo
Z34 /
Lumina LTZ
(Chevrolet)
Camaro
(Chevrolet)
Camaro
(Chevrolet)
Firebird
(Pontiac)
Firebird
(Pontiac)
Aurora
(Oldsmobile)
Riviera
(Buick)
Park Avenue
/ Ultra
(Buick)
Catera
(Cadillac)
EV1
(GMEV)
Eighty-Eight
/ Regency
(Oldsmobile)
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3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.8L V6
SFI / SFI
(SC)
L36 /
L67
4T65E / 4T65EHD
M15 / MN7
3.8L V6
SFI
L36
4T65E
M15
4.6L V8
SFI
LD8 /
L37
4T80E
MH1
4.6L V8
SFI
LD8 /
L37
4T80E
MH1
4.6L V8
SFI
LD8/
L37
4T80E
MH1
5.7L V8
SFI
LS1
4L60E / T-56
M30 / MM6
TRUCK
LINE &
BODY TRUCK ENGINE FUEL ENGINE TRANSMISSION TRANSMISSION
TYPE TYPE
SIZE SYSTEM RPO
USED
RPO
C1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC
GMT430
Suburban
2WD 1/2 TON
C2500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC 7.4L V8
SFI
L29
4L80E
MT1
GMT430
Suburban
2WD 3/4 TON
C1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC
GMT420
Tahoe /
Yukon
2WD 1/2 TON
K1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC 6.5L V8
SFI
L56
4L80E
MT1
GMT430 DSL
Suburban TURB.
LSS
(Oldsmobile)
Bonneville /
H
SSE / SSEi
(Pontiac)
Le Sabre
H
(Buick)
Eldorado /
Eldorado
E
Touring
Coupe
(Cadillac)
Seville SLS /
K
Seville STS
(Cadillac)
DeVille /
DeVille
K-sp
Concours
(Cadillac)
Corvette
Y
(Chevrolet)
H
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Body
Type
C2500
K2500
C3500
5.7L V8
6.5L V8
DSL
TURB.
7.4L V8
CSFI
SFI
L31
L65
4L60E
4L80E
M30
MT1
SFI
L29
4L80E
MT1
5.7L V8
6.5L V8
DSL
TURB.
CSFI
SFI
L31
L56
4L80E / NV4500
4L80E / NV3500
MT1 / MW3
MT1 / MG5
5.7L V8
CSFI
L31
4L60E
M30
Chevrolet / GMC
Chassis Cab
2WD - 3/4 TON
Single And Dual
Rear Tires
Chevrolet / GMC
Chassis Cab
4WD - 1TON
Single And Dual
Rear Tires
Chevrolet / GMC
Chassis Cab
2WD - 1 TON
Single And Dual
7.4L V8
Rear Tires
SFI
L29
4L80E
Transmission
RPO
MT1 / MW3
MT1
MT1 / MW3
MT1
MT1 / MW3
MT1
MT1 / MW3
MT1
MT1
MT1
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Chevrolet / GMC
Chassis Cab
K3500
4WD - 1 TON
Single And Dual
Rear Tires
Chevrolet / GMC
Crew Cab And
Chassis Crew
C3500HD
Cab 2WD - 1
TON Single And
Dual Rear Tires
K3500
SFI
L65
4L80E
MT1
7.4L V8
SFI
L29
4L80E
MT1
6.5L V8
DSL
TURB.
SFI
L65
4L80E /
NV4500
MT1 / MW3
7.4L V8
SFI
L29
4L80E /
NV4500
MT1 / MW3
5.7L V8 CSFI
L31
4L80E /
NV4500
MT1 / MW3
6.5L V8
DSL
TURB.
SFI
L65
4L80E /
NV4500
MT1 / MW3
7.4L V8
SFI
L29
4L80E /
NV4500
MT1 / MW3
SFI
L65
4L80E
MT1
SFI
L29
4L80E
MT1
TRUCK
BODY LINE &
TYPE TRUCK
TYPE
Chevrolet /
GMC
GMT325
2WD S Pick-Up /
S
Sonoma
Pick-Up
And
Extended
Cab
GM Postal
POST
S-Chassis
Chevrolet /
GMC
GMT325
4WD S T
Pick-Up /
Sonoma
Pick-Up
And
SFI
CSFI
LN2
LF6
4L60E / NV1500
4L60E / NV3500
M30 / MW2
M30 / M50
4.3L V6
CSFI
L35
4L60E / NV3500
M30 / M50
2.2L L4
SFI
LN2
3L30
MD2
4.3L V6
CSFI
LF6
4L60E / NV3500
M30 / M50
4.3L V6
CSFI
L35
4L60E / NV3500
M30 / M50
C3500
Chevrolet / GMC
Crew Cab And
Chassis Crew
Cab 2WD - 1
TON Single And
Dual Rear Tires
6.5L V8
DSL
TURB.
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Body
Type
CSFI
LF6
4L60E / NV3500
M30 / M50
CSFI
L35
4L60E / NV3500
M30 / M50
CSFI
L35
4L60E
M30
Engine
Fuel Engine Transmission Transmission
Size System RPO
Used
RPO
4.3L V6
CSFI
L35
4L60E
M30
4.3L V6
CSFI
L35
4L60E
M30
4.3L V6
5.0L V8
CSFI
CSFI
L35
L30
4L60E
4L60E
M30
M30
5.7L V8
CSFI
L31
4L60E
M30
4.3L V6
5.0L V8
CSFI
CSFI
L35
L30
4L60E
4L60E
M30
M30
5.7L V8
CSFI
L31
4L60E
M30
4.3L V6
CSFI
L35
CSFI
L31
SFI
L65
4L80E
MT1
SFI
L29
4L80E
MT1
Chevrolet / GMC
5.7L V8
Express / Savana
G3500
1 TON Full Size 6.5L V8
Van
DSL
TURB.
7.4L V8
4L60E /
4L80E
4L60E /
4L80E
M30 / MT1
M30 / MT1
Specification
Application
All Metal Prevailing Torque Fasteners
6 mm
8 mm
Metric
English
0.4 N-m
0.8 N-m
4 lb in
7 lb in
Extended
Cab
Chevrolet / 4.3L V6
GMC
GMT325
4WD
T
Blazer / 4.3L V6
Jimmy
Sport
Utility
Oldsmobile
GMT325
OLDS
4WD
4.3L V6
T
Bravada
Sport
Utility
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12 lb in
19 lb in
27 lb in
37 lb in
62 lb in
93 lb in
3 lb in
5 lb in
10 lb in
13 lb in
20 lb in
30 lb in
49 lb in
75 lb in
Specification
Application
Metric
Meaning
A
A
ABS
A/C
AC
Ampere(s)
Antilock Brake System
Air Conditioning
Alternating Current
English
4.5 lb in
7.5 lb in
11.5 lb in
16 lb in
20 lb in
28 lb in
36 lb in
54 lb in
3 lb in
5 lb in
9 lb in
12 lb in
16 lb in
22 lb in
30 lb in
45 lb in
10 mm
1.4 N-m
12 mm
2.1 N-m
14 mm
3 N-m
16 mm
4.2 N-m
20 mm
7 N-m
24 mm
10.5 N-m
Nylon Interface Prevailing Torque Fasteners
6 mm
0.3 N-m
8 mm
0.6 N-m
10 mm
1.1 N-m
12 mm
1.5 N-m
14 mm
2.3 N-m
16 mm
3.4 N-m
20 mm
5.5 N-m
24 mm
8.5 N-m
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B+
BBARO
batt
BBV
BCM
BHP
BLK
BLU
BP
BPM
BPMV
BPP
BRN
BTDC
BTSI
Btu
ACC
ACL
ACR4
A/D
ADL
A/F
AIR
ALC
AM/FM
Ant
AP
API
APP
APT
ARS
ASR
A/T
ATC
ATDC
Auto
avg
AWD
AWG
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Degrees Celsius
Charge Air Cooler
Corporate Average Fuel Economy
Calibration
Camshaft
California Air Resources Board
cubic centimeters
Central Control Module
Cycling Clutch Orifice Tube
Climate Control Panel
Compact Disc
Commutator End
Cold Engine Air Bleed
Counter Electromotive Force
cubic feet per minute
center of gravity
Cubic Inch Displacement
Crankshaft Position
Circuit
Closed Loop
Cigar Lighter
Camshaft Position
Compressed Natural Gas
Carbon Monoxide
Carbon Dioxide
Coaxial
Communication
Connector
Connector Position Assurance
Clutch Pedal Position
Central Power Supply
Central Processing Unit
Cathode Ray Tube
Cathode Ray Tube Controller
Charging System
Closed Throttle Position
cubic foot/feet
cubic inch/inches
Contant Velocity (joint)
Continuously Variable Road Sensing Suspension
Cylinder(s)
D
C
CAC
CAFE
Cal
Cam
CARB
cc
CCM
CCOT
CCP
CD
CE
CEAB
CEMF
cfm
cg
CID
CKP
CKT
CL
C/Ltr
CMP
CNG
CO
CO2
Coax
COMM
Conn
CPA
CPP
CPS
CPU
CRT
CRTC
CS
CTP
cu ft
cu in
CV
CVRSS
Cyl
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DAB
dB
dBA
DC
DCM
DE
DEC
DERM
DI
dia
DIC
Diff
DK
DLC
DMM
DOHC
DR
DRL
DTC
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F
FC
FDC
FED
FEDS
FF
FI
FMVSS
F/P
ft
FT
F4WD
4WAL
4WD
FW
FWD
g
GA
gal
gas
GCW
Gen
GL
GM
GM SPO
gnd
gpm
GRN
GRY
EPA
EPR
EPROM
ESC
ESD
ETC
ETCC
ETR
EVAP
EVO
Exh
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GVWR
IAC
IAT
IC
ICM
ID
IDI
ign
ILC
in
INJ
inst
I/P
IPC
I/PEC
ISC
ISO
ISS
H
H2O
Harn
HC
H/CMPR
HD
HDC
hex
Hg
Hi Alt
HO2S
hp
HPL
HPS
HPV
Htd
HTR
HUD
HVAC
HVACM
HVM
Hz
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K
Keep Alive Memory
Keyboard Display Driver
kilogram
kilohertz
kilometer
kilometers per hour
kilometers per liter
kilopascals
Knock Sensor
kilovolts
L
L
L4
L6
lb
lb ft
lb in
LCD
LDCL
LDCM
LED
LF
LH
lm
LR
lt
LT
MAF
Man
MAP
MAT
max
M/C
MDP
MFI
mi
MIL
min
ml
mm
Liter
Four Cylinder Engine, In-line
Six Cylinder Engine, In-Line
pound
pound feet (torque)
pound inch (torque)
Liquid Crystal Display
Left Door Closed Locking
Left Door Control Module
Light Emitting Diode
Left Front
Left Hand
lumens
Left Rear
left
Light
M
Mass Air Flow
Manual
Manifold Absolute Pressure
Manifold Absolute Temperature
maximum
Mixture Control
Manifold Differential Pressure
Multiport Fuel Injection
miles
Malfunction Indicator Lamp
minimum
milliliter
millimeter
KAM
KDD
kg
kHz
km
km/h
km/l
kPa
KS
kV
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mpg
mph
ms
MST
M/T
MV
mV
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qt
R-12
R-134a
RAM
RAP
RAV
RCDLR
RDCM
Ref
Rev
RF
RFA
RFI
RH
RKE
Rly
ROM
RPM
PCV
PM
P/N
PNK
PNP
PRNDL
POA
POS
POT
PPL
ppm
PROM
P/S
PSD
PSP
psi
psia
psig
pt
PWM
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RPO
RR
rt
RTD
RTV
RWAL
RWD
Tach
TBI
TC
TCC
TCS
TDC
TEMP
Term
TFP
TFT
s
SAE
SC
SCB
SCM
SDM
SEO
SFI
SI
SIR
SLA
sol
SO2
SP
SPO
sq ft
sq in
SRC
SRI
ST
S4WD
Sw
syn
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UART
U/H
U/HEC
U-joint
UTD
UV
V
V6
V8
Vac
VAC
VATS
VCM
VDOT
VDV
vel
VES
VF
VIO
VIN
VMV
VR
V ref
VSS
w/
W/B
WHL
TOC
TP
TPA
TPM
TR
TRANS
TV
TVRS
TVV
TWC
TWC+OC
TXV
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WHT
w/o
WOT
W/P
W/S
WSS
WU-OC
WU-TWC
yd
YEL
Application
Transmission Oil Pan Bolt
Vacuum Modulator Assembly Bolt
Extension Housing to Case Bolt
Line Pressure Test Plug
Converter Housing to Cylinder Block Bolt
Transmission Support to Case Extension Bolt
Shift Lever to Selector Lever Shaft Bolt
Detent Cable Retainer to Case Bolt
Oil Cooler Fittings to Case
Oil Cooler Fittings to Radiator
Oil Cooler Hose Clamps to Cooler Lines
Shifter Assembly to Console Bolt
Neutral Safety Switch to Bracket Bolt
Lower Cover to Converter Housing Bolt
Flexplate to Converter Bolt
Reinforcement Plate to Case Bolt
Control Valve Body Assembly to Case Bolt
Servo Cover to Case Bolt
Converter Housing To Case Bolt
Converter Housing to Oil Pump Bolt
Manual Shaft Lever Locknut
Governor Body to Governor Hub Bolt
Servo Adjusting Bolt Locknut
Governor Pressure Switch
Solenoid
Oil Filter Bolt
Liters
N-m
11
52
31
8
34
44
27
9
20
27
1
9
2
10
48
19
19
24
33
19
12
8
18
10
19
19
Lb Ft
33
23
25
33
20
15
20
35
14
14
18
25
14
9
14
14
14
Quarts
Lb In
96
71
80
9
80
18
89
71
89
X-valve
White
without
Wide Open Throttle
Water Pump
Windshield
Wheel Speed Sensor
Warm Up Oxidation Converter (Catalytic)
Warm Up Three Way Converter (Catalytic)
X
Expansion valve
Y
yard(s)
Yellow
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(approximate)
Dry
Specification
Planetary Carrier Pinion Gear Clearance
Thickness (mm)
0.1270.889
Thickness (in)
0.0050.035
Specification
Metric
English
8.014.0 N610 lb ft
m
42.0
35.0
48.0 N-m
39.4 lb ft
11.2
8.3
22.6 N-m
16.7 lb ft
65.0
4855 lb ft
75.0 N-m
35.0
2630 lb ft
41.0 N-m
20.0
1520 lb ft
27.0 N-m
8.014.0 N610 lb ft
m
8.014.0 N610 lb ft
m
27.0
2025 lb ft
34.0 N-m
814.0 N-m 610 lb ft
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
8.014.0 N610 lb ft
m
26.0
1924 lb ft
32.0 N-m
20.0
1520 lb ft
27.0 N-m
Thickness (mm)
1.781.88
1.932.03
2.062.16
2.182.29
2.312.41
2.462.57
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Specification
Application
Metric
4.7 liters
10.6 liters
Pan Removal
Overhaul
Identification
67
68
69
70
71
72
73
74
English
5 quarts
11 quarts
Measured Dimension
28.06527.545 mm (1.105
1.084 in)
28.58628.066 mm (1.125
1.105 in)
27.54427.026 mm (1.084
1.064 in)
Identification
None
0
1
Plate Thickness
6.927.07 mm (0.2720.278 in)
6.336.48 mm (0.2490.255 in)
5.745.89 mm (0.2260.232 in)
5.155.30 mm (0.2030.208 in)
4.564.71 mm (0.1800.185 in)
Backing Plate Travel: 0.7661.756 mm (0.0300.069 in)
Dimension
5.885.68 mm (0.2310.224 in)
4.994.76 mm (0.1960.187 in)
Identification
A
B
C
D
E
Identification
A
B
8.014.0 N610 lb ft
m
10.5
7.710 lb ft
13.5 N-m
8.014.0 N610 lb ft
m
35.0
2630 lb ft
41.0 N-m
9.513.8 N710 lb ft
m
8.014.0 N610 lb ft
m
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Thickness (in)
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
Thickness (mm)
Oil Pump Rotor
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013
Oil Pump Slide
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013
Identification
2
3
4
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Pin Length
mm
65.8266.12
67.2367.53
68.6468.94
inch
2.592.60
2.652.66
2.702.71
Pin Identification
1 Groove
2 Grooves
No Groove
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Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so
that it hangs over the side of the transmission.
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Lift the valve body carefully so that the checkballs remain on the spacer plate in the
correct location. While lifting the valve body, disconnect the manual valve link
from the manual valve.
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Remove the valve body gasket (52), the valve body spacer plate (48) and the case
gasket (47).
Discard gaskets. Do not reuse.
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Remove the following parts: hex head nut (90) and the manual valve link (89);
inside detent lever (88) and the parking lock actuator assembly (85); manual
shaft retainer (83) and the manual shaft (84).
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Inspect the spacer plate to case gasket for witness marks. The witness marks should
be complete. Incomplete witness marks may come from an uneven case surface
or from cross channel leaks.
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Inspect the 2-4 servo bore, the 3rd accumulator retainer and ball assembly (40), the
orifice cup plug (11) in the servo bore, and the 2nd apply piston pin bore for any
of the following conditions:
Porosity
Burrs
Debris
Any other damage
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Inspect the 3-4 accumulator bore and the orifice cup plug (38) for any of the
following conditions:
Porosity
Burrs
Blockage
Any other damage
Inspect all bolt holes for thread damage. Use heli-coil to repair damaged threads.
Inspect the cooler connectors for damage and proper torque.
Specification
Cooler connector torque should be 38 N-m (28 lb ft)
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Remove the third accumulator retainer and ball assembly, using a 44.8 mm
(1.763 in) #4 screw extractor.
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Check the third accumulator retainer and ball assembly (40) for alignment. The slot
in the retainer must be completely open in the servo bore.
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The parking pawl return spring (80) for being broken or missing
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Install the valve body over the J 25025-5 Guide Pins, and connect the manual valve
link to the manual valve.
Install two bolts to hold the valve body in place.
Remove the J 25025-5 .
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Inspect the Transmission Fluid Pressure Manual Valve Position Switch (TFP Val.
Position Sw.) Assembly for the following conditions:
Damage
Debris
Damaged or missing O-rings
Cracked connector
Loose pins
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Install the TFP Val. Position Sw. (69) and bolts (62, 70).
Inspect the wiring harness solenoid assembly for the following conditions:
Damage
Cracked connectors
Exposed wires
Loose pins
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Install the TCC PWM solenoid (396) and the solenoid retainer (379).
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Worn bushings
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Using the J 34196-4 which is part of kit J 34196-B and the J 8092 , install a case
extension bushing (33).
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Control Valve Body Assembly Legend (1 of 2) 1999 4L60-E Document ID: 413572
Control Valve Body Assembly (1 of 2)
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Bore Plug
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Bore Plug
Bore Plug
Bore Plug
Bore Plug
4-3 Sequence Valve Spring
4-3 Sequence Valve
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Forward Sprag Clutch Inner Race and Input Sun Gear Assembly
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Cup Plug
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Case Bushing
Case Extension Bushing
Stator Shaft Bushing (Front)
Stator Shaft Bushing (Rear)
Oil Pump Body Bushing
Thrust Washer (Pump to Drum)
Reverse Input Cl. Bushing (Front)
Reverse Input Clutch Bushing (Rear)
Stator Shaft/Selective Washer Bearing Assembly
Thrust Washer (Selective)
Input Sun Gear Bearing Assembly
Input Sun Gear Bushing (Front)
Input Sun Gear Bushing (Rear)
Thrust Bearing Assembly (Input Carrier to Reaction Shaft)
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Case Fluid Passages (Control Valve Body Side) 98 4L60-E Document ID: 338653
Case Fluid Passages (Control Valve Body Side)
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Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Filtered Actuator Feed
Torque Signal
Torque Signal
Torque Signal
Torque Signal
Line
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Torque Signal
PR
PR
PR
PR
PR
D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed
Rear Lube
Accumulator
D4-3-2
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Orificed Accumulator
Signal A
Signal A
Signal A
2nd
2nd
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
Servo Feed
4th
4th
3-4 Accumulator
2nd
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3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
D3
D3
D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch Feed
Overrun Clutch
Overrun Clutch
Overrun Clutch
D2
D2
D2
D2
Orificed D2
Lo
Lo
Lo
Lo/1st
Lo/1st
D3
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Exhaust
Exhaust
Orificed Exhaust
Orificed Exhaust
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Regulated Apply
Regulated Apply
Void
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Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
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D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
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2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
2nd Clutch
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Servo Feed
Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
D3
D3
D3
D3
D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
Orificed D2
Orificed D2
Lo
Lo
3-4 Accumulator
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Lo
Lo
Lo/1st
Lo/1st
Exhaust
Exhaust
Orificed Exhaust
Void
Void
Regulated Apply
Regulated Apply
Orificed Exhaust
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Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
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D4
D4
D4
D4
D4
D4
D4
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2nd/2nd Clutch
2nd/2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch/3rd Accumulator
3-4 Clutch/3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed
Servo Feed
2nd Clutch
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Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
D3
D3
D3
D3
D3
Overrun
Overrun
Overrun/Overrun Clutch Feed
Overrun/Overrun Clutch Feed
Overrun/Orificed D2
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
D2/Orificed D2
Lo
Lo
Lo
D3
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Lo
Lo/1st
Lo/1st
Exhaust
Exhaust/Orificed Exhaust
Exhaust/Orificed Exhaust
Void
Regulated Apply
Regulated Apply
Shift Solenoids Screen
Pressure Control Solenoid Screen
Spacer Plate to Control Valve Body Gasket 98 4L60-E Document ID: 338657
Spacer Plate to Control Valve Body Gasket
Orificed Exhaust
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Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
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Torque Signal
Torque Signal
PR
PR
PR
PR
PR
D4-3-2
D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse
Reverse Input (Rev. Cl.)
D4
D4
D4
Torque Signal
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D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed
Accumulator
Accumulator
Orificed Accumulator
Signal A
Signal A
Signal A
Signal B
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd Clutch
2nd Clutch
2nd Clutch
Accumulator
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2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed
Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
C.C. Signal
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3-4 Accumulator
D3
D3
D3
D3
D3
Overrun
Overrun
Overrun/Orificed D2
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
D2
3-2 Signal
3-2 Signal
Lo
Lo
Lo
Lo
Lo/1st
Lo/1st
Exhaust
D3
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Exhaust
Orificed Exhaust
Orificed Exhaust
Void
Regulated Apply
Regulated Apply
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Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)
Line
Line
Line
Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Filtered Actuator Feed
Filtered Actuator Feed
Torque Signal
Torque Signal
Checkball (61)
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Torque Signal
Torque Signal
PR
PR
PR
D4-3-2
Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse
Reverse Input (Rev. Clutch
D4
D4
D4
D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Accumulator
Accumulator
Signal A
Signal A
D4-3-2
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Signal B
2nd
2nd
2nd
2nd
2nd
2nd
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed
2nd
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Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
D3
D3
D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
3-2 Signal
Lo
Lo
Lo
Lo/1st
Lo/1st
Lo/1st
Exhaust
Exhaust
D3
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Exhaust
Exhaust
Exhaust
Exhaust
Exhaust
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
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Void
Regulated Apply
Regulated Apply