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1994 CHEVROLET CAMARO AND PONTIAC FIREBIRD
SERVICE MANUAL
BOOK1
FOREWORD
This manual provides information on diagno- TABLE OF CONTENTS
sis, service procedures, adjustments and specifi-
SECTION
cations for the 1994 Chevrolet Camaro and NO.
SUBJECT
Pontiac Firebird.
An understanding of the material contained in 0 GENERAL INFORMATION
this manual and in the appropriate Dealer Service
HEATING AND
Bulletins will help technicians to better serve 1
AIR CONDITIONING
vehicle owners.
The 1994 Camaro/Firebird service manual STEERING, SUSPENSION,
3
TIRES AND WHEELS
has been separated into two books:
Book 1 - Contains all sections EXCEPT 4 FINAL DRIVE
Driveability and Emissions (Sec-
tions SE and SE3) and Electrical 5 BRAKES
Diagnosis (Section 8A). 6 ENGINE
Book 2 - Contains Driveability and Emis-
sions (Sections SE and SE3) and 7 TRANSMISSION
Electrical Diagnosis (Section 8A). ELECTRICAL -
When reference is made in this manual to a 8
BODY AND CHASSIS
brand name, number, or specific tool, an equiva-
lent product may be used in place of the recom- 9 ACCESSORIES
mended item. 10 BODY SERVICE
All information, illustrations and specifications
contained in this literature are based on the latest 11 BODY STRUCTURE
product information available at the time of publi- INDEX
cation approval. The right is reserved to make
changes at any time without notice.
 CHEVROLET CAMARO AND PONTIAC FIREBIRD
CONTENTS - BOOK 1
TABLE OF CONTENTS SECTION I TABLE OF CONTENTS SECTION
GENERAL INFORMATION Battery 601
General Information OA Cranking System 602
Maintenance and Lubrication OB Charging System 603
Ignition Wlstem 604
HEATING AND AIR CONDITIONING Engine iring 605
Heater and Ventilation 1/1A Exhaust System 6F
Heater, Ventilation and Air
Conditioning 18 TRANSMISSION
Manual Control Air Conditioning 191 Automatic and Manual Transmission 7
HD6/HR6-HE Air Conditioning Automatic Transmission On-Vehicle
Compressor Service or Unit Repair 102 Service 7A
HYDRA-MATIC 4L60-E Automatic
STEERING, SUSPENSION, TIRES Transmission Diagnosis
AND WHEELS RPO M30 . 7A·14A
Steering, Suspension, Tires and HYDRA-MATIC 4L60-E Automatic
Wheels Diagnosis 3 Transmission Unit Repair
Wheel Alignment 3A RPO M:30 7A-148
Power Steerin~ Gear and Pump Manual Transmission On-Vehicle
On-Vehicle ervice 38 Service RPO MM6 and M49 78
Power Steering Gear Unit Repair 381A Borg-Warner (T5) 5-Speed Manual
Power SteerinQ Pump Unit Repair 3B1B Transmission Unit Repair
Front Suspension 3C RPO M49 78-68
Rear Suspension 30 Borg-Warner (T56) 6-Speed Manual
Tires and Wheels 3E Transmission Unit Repair
Steering Wheel and Column RPO MM6 78-108
On-Vehicle Service 3F Clutch 7C
Supplemental Inflatable Restraint
(SIR) Tilt Steering Column Unit ELECTRICAL - BODY AND CHASSIS 8
Repair 3F5B Lighting Systems and Horns 88
Instrument Panel, Gages and
FINAL DRIVE Console SC
Propeller Shaft 4A Windshield Wiper/Washer System SE
Rear Axle 48
ACCESSORIES 9
BRAKES Audio Systems 9A
Brakes 5 Cruise Control 98
Master Cylinder SA Theft Deterrent Systems 90
Front Disc Brakes 581 Engine Coolant Heater 9E
Rear Disc Brakes 582 Supplemental Inflatable Restraint
Duo-Servo Drum Brakes 5C2 (SIR) ~stem 9J
Vacuum Booster System 501 Remote eyless Entry 9K
Antilock Brake System 5E1
Antilock Brake System with Traction BODY SERVICE 10
Control System (Refer to General Body Service 10·1
Supplement) 5E2 Stationary Windows 10·2
Parking Brake SF Body Dimensions, and Underbody 10·3
Bumpers 10·4
ENGINE Body Front End 10·5
Engine General Description 6 Doors 10·6
3.4 Liter V6 Engine On-Vehicle Rear Quarters 10-7
Service RPO L32 - VIN S 6A2A Body Rear End 10·8
3.4 Liter V6 E"ine Unit Repair Roof and Folding Top 10·9
RPO L32- INS 6A2B Seats and Carpet 10-10
5.7 Liter V8 Engine On-Vehicle Seat Belts 10-11
Service RPO LT1 - VIN P 6A3A
5.7 Liter V8 Engine Unit Repair BODY STRUCTURE
RPO LT1 -VIN P 6A3B Structural Body Repair and
Cooling and Radiator 68 Dimensions 11
Engine Fuel 6C
Engine Electrical 60 INDEX INDEX·1

CONTENTS - BOOK 2

TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION

ENGINE ELECTRICAL - BODY AND CHASSIS

Driveability and Emissions - Electrical Diagnosis SA
General Information 6E
Driveability and Emissions - INDEX INDEX-1
Fuel Injection (Port) (3.4L) 6E3 (3.4L)
Driveability and Emissions -
Se~uential Multiport Fuel Injection
(SF) (5.7L) 6E3 (5.7L)
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·1

SECTION OA

GENERAL INFORMATION
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in SecUon 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CONTENTS
Supplemental Inflatable Restraint (SIR)
Handling ................ ., ....., . . . . . . . . .
Disconnecting the Battery Negative Cable
Assembly ..............................
Handling Electrostatic Discharge (ESD)
Sensitive Parts ..........................
Special Tool Ordering Information ............
Body Identification ........................
Federal Vehicle Theft Prevention Standard ......
Vehicle Identification Number ................
Model Identification .......................
Engine Identification .......................
Transmission Usage ........................
Transmission Identification ..................
Differential Ratios and Tire Information . . . . . . . .
General Vehicle Lifting and Jacking ...........
Lock Cylinder Coding ......................
Key Identification and Usage . . . . . . . . . . . . . . OA-6
OA-1 Cutting Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-8
Replacement Lock Cylinders . . . . . . . . . . . . . . . OA-8
OA-1 Assembling and Coding Lock Cylinders ... ; . . OA-8
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-9
OA-1 Fastener Strength Identification . . . . . . . . . . . . . . . OA-9
OA-2 Prevailing Torque Fasteners ................. OA-10
OA-2 English-Metric Conversions ................ OA-11
OA-2 Decimal and Metric Equivalents ............. OA-11
OA-2 Standard Nomenclature for Electrical/Electronic
OA-4 Components and Systems ................ OA-11
OA-4 Abbreviations ............................ OA-16
OA-5 Replacement Labels ....................... OA-19
OA-5 Service Parts Identification Label ............ OA-19
OA-5 Option Codes ............................ OA-19
OA-5 Option and Process Codes .................. OA-20
OA-6

SUPPLEMENTAL INFLATABLE RESTRAINT HANDLING ELECTROSTATIC DISCHARGE

(SIR) HANDLING . (ESD) SENSITIVE PARTS
Refer to CAUTIONS and the SIR Component and Figure 1
Wiring Location view in Section 9J when performing NOTICE: When handling an electronic part that has
service on or around SIR components or SIR wiring. SIR an ESD sensitive label (Figure 1) or is identified as
equipped vehicles can be identified by: ESD sensitive in the list that follows, the service
• Steering wheel hub marked "INFLATABLE technician should follow these guidelines to reduce
RESTRAINT." any possible electrostatic charge buildup on the ser-
vice technician's body and the electronic part in the
• "INFLATABLE RESTRAINT" indicator lamp in dealership:
instrument cluster. 1. Do not open package until it is time to install the
part.
• Code "2," "3" or "5" for the seventh digit of the
vehicle identification number (VIN). · 2. Do not touch electrical terminals of the part or its
pigtail connector(s) with a finger or tool.
3. Before removing the part from its package, ground
the package to a known good ground on the vehicle.
DISCONNECTING THE BATTERY NEGATIVE
CABLE ASSEMBLY . 4. Always touch a known good ground before handling
the part. This should be repeated while handling the
CAUTION: Before removing or instal- part and more frequently after sliding across the
ling any electrical unit or when a tool seat, sitting down from a standing position or walk-
or equipment could easily come in ing a distance.
contact with "live" exposed electrical Not all parts that can be damaged by BSD have an
terminals, disconnect the battery neg- BSD label. Components that can be damaged by BSD are:
ative cable assembly to help prevent Inflatable restraint diagnostic energy reserve
personal injury and/or damage to the module (DERM) and resistor module
vehicle or components. Unless instruc-
ted otherwise, the ignition switch must Powertrain control module (PCM)
be in the "OFF" or "LOCK" position. Instrument panel cluster
OA-2 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

Solid state components also can be damaged if they

are bumped or dropped, or if they are laid on a metal work
bench or on an electrically operated item such as a radio, a
TV or an oscilloscope. NOTICE
SPECIAL TOOL ORDERING INFORMATION
Special service tools that are shown in this service
manual that have tool product numbers beginning with
"J" or "BT" are available for worldwide distribution
from:
Kent-Moore
SPX Corporation
29784 Little Mack
Roseville, MI 48066-2298
CONTENTS SENSITIVE
1-800-345-2233
Monday through Friday
TO
8:00 a.m. through 8:00 p.m. EST STATIC ELECTRICITY
Telex: 244040 KMTR YR
Fax: 313-578-7375
General Motors dealers can purchase TECH 1 scan
tools and accessories through Kent-Moore at the above
address and phone number. Non General Motors dealer
repair facilities can purchase TECH 1 scan tools and MC0008-0A-B-RP

accessories from Kent-Moore at the above address or:
Sun Electric Corporation
One Sun Parkway
Crystal Lake, IL 60014
1-800-CALLSUN (225-5786)
6:45 a.m. through 7:00 p.m. CST.
BODY IDENTIFICATION
A body identification tag is attached to the vehicle
on the center of the radiator tie. The tag gives a schedule
number and the last four digits of the vehicle identifica-
tion number (VIN) sequence number. Refer to "Vehicle
Identification Number" in this section
Paint codes, trim numbers, seat option codes and
other body information are included on the Service Parts
Identification Label. Refer to "Service Parts Identifica-
tion Label" in this section.
FEDERAL VEHICLE THEFT PREVENTION
STANDARD
Federal law requires General Motors to place a
vehicle identification number (VIN) label on certain parts
of selected vehicles. The purpose of the standard is to
reduce motor vehicle thefts by making parts removed
from stolen vehicles easier to trace and recover.
The label is permanently attached to an interior sur-
face of the part and displays the complete VIN. The label
on a replacement part contains the letter "R," the
manufacturer's logo and the symbol "DOT."
Figure 1 - ESD Sensitive Parts Label
[I] Important
• THESE LABELS ARE NOT TO BE DEFACED,
REMOVED OR COVERED. The labels must be
shielded from paint, rustproofing and undercoating
(dealer preparation included).
The theft deterrent labels are found on the front side
door windows.
VEHICLE IDENTIFICATION NUMBER
Figures 2 through 4
The vehicle identification number (VIN) legally
identifies the vehicle. A VIN plate is attached to the upper
left of the instrument panel and can be seen from outside
the vehicle. Each sequential unit number is prefixed by
letters and numbers that are explained in Figure 2. The
VIN also appears on the Vehicle Certificate of Title and
Registration.
A derivative of the VIN is stamped on the engine
and transmission. The code gives the model year, plant of
manufacture and a sequence number that also indicates
the car division. A VIN number is also stamped on the
frame.
A bar code VIN is also on the vehicle identification
plate.
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·3

J Vehicle Identification Number

£~ _,l_ ]._ _S__0_ Q. _2_ ~

PLANT SEQUENCE NUMBER

VIN POSITIONS
#12 THROUGH #17

G.M. MAKE IDENTIFIERS

VIN POSITIONS #1, 2, 3
MAKE USA CANADA
CODE CODE
G.M. PLANT CODES
CHEVROLET 1G1 2G1 VIN POSITION #11

PONTIAC 1G2 2G2

~ 2 I ST. THERESE

MODEL YEAR CODES

VIN POSITION #10

CODE YEAR

SERIES AND MODEL TABLE

/ p

Q
1993

1994

VIN POSITIONS #4 AND #5

#4 #5 DIVISION

CAR
LINE SERIES CHEVROLET x CHECK
DIGIT
VIN
F p CAMARO SPORT COUPE POSITION #9

F
s
v
FIRE BIRD

FORMULNTRANS AM
~
ENGINE CODES
VIN POSITION #8
VIN RPO ENG. FUEL DISPL. MFT.
CODE CODE TYPE SYSTEM (LITERS) DIVISION

s L32 V6 SPFI 3.4 CPC

p LT1 vs SPFI 5.7 CPC
BODY TYPES
VIN POSITION #6
CODE

1
DESCRIPTION

TWO DOOR COUPE/SEDAN

/r~ RESTRAINT CODES
VIN POSITION #7
2 TWO DOOR HATCHBACK
CODE DESCRIPTION
3 TWO DOOR CONVERTIBLE
1 MANUAL BELTS

2 MANUAL BELTS WITH DRIVER

AND PASSENGER INFLATABLE
RESTRAINT SYSTEM

3 MANUAL BELTS WITH DRIVER INFLATABLE

RESTRAINT SYSTEM

4 AUTOMATIC BELTS

5 AUTOMATIC BELTS WITH DRIVER

INFLATABLE RESTRAINT SYSTEM

RC0001-0A-F-RP

Figure 2 -VIN Codes

OA-4 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

VIN NUMBER PLATE MODEL IDENTIFICATION

LOCATION Models (series) and body styles for the current year
are listed in Figure 2.

ENGINE IDENTIFICATION

Figures 2 and 4 through 6

The VIN code (Figure 2) provides detailed engine
information by the engine code letter located on the
vehicle identification plate.
KC1002-0A-F-RP
Stick-on-labels attached to the engine indicate the
engine unit number and code. These labels also contain
Figure 3 - VIN Plate Location
bar codes for in-plant identification.
Vehicle Identification Number Engines are stamped with an engine identification
number which identifies the assembly plant, the month
1 G 1 F P 3 2 S O Q 2 100001 produced, the day produced and the engine type code.

Diron M~LT
Year
All engines and transmissions are stamped with a
VIN derivative, created from the complete VIN. Refer to
"Vehicle Identification Number" in this section. The
.-------__.I Plant of
Manufacture
stamping contains nine positions. Position 1 is the GM car
division identifier. Position 2 is the model year code. Posi-
I

Sequence
tion 3 is the car assembly plant code. Positions 4 through 9
Number contain the assembly plant sequential number of the
I vehicle (Figure 4).
If the engine in .the vehicle is the original engine,
information can be derived from the eighth VIN position
letter or number (Figure 2). To determine if the engine is
-1- Q 2 100001 original, compare the VIN and the VIN derivative. The
VIN Derivative VIN derivative should be the same as positions 3 and 10
RC1002-0A-F-RP through 17 of the VIN.
Figure 4 - VIN Derivative (Typical)

A c

A V6
B VS
C VIN DERIVATIVE (PRIMARY)
D VIN DERIVATIVE (OPTIONAL)
E ENGINE ID NUMBER VERIFICATION LABEL
LOCATED ON OIL PAN ASSEMBLY

Figure 5 - Engine Identification Locations (Typical)

1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·5

TRANSMISSION USAGE DIFFERENTIAL RATIOS AND TIRE

Figure 7
Transmission usage affects axle usage. The trans-
mission usage chart lists each engine with the axles and
transmissions used for each.
TRANSMISSION IDENTIFICATION
Figures B and 9
The transmission has two identifying stampings: the
transmission identification and the VIN derivative. The
transmission identification number gives the transmission
model and when it was made. On the automatic transmis-
sion, the transmission identification number is located on
the plate on the automatic transmission case. On the
manual transmission, the transmission identification num-
ber is located either on the transmission case or the bell
housing. The VIN derivative is created from the complete
VIN and is stamped in either of 2 places (Figure 8). Refer
to "Vehicle Identification Number" in this section. For
more information on rear axle differential ratio codes,
refer to SECTION 4B.
INFORMATION
For differential ratios, refer to SECTION 4B. For
tire information, refer to SECTION 3E.
GENERAL VEHICLE LIFTING AND JACKING
Figure 10
CAUTION: To help avoid personal
injury when a vehicle is on a hoist,
provide additional support for the vehi-
cle at the opposite end from which
components are being removed. The
additional support will reduce the pos-
sibility of the vehicle's falling off the
hoist. When removing major com-
ponents of the vehicle while the vehicle
1s on a hoist, the vehicle frame should
be chained to the hoist pads at the
same end as the removed components
to prevent tip-off. Failure to follow
these precautionary measures could
result in vehicle damage, serious per-
sonal injury or death.
NOTICE: When jacking or lifting a vehicle at the
frame side rails or other prescribed lift points, be

Engine Identification Number

0 00 00 000

Type Code
Source Code

F-Flint Motor
Month Produced
V-Flint Engine
T-Tonawanda
01 January
5-Saginaw Parts
02 February
K-GM of Canada LTD.
M-GM of Mexico Day Produced
H-Hydra-Matic
12 December
LC0003-0A·B·RP

Figure 6 - Engine Identification Number

TRANSMISSION USAGE
Engine Axle (RPO-Ratio) Transmission

3.4L, V6 (VIN S) GUS 3.23 M49-Borg-Warner Manual 5-speed

M30 Hydra-Matic 4L60-E

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

MM6 Borg-Warner Manual 6-Speed
M30 Hydra-Matic 4L60-E

RCOQ03-0A·f·RP

Figure 7 - Transmission Usage Chart

OA-6 GENERAL INFORMATION 1994 CAMARO AND FJREBIRD

HYDRA-MATIC 4L60-E I JULIAN DATE

(OR DAY OF THE YEAR)

4 = 1994
CALENDAR
YEAR
4 = 1994

TRANSMISSION I.D.
LOCATION MODEL SHIFT BUILT
A, B or J = FIRST SHIFT
C, H or W = SECOND SHIFT

RC0004-0A·B-RP

Figure 8 - Hydra-Matic 4L60-E Transmission I.D. Location

Jackstands should be used to provide additional support.

B Two noninterchangeable keys are used.
A SIX-SPEED
B FIVE-SPEED
C PRIMARY LOCATION
D SECONDARY LOCATION
PC0003-0A-F-RP
Figure 9 - Manual Transmission Identification
certain that lift pads do not contact the catalytic con-
verter, brake pipes or fuel lines. Such contact may
result in damage or unsatisfactory vehicle perfor-
mance.
When a vehicle is lifted with a vehicle jack or floor
jack, the wheels at the opposite end should be blocked.
Jackstands should be placed under either the frame, the
front suspension crossmember or the axle.
The vehicle should be on a clean, hard, level surface
before any lifting procedure begins. All lifting equipment
must meet weight standards and be in good working order.
Make sure all vehicle loads are equally distributed and
secure. If the only support for the vehicle is at the frame
side rails, make sure the lifting equipment does not put too
much stress on or weaken the frame side rails.
Recommended vehicle lifting points are shown in
Figure 10. If any other hoist methods are used, take spe-
cial care not to damage the fuel tank, filler neck, exhaust
system or underbody.
LOCK CYLINDER CODING
Key Identification and Usage
Figure 11
The lock cylinder keyway is designed so that other
model keys will not enter a current model lock cylinder.
• Square-headed key is used in the ignition lock cylin-
der.
• Oval-headed key is used in all other lock cylinders.
Key identification is obtained from the four-charac-
ter key code stamped on the knockout portion of the key
head and from an identification letter stamped on the key
shank. After the code number has been recorded by th.e
owner, the plugs should be knocked out of the key head.
Using these numbers, owners of key-cutting equipment
can determine the lock combination by consulting a code
list available from equipment suppliers. If the key code
numbers are not available from records or from the
knockout plug, the lock combination (tumbler numbers
and position) can be determined by laying the key on the
diagram (Figure 11). For information on the square-
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA-7

A USING FRAME CONTACT HOIST REARWARD OF

FRONT TIRE
B USING FRAME CONTACT HOIST FORWARD OF
REAR TIRE
C USING SUSPENSION CONTACT HOIST UNDER FRONT
LOWER CONTROL ARM ASSEMBLY
D USING SUSPENSION CONTACT HOIST LIFTING ON REAR
AXLE ASSEMBLY
PC0004-0A-F-RP

Figure 10 - Vehicle Lifting Points

OA·8 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

headed ignition key and lock cylinder, refer to SECTION
9D.
Cutting Keys
Figure 11
1. Determine special code from the code list or key
code diagram.
2. Cut a blank key to proper level for each of six tum-
bler positions or according to directions supplied by
the key-cutting equipment manufacturer.
3. Check key operation in lock cylinder.
Replacement Lock Cylinders
Figure 12
Lock cylinders (3) are available from service parts
warehouses completely coded and with a new key. The
new lock cylinder (3) has a locking bar staked in place.
Tumblers (1) and springs are also available and must be
assembled into the lock cylinder (3) according to the key
code.
Assembling and Coding Lock Cylinders
All Lock Cylinders Except Rear Stowage
Compartment
Figures 11 through 14
Tumblers (1) for all locks are shaped exactly alike,
with the exception of the notch position on one side. As
the key is inserted in the lock cylinder (3), tumblers (1) are
lowered to the correct height so that notches on each tum-
bler ( 1) are at the same level. When the notches on all six
tumblers line up, the side bar (4) is pushed into the
notches by two small springs. This allows the lock cylin-
der (3) to turn in its bore. Five types of tumblers (1) are
used to make the various lock combinations. Each tumbler
(1) is coded according to a number, one through five,
stamped on its side.
!+!+! Assemble
L Determine tumbler numbers and arrangement.
• With the numerical key code, use code list pro-
vided by the key cutting equipment supplier.
• Without the numerical key code or without the
code list, refer to Figure 11.
A. Lay key on the key code diagram. Be sure
key is outlined by the diagram.
B. Start with position number one. Find and
record the lowest level (tumbler number)
that is visible. Repeat for each of the
remaining five positions.
2. Tumblers (1) in their proper slots in the order called
for by the code (Figure 12).
• Start with position number one, nearest open
end or lock cylinder head (2).

8[iJMARK OF EXCELLENCE
r '
.... _J

111111
..
123456
/

A STAKE POINTS FOR RETAINER

2 CYLINDER HEAD, LOCK
5 RETAINER, SPRING
PC6006-0A·D·RP

1 2 3 4 5 Figure 13 - Installing Spring Retainer

A B
A POSITION
B LEVELS PC4011-0A·B-RP

Figure 11 - Key Code Diagram

3 ~.
v
4
1 TUMBLER
1 TUMBLER 2 CYLINDER HEAD, LOCK
2 CYLINDER HEAD, LOCK 4 SIDE BAR
3 CYLINDER, LOCK 5 RETAINER, SPRING
4 SIDE BAR 6 SPRING, TUMBLER
PC6005·0A·D·RP PC6007·0A·D·RP

Figure 12 - Lock Cylinder Components Figure 14 - Installing Tumblers

1994 CAMARO AND FIREBIRD
3. Tumblers ( 1) by pulling side bar (4) out with fingers.
4. One tumbler spring (6) above each tumbler (1).
5. Spring retainer (5) so that end prongs slide into slots
at each end of lock cylinder (3).
• Press spring retainer (5) down (Figure 13).
6. Insert key into lock cylinder (3) to check for proper
installation.
• Side bar (4) will drop down if tumblers ( 1) are
installed properly. If incorrectly assembled,
take apart and assemble correctly.
NOTICE: Use leather or wood at each vise jaw to
prevent damage to the cylinder.
7. Remove key and secure lock cylinder (3) in a vise
with spring retainer (5) exposed.
A. Stake spring retainer (5) securely in place at
each end. Use a suitable staking tool and stake
cylinder metal over the spring retainer (5).
B. Black lock cylinders should be lubricated with
Multi-Purpose Lubricant (GM P/N 12345120
or equivalent) or light machine oil. All other
lock cylinders should be lubricated with a gen-
eral purpose silicone lubricant.
Rear Stowage Compartment Lock Cylinder
Figures 12, 14 and 15
A lock cylinder with snap-in tumblers (1) is used for
the rear stowage compartment lock. The lock cylinder has
four or five tumbler positions. The number one or two
position (closest to the lock cylinder head (2)) is a brass
retainer tumbler. The two through five positions or three
through five positions are standard tumbler positions
depending upon cylinder type. Therefore, only the last
four or five tumbler combinations are required.
!•!+! Assemble
1. Determine tumbler numbers and arrangement as
previously described and install tumblers (1).
2. After installation, tap tumblers (1) flush with the
cylinder.
METRIC FASTENERS
Figure 16
NOTICE: When fasteners are removed, always
reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use
the correct part number fastener for that application.
If the correct part number fastener is not available, a
fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those
requiring thread locking compound will be called
out. The correct torque value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage
could result.
GENERAL INFORMATION OA·9
0 WOODEN BLOCK
KC00&0-101-B-RP
Figure 15 - Locking Tumblers in Place
Many fasteners are metric. Metric fasteners may be
close in dimension to well-known customary fasteners in
the inch system. Replacement fasteners must be the cor-
rect nominal diameter, thread pitch and strength.
Original equipment metric fasteners, except for
exposed bumper bolts and other beauty bolts and cross-re-
cess head screws, have numbers on their heads that iden-
tify them as metric. Cross-recess head screws can be
identified by a Posidriv or a Type lA cross-recess. Either
type of cross-recess screwdriver can be used to remove
Posidriv recess head screws, but Type lA will perform
better.
NOTICE: Most metric fasteners have a blue color
coating. This coating should not be used to posi-
tively identify fasteners because not all metric fas-
teners are color-coated. Damage to the fastener or
part could result if a customary fastener is incor-
rectly used to replace a metric fastener.
Metric and customary thread notations differ
slightly. For example, the thread major diameter of a
1/4-20 bolt/screw is 1/4 inch, and the bolt/screw has 20
threads per inch. The thread major diameter of an M6.0xl
bolt/screw is 6.0 mm, and the bolt/screw has 1 mm
between threads
FASTENER STRENGTH IDENTIFICATION
Figure 17
Most commonly used metric fastener strength prop-
erty classes are 9.8 and 10.9. The class identification is
embossed on the head of each bolt/screw. Customary fas-
tener strength property classes range from grade 2 to 8.
Radial lines are embossed on the head of each bolt/screw
to identify the strength class. Some metric nuts are
marked with strength identification numbers on the nut
face (Figure 17).
When replacing fasteners, be careful to use bolts/
screws and nuts of a strength class equal to, or higher than,
the original fasteners (the same number marking or
higher). Also select replacement fasteners of the correct
size. Correct replacement bolts/screws and nuts are avail-
OA-10 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

able through General Motors Service Parts Operation
(GMSPO).
Many metric fasteners available in the aftermarket
parts channels were designed to metric standards of coun-
tries other than the United States. The fasteners may have
different strength or thread pitch and may not have the
numbered head marking system. The metric fasteners
used on GM products are designed to new international
standards that might not be used by some nondomestic
bolt/screw and nut suppliers.
PREVAILING TORQUE FASTENERS
Figures 18 and 19
A prevailing torque nut is designed to develop an
interference between the nut and bolt/screw threads. This
interference is usually created by distortion of the top of
an all-metal nut or by a nylon patch in the threads in the
middle of a hex flat. In other cases, a nylon insert may be
used (Figure 18).
A prevailing torque bolt/screw is designed to
develop an interference between the bolt/screw and nut
threads or between the bolt/screw and tapped hole threads.
This interference is created by distorting some of the
threads or by using a nylon patch or adhesive (Figure 18).
Rusty or damaged bolts/screws and nuts should be
. replaced with new parts of the same strength class or
higher. Clean, unrusted bolts/screws and nuts can be
reused. Be sure to use the following recommendations:
1. Clean dirt and other foreign material from nut or
bolt/screw.

CUSTOMARY METRIC

1/4 20 M6.0 x 1
THREAD MAJOR NUMBER OF THREADS THREAD MAJOR DIAMETER DISTANCE BETWEEN
DIAMETER IN INCHES PER INCH IN MILLIMETERS THREADS IN MILLIMETERS

I I
THREAD PITCH

Figure 16 - Thread Notation

NUT STRENGTH
GRADE 2 GRADE 5 GRADE7 GRADE 8 IDENTIFICATION
(GM 260-M) (GM 280-M) (GM 290-M) .(GM 300-M)
CUSTOMARY (INCH) BOLTS/SCREWS - IDENTIFICATION MARKS CORRESPOND TO
BOLT/SCREW STRENGTH - INCREASING NUMBERS REPRESENT INCREASING STRENGTH.

METRIC BOLTS/SCREWS- IDENTIFICATION CLASS NUMBERS CORRESPOND TO BOLT/SCREW

STRENGTH - INCREASING NUMBERS REPRESENT INCREASING STRENGTH.

PC8008-0A·D·RP

Figure 17 - Fastener Strength Markings

1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·11

2. Inspect nut or bolt/screw for cracks, elongation or ENGLISH-METRIC CONVERSIONS

other signs of abuse or overtightening.
• If nut or bolt/screw is worn in any way, replace
with a nut or bolt/screw of the same strength
class or higher.
3. Assemble the parts and hand-start nut or bolt/screw.
4. Check that nut or bolt/screw develops the proper
torque before it seats (Figure 19):
• If nut or bolt/screw fails to develop torque cor-
rectly, replace with a nut or bolt/screw of the
same strength class or higher.
5. Tighten fastener to the torque specified in the
appropriate installation procedure in this manual.
Figure 20
To convert customary units to metric units, multiply
the customary units by the conversion factor shown in
Figure 20. To convert metric units to customary units,
divide the metric units by the conversion factor shown in
Figure 20.
DECIMAL AND METRIC EQUIVALENTS
Figure 21
Inch-to-millimeter decimal equivalents are shown in
Figure 21;

STANDARD NOMENCLATURE FOR

ELECTRICAL/ELECTRONIC COMPONENTS
AND SYSTEMS

CENTER TOP NYLON NYLON NYLON

Figures 22 and 23
LOCK LOCK PATCH WASHER INSERT Starting with the 1993 model, General Motors will
INSERT be complying with the Society of Automotive Engineers
(SAE) Recommended Practice Jl 930. Jl 930, an industry-

a a a
wide standard that was adopted into government regula-

DRY
AQHESIVE
THREAD
PROFILE
i
NYLON
STRIP
OUT OF
ROUND
tions, requires identical nomenclature for certain
electrical/electronic components and systems that have
the same function. The standard is also being applied to
abbreviations and acronyms and is being used in all 1993
GM service publications.
COATiNG DEFORMED THREAD To make this standard work, some names and
AREA abbreviations are being replaced with those recommended
by the SAE Standard. Figures 22 and 23 are a listing of
520012-0A former GM names and abbreviations beside the new
Figure 18 - Prevailing Torque Nuts and Bolts/Screws Jl930 name and abbreviations.

FASTENER TORQUE METRIC-SIZE FASTENERS

TYPE UNITS 6 6.3 8 10 12 14 16 20
Nuts and All N•m 0.4 0.4 0.8 1.4 2.2 3.0 4.2 7.0
Metal Bolts/Screws Lb. In. 4 4 7 12 19 27 37 62
Adhesive or Nylon N•m 0.4 0.4 0.6 1.2 1.6 2.4 3.4 5.6
Coated Bolts/Screws Lb. In. 4 4 5 11 14 21 30 50
FASTENER TORQUE INCH-SIZE FASTENERS
TYPE UNITS .250 .312 .375 .437 .500 .562 .625 .750
Nuts and All N•m 0.4 0.6 1.4 1.8 2.4 3.2 4.2 6.2
Metal Bolts/Screws Lb. In. 4 5 12 16 21 28 37 55
Adhesive Nylon N•m 0.4 0.6 1.0 1.4 1.8 2.6 3.4 5.2
Coated Bolts/Screws Lb. In. 4 5 9 12 16 23 30 49
PC6009-0A-D-RP

Figure 19 - Prevailing Torque Fastener Specifications

OA-12 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

Multiply by to get equivalent Multiply by to get equivalent

number of: number of:

LENGTH ACCELERATION
Inch 25.4 millimeters (mm) Foot/sec 2 0.3048 meter/sec 2 (m/s 2 )
Foot 0.3048 meters (ml lnch/sec 2 0.0254 meter/sec 2
Yard 0.9144 meters
Mile 1.609 kilometers (km) TORQUE

AREA Pound-inch 0.112 98 newton-meters (N.m)

Pound-foot 1.355 8 newton-meters
lnch 2 645.2 millimeters 2 (mm 2 )
6.45 centimeters' (cm 2 ) POWER
Foot 2 0.092 9 meters' (m 2 ) Horsepower 0.746 kilowatts (kW)
Yard 2 0.8361 meters'

VOLUME PRESSURE OR STRESS

lnch3 16387. mm 3 Inches of water 0.2491 kilopascals (kPal

16.387 cm 3 Pounds/sq. in. 6.895 kilopascals
0.0164 liters (I)
Quart 0.9464 liters ENERGY OR WORK
Gallon 3.7854 liters
Yard 3 0.764 6 meters 3 (m 3 ) BTU 1 055. joules (J)
Pound-foot 1.355 8 joules
MASS Kilowatt-hour 3 600000. joules (J = one W. s)
or 3.6 x 106
Pound 0.453 6 kilograms (kg)
Ton 907.18 kilograms (kg) LIGHT
Ton 0.907 tonne (t)
Foot candle 10.76 4 lumens/meter2 (lm/m 2 )
FORCE
FUEL PERFORMANCE
Kilogram 9.807 newtons (N)
Ounce 0.2780 newtons Miles/gal 0.4251 kilometers/liter (km/I)
Pound: 4.448 newtons Gal/mile 2.352 7 liter/kilometer (I/km)

VELOCITY

Miles/hour 1.609 3 kilometers/hr. (km/h)

TEMPERATURE

To convert Fahrenheit temperature To convert Celsius temperature

to Celsius temperature, use formula: to Fahrenheit temperature, use formula:
C = 5 /s (F-32) F = 9 /s C + 32

LC1005-0A·f·RP

Figure 20 - English-Metric Conversion Chart

1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA-13

DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal Metric Fractions Decimal Metric

In. MM. In. MM.

1/64 .015625 .39688 33/64 .515625 13.09687

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

520014-0A

Figure 21 - Inch-to-Millimeter Decimal Equivalents

OA-14 GENERAL INFORMATION
Former GM Name
Absolute Pressure Sensor Aps - APS
Air Cleaner Assembly
Air Cleaner Filter Element
Air Injection Reaction System - A.LR. System
Assembly Line Communication Link - ALCL
Assembly Line Data Link - ALDL
Barometric Pressure Sensor - BARO Sensor
BCM-PCM Data Problem
Calibration Pack - CAL-PAK
Calibration Pack - CAL-PAK
Calibration Pack - CAL-PAK
Camshaft Sensor
Canister Purge - CP
Catalytic Converter - Cat. Conv.
Catalytic Converter - Cat. Conv.
Catalytic Converter - Cat. Conv.
Catalytic Converter - Cat. Conv.
Catalytic Converter - Cat. Conv.
Check Engine Indicator
Code
Computer Command Control - CCC
Computer Controlled Coil Ignition - C31
Controlled Canister Purge - CCP
Coolant Temperature Sensor - CTS
Coolant Temperature Switch - CTS
Detonation Sensor
Diagnostic Circuit Check
Digital Electronic Fuel Injection - DEFI
Digital Electronic Fuel Injection - DEFI
Digital Fuel Injection - DFI
Digital Fuel Injection - DFI
Direct Ignition System - DIS
Distributor HEI Module
Distributorless Ignition System - DIS
Dual Bed Monolith - DBM
Dual Bed Monolith - DBM
Electronic Air Control - EAC
Electronic Air Switching - EAS
Electronic Control Module - ECM
Electronic Fuel Injection - EFI
Electronic Fuel Injection - EFI
Electronic Fuel Injection - EFI
Electronic Spark Control Circuit - ESC Circuit
Electronic Spark Control System - ESC System
Figure 22 - Standard Nomenclature for Electrical/Electronic Components and Systems (1 of 2)
1994 CAMARO AND FIREBIRD
New SAE Name Term
Manifold Absolute Pressure Sensor - MAP Sensor
Air Cleaner - ACL
Air Cleaner Filter -ACL Filter
Secondary Air Injection System - AIR System
Data Link Connector - DLC
Data Link Connector - DLC
Barometric Pressure Sensor - BARO Sensor
BCM-PCM Data Link
Electronically Erasable Programmable Read Only
Memory - EEPROM
Erasable Programmable Read Only Memory - EPROM
Programmable Read Only Memory - PROM
Camshaft Position Sensor - CMP Sensor
Evaporator Emission Canister Purge - EVAP
Canister Purge
Oxidation Catalytic Converter - OC
Three Way+ Oxidation Catalytic Converter- TWC + OC
Three Way Catalytic Converter -TWC
Warm Up Oxidation Catalytic Converter - WU-OC
Warm Up Three Way Catalytic Converter - WU-TWC
Malfunction Indicator Lamp - MIL
Diagnostic Trouble Code - DTC
Engine Control Module - ECM
Electronic Ignition - El
Evaporative Emission Canister Purge - EVAP
Canister Purge
Engine Coolant Temperature Sensor - ECT Sensor
Engine Coolant Temperature Switch - ECT Switch
Knock Sensor - KS
On-Board Diagnostic System Check - OBD System
Check
Multiport Fuel Injection - MFI
Sequential Multi port Fuel Injection - SFI
Multiport Fuel Injection - MFI
Sequential Multiport Fuel Injection - SFI
Electronic Ignition System - El System
Distributor Ignition Control Module - DI Control
Module
Electronic Ignition System - El System
Oxidation Catalytic Converter - OC
Three Way Catalytic Converter - TWC
Secondary Air Injection Bypass Valve - AIR
Bypass Valve
Secondary Air Injection Switching Valve - AIR
Switching Valve
Powertrain Control Module - PCM
Multiport Fuel Injection - MFI
Sequential Multi port Fuel Injection - SFI
Throttle Body Fuel Injection - TBI
Knock Sensor Circuit - KS Circuit
Knock Sensor System - KS System RC0005-0A·F-RP
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA-15

Former GM Name New SAE Name Term

Electronic Spark Timing - EST Ignition Control - IC

Electronic Spark Timing Circuit - EST Circuit
Electronic Vacuum Regulator Valve - EVRV
Engine Calibration Unit - ECU
Evaporative Emission Control System - EECS
Exhaust Gas Recirculation/Thermostatic Vacuum
Switch - EGR/TVS
Ignition Control Circuit- IC Circuit
Exhaust Gas Recirculation Electronic Vacuum
Regulator Solenoid Valve - EGR Electronic
Vacuum Regulator Solenoid Valve
Programmable Read Only Memory - PROM
Evaporative Emission System - EVAP System
Exhaust Gas Recirculation Thermal Vacuum
Valve - EGR TVV

Fuel CAL-PAK Missing Programmable Read Only Memory Missing -

PROM Missing

High Energy Ignition - HEI Distributor Ignition - DI

Lean Exhaust Lean Heated Oxygen Sensor Signal - Lean H02S

Lean Exhaust Lean Oxygen Sensor Signal - Lean 0 2 S Signal

Manifold Air Temperature Sensor - MAT Sensor
MEM-CAL Error
MEM-CAL Error
· Memory and Calibration Unit-MEM-CAL
Memory and Calibration Unit - MEM-CAL
Multi-Port Fuel Injection - MPFI
Intake Air Temperature Sensor - IAT Sensor
Erasable Programmable Read Only - Only Memory
Error - EPROM Error
Programmable Read Only Memory Error - PROM
Error
Erasable Programmable Read Only Memory - EPROM
Programmable Read Only Memory - PROM
Multiport Fuel Injection - MFI

Oxygen Sensor - 0 2 Heated Oxygen Sensor - H02 S

Oxygen Sensor - 0 2 Oxygen Sensor - 0 2 S

Park/Neutral Switch - P/N Switch Park/Neutral Position Switch - PNP Switch

Port Fuel Injection - PFI Multiport Fuel Injection - MFI
Pulse Air Injection System - PAIR Pulsed Secondary Air Injection System - PAIR System

Revolutions Per Minute - rpm Engine Speed - RPM

Rich Exhaust Rich Heated Oxygen Sensor Signal - Rich H02S Signal
Rich Exhaust Rich Oxygen Sensor Signal - Rich 0 2 S Signal

"Scan" Data Scan Tool Data - ST Data

Service Engine Soon Indicator - SES Indicator Malfunction Indicator Lamp - MIL

Thermal Vacuum Switch - TVS Thermal Vacuum Valve - TVV

Thermostatic Air Cleaner -TAC
Throttle Body Injection - TBI
Throttle Position Sensor - TPS
Throttle Position Switch - TPS
Throttle Switch
Throttle Switch
Tuned Port Injection - TPI
Air Cleaner - ACL
Throttle Body Fuel Injection - TBI
Throttle Position Sensor - TP Sensor
Closed Throttle Position Switch - CTP Switch
Closed Throttle Position Switch - CTP Switch
Wide Open Throttle Switch - WOT Switch
Multiport Fuel Injection - MFI

Viscous Converter Clutch - VCC Torque Converter Clutch - TCC

PC6012·0A·D·RP

Figure 23 - Standard Nomenclature for Electrical/Electronic Components and Systems (2 of 2)

OA-16 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

ABBREVIATIONS

The following abbreviations may appear in this manual.

A CCM Central Control Module

CCOT Cycling Clutch Orifice Tube
A-6 Axial 6 Cylinder A/C Compressor Cd Cadmium
A/C Air Conditioning CD Compact Disc
A/F Air/Fuel (A/F Ratio) CDRV Crankcase Depression Regulator Valve
ABDC After Bottom Dead Center CEAB Cold Engine Airbleed
ABS (Body) Aery loni trile-Butadiene-Styrene CEMF Counter Electromotive Force
(Brake) Antilock Brake System cfm cubic feet per minute
ac alternating current cg center of gravity
AC A GM Division CHA Carburetor Hot Air
ACC Automatic Climate Control CID Cubic Inch Displacement
ACL Air Cleaner ckt circuit
AID Analog-to-Digital CLCC Closed Loop Carburetor Control
ADP Air Deflector Valve CLTBI Closed Loop Throttle Body Injection
AIR Air Injection Reaction cm3 cubic centimeter
Al Aluminum CMP Camshaft Position
ALC Automatic Level Control co Carbon monoxide
AM/FM Amplitude Modulation/ COA Carburetor Outside Air
Frequency Modulation CPA Connector Position Assurance
amp amperes CPS Central Power Supply
API-GL American Petroleum Institute-Gear CPU Central Processing Unit
Lubricant CRT Cathode Ray Tube
APT Adjustable Part Throttle CRTC Cathode Ray Tube Controller
ARS Automatic Restraint System CTP Closed Throttle Position
ASM Assembly CTS Cold Trapped Spark
ASR Acceleration Slip Regulation cu ft or ft 3 cubic foot, or feet
A/T Automatic Transmission cu in or in 3 cubic inch, or inches
ATC Automatic Temperature Control CV constant velocity
ATDC After Top Dead Center CYL Cylinder(s)
ATS Air Temperature Sensor
Auto Automatic D
avg average
AWD All Wheel Drive dB decibels
AWG American Wire Gage dBA decibels on A-weighted scale
DBB Dual Bed Bead
B de direct current
DEC Digital Electronic Controller
BARO Barometric Absolute Pressure Sensor DERM Diagnostic Energy Reserve Module
batt battery DI Distributor Ignition
BAT+ battery positive dia diameter
BBDC Before Bottom Dead Center DIFF Differential
BCM Body Computer Module DIS Distributorless Ignition System
BHP Brake Horsepower DLC Data Link Connector
BLM Block Learn Multiplier DRL Daytime Running Lamps
BP Back Pressure DTC Diagnostic Trouble Code
BTDC Before Top Dead Center DVM Digital Volt Meter ( 10 Megaohm)
Btu British thermal units

c E

c Celsius E/P Ethylene/Propylene

CLOOP Closed Loop EBTCM Electronic Brake Traction Control
C-4 Computer Controlled Catalytic Module
Converter ECC Electronic Climate Control
CAD Computer Aided Design
CAM Computer Aided Manufacturing
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·17

ECI Extended Compressor at Idle HD Heavy Duty

ECM Engine Control Module HDC Heavy Duty Cooling
ECS Emission Control System hex hexagon
ECT Engine Coolant Temperature Sensor, Hg mercury ..
Engine Coolant Temperature Switch Hi Alt High Altitude
EDES Electric Divert/Electric Air Switching HIC High Idle Compensator
Valve H02S Heated Oxygen Sensor
EEC Evaporative Emission Control hp horsepower
EEPROM Electronically Eraseable Programmable HPCA Housing Pressure Cold Advance
Read Only Memory HPL High Pressure Liquid
EES Evaporative Emission System HPV High Pressure Vapor
EE-VIR Evacuator Equalized HVAC Heater-Vent-Air Conditioning
Values-In-Receiver HVACM Heater-Vent-Air Conditioning Module
EEVIR Evaporator Equalized Values in HVM Heater Vent Module
Receiver Hz hertz
EFE Early Fuel Evaporation
EGR Exhaust Gas Recirculation
EGR TVV Exhaust Gas Recirculation Thermal I
Vacuum Valve
EI Electronic Ignition IAC Idle Air Control
ELC Electronic Level Control IAT Intake Air Temperature
EMF Electromotive Force IC Integrated Circuit, Ignition Control
EOS Exhaust Oxygen Sensor ID Inside Diameter, identification
EPR Exhaust Pressure Regulator IDI Integrated Direct Ignition
EPROM Erasable Programmable Read Only ign ignition
Memory ILC Idle Load Compensator
ESD Electrostatic Discharge INJ Injection
ETC Electronic Temperature Control I/P Instrument Panel
ETCC Electronic Touch Comfort Control, ISC Idle Speed Control
Electronic Touch Climate Control
ETR Electronically Tuned Receiver
EVAP Evaporator Emmision K

KAM Keep Alive Memory

F kg kilogram
kHz kilohertz
F Fahrenheit km/h kilometers per hour
FDC Fuel Data Center km/1 kilometers per liter
FEC Fuel Evaporator Control kPa kilopascals
Fed Federal (all states except California) KS Knock Sensor
FI Fuel Injection kv kilovolts
FICD Fast Idle Control Diaphragm
4WAL Four Wheel Antilock
ft foot, feet L
FWD Front Wheel Drive, Four Wheel Drive
I liter
L4 Four Cylinder, In-Line Engine
G L6 Six Cylinder, In-Line Engine
lb. ft. pound feet (torque)
g gravitational acceleration, grams lb. in pound inch (torque)
GA gage LCD Liquid Crystal Display
gal gallon LF Left Front
gas gasoline LH Left Hand
GCW Gross Combination Weight LR Left Rear
Gen Generator It left
GM General Motors
gnd ground
M

H MIC Mixture Control

MAP Mass Air Flow
H20 water Man Manual
H/CMPR High Compression MAP Manifold Absolute Pressure
HC hydrocarbons
OA·18 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

Max Maximum POLYP polypropylene

MDP Manifold Differential Pressure POLYU polyurethane
MFI Multi-port Fuel Injection POS Positive
mgd million gallons per day POT Potentiom.eter (Variable Resistor)
mi miles POM polyoxymethylene
MIL Malfunction Indicator Lamp pp polypropylene
min minimum PPE polyphenylene ether
ml milliliters ppm parts per million
mm millimeters PROM Programmable Read Only Memory
MFI Multiport Fuel Injection PS Power Steering
mpg miles per gallon PSPS Power Steering Pressure Switch
mph miles per hour psi pounds per square inch
ms millisecond psia pounds per square inch absolute
M{f Manual Transmission psig pounds per square inch gage
MV megavolt pt pint
mv millivolt PTO Power Take Off
MVS Metering Valve Sensor PUR polyurethane (thermoset)
MVSS Motor Vehicle Safety Standards PWM Pulse Width Modulated

N Q

NC Normally Closed qt quart(s)

NEG Negative
NEU neutral
NLGI National Lubricating Grease Institute R
Ni nickel
N•m Newton-meters (torque) R-4 Radial Four Cylinder Air Compressor
NO Normally Open R-12 Refrigerant-12
N03 oxides of nitrogen R-134A Refrigerant-R 134A
NPTC National Pipe Thread Coarse RAM Random Access Memory
NPTF National Pipe Thread Fine RAP Retained Accessory Power
Ref Reference
RF Right Front
0 RFI Radio Frequency Interference
02S Oxygen Sensor RH Right Hand
OBD On-Board Diagnostic RIM Reaction Injection Molded Urethane
oc Oxidation Catalytic Converter RPM Engine Speed
OD Outside Diameter RPO Regular Production Option
OEM Original Equipment Manufacturer RR Right Rear
ORC Oxidizing Reducer Converter RRIM Reinforced Reaction Injection Molded
oz ounce(s) Urethane
rt right
RTV Room Temperature Vulcanizing (sealer)
p RVB Rear Vacuum Brake
RVR Response Vacuum Reducer
PIN Part Number RWAL Rear Wheel Antilock
PA polyamide RWD Rear Wheel Drive
PAIR
PBT polybutylene terephthalate s
PC polycarbonate
PCM Powertrain Control Module SAE Society of Automotive Engineers
PCV Positive Crankcase Ventilation sec second(s)
PE polyethylene SEO Special Equipment Option
PECV Power Enrichment Control Valve SES Service Engine Soon
PEDESV Pressure Operated Electric Divert/Air SFI Sequential Multiport Fuel Injection
Electric Switching Valve SI System In.ternational
PF phenol-formaldehyde Si silicone
PFI Port Fuel Injection SIR Supplemental Inflatable Restraint
PM Permanent Magnet (Generator) SLA short/long arm
PNP Park/Neutral Position SMC Sheet Molded Compound
POA Pilot Operated Absolute Valve S02 sulfur dioxide
POLYE polyethylene sq ft, ft 2 square foot(feet)
POLYF polyfoam
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA-19

sq in, in 2 square inch(es) V4 Four Cylinder Engine

ST Scan Tool V6 Six Cylinder Engine
V8 Eight Cylinder Engine
T Vac vacuum
VATS Vehicle Anti-Theft System
VDV Vacuum Delay Valve
TBI Throttle Body Fuel Injection vel velocity
TCC Torque Converter Clutch, Transmission VF Vacuum Fluorescent
Converter Clutch VIN Vehicle Identification Number
TCCTVMV Torque Converter Clutch Trim Vacuum VIR Valves In Receiver
Modulator Valve VLV Vacuum Limiting Valve
TDC Top Dead Center VLVMV Vacuum Limiting Vacuum Modulator
TEMP Temperature Valve
THM Turbo Hydra-Matic VMV Vacuum Modulator Valve
THERM AC Thermostatic Air Cleaner VRV Vacuum Reducer Valve
TP Throttle Position vss Vehicle Speed Sensor
TPE Thermo Plastic Elastomer
TPI Tuned Port Injection
TPO Thermo Plastic Olefin w
TPU Polyurethane (thermoplastic)
TRANS Transmission W/S Windshield
TRC Throttle Return Control WOT Wide Open Throttle
Turbo Turbocharger wss Wheel Speed Sensor
TV Throttle Valve WU-OC Warm Up Oxidation Catalytic Con-
TVBV Turbocharger Vacuum Bleed Valve verter
TVRS Television and Radio Suppression WU-TWC Warm Up Three Way Catalytic Con-
TVV Thermal Vacuum Valve verter
TWC Three Way Catalytic Converter
TWC+OC Three Way+ Oxidation Catalytic Con- x
verter
TXV Thermal Expansion Valve X-valve expansion valve

u y

U-joint universal joint yd yard

v z
v volt(s), voltage Zn zinc

REPLACEMENT LABELS The Vehicle Certification Label, Tire Pressure Plac-

ard and Service Parts Identification Label are NOT avail-
Replacement labels are available through GM Ser- able as service parts.
vice Parts Operations for the following:
Vehicle Emission Control Information (Exhaust SERVICE PARTS IDENTIFICATION LABEL
Emission Tune Up)
Figure 24
Spare Wheel Caution
The Service Parts Identification Label has been
Superlight® Shock Absorber Information developed and placed on the vehicle to aid service and
Jacking parts personnel in identifying parts and options originally
installed on the vehicle. The label is attached to the inside
Spare Tire Storage of the instrument panel compartment.
Serpentine Belt Routing (when it is a separate label)
OPTION CODES
Engine Fan Caution Vehicle options are identified on the Service Parts
IRS/SIR Service Caution Identification Label by option codes. Option codes are
three-digit combinations of letters and numbers. They
Odometer Reset identify equipment installed on the vehicle, and trim and
These and other labels will be found in the Standard paint colors. Refer to "Option and Process Codes" in this
Parts Catalog. section.
OA-20 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

OPTION AND PROCESS CODES

AAA Standard Equipment JIF Brake Provisions, Special to Suit
ACM Lead Units Foreign Regulations
AC3 Adjuster, 6-Way Power, Driver Seat J41 Brake System, Power, Front Disc, Rear
AH3 Adjuster, 4-Way Manual, Driver Seat Drum, Cast Iron
AK5 Restraint System Front Seat, Inflatable, J65 Brake System, Power, Front and Rear
Driver and Passenger Disc
AN4 Restraint Provisions, Child KC4 Cooling System, Engine Oil
AQ9 Seat, Passenger and Driver, Recline KG7 Generator, 125 Amp
AR9 Seat, Passenger and Driver, Recline KOS Heater, Engine Block
(European Style) K34 Cruise Control, Automatic Electronic
AUO Lock Control, Remote Entry K68 Generator, 105 AmpEXP
AU3 Lock, Side Door, Electric LTl Engine, 5.7L (V8) MFI
AX4 Restraint Conversion Seat, Manual, L32 Engine, 3.4L (V6) MFI
European MM5 Transmission - 5-Speed Manual
A26 Window, European Glazing, All (Merchandising Option)
A31 Window, Power Operated, Side MM6 Transmission, Manual, 6-Speed, Borg
A90 Lock, Rear Compartment Lid, Remote Warner, 85 mm, 2.66 1st, 0.50 6th, 0/D
Control, Electric MN6 Transmission - 6-Speed Manual
BF9 Delete Floor Mats (Merchandising Option)
B3E Noise Control MXO Transmission - Automatic 0/D
B35 Floor Mats, Rear, Carpeted Insert (Merchandising Option)
B71 25th Anniversary Trans Am M30 Transmission - Automatic, 4-Speed,
B84 Ornamentation Exterior Molding, Body 4L60-E, Electronic
Side M49 Transmission, Manual, 5-Speed, Borg
CCI Roof Hatch, Removable Glass Panels Warner, 77 mm, 3.75 1st, 0.76 5th, 0/D
C41 HVAC System, Heater NA5 Emission System - Federal
C49 Defogger, Rear Window Electric Requirements.
C60 HVAC System, Air Conditioner, NB2 Emission System - California
Manual Control Requirements
C9C Paint Special (Black) NB8 Emission System - Override California
DD9 Mirror, Outside, LH and RH, Remote NC3 Tailpipe Modifications
Control, Electric, Breakaway, Painted NK3 Steering Wheel, Sport, Soft Rim,
DE4 Sunshade, Removable Hatch Roof Simulated Leather
DG7 Mirror, Outside LH & RH, Remote NM8 Leaded Fuel System Compatible
Control, Electric, Painted NP5 Steering Wheel; Leather Wrapped
D3W Speedometer Driven Gear NW9 ASR-Traction Control
D35 Mirror, Outside LH Remote, RH N36 Steering Wheel, 4 Spokes, Sport
Manual, Painted N96 Wheel, 16 x 8, Cast Aluminum
DSR Speedometer Driven Gear PW7 Wheel, 16 x 8, Aluminum Styled
D5X Speedometer Driven Gear QA7 Wheel, 16 x 7.5, Aluminum
D8I Sensor, Vehicle Speed QB3 Wheel, 16 x 7.5, Steel
DSM Sensor, Vehicle Speed QII Tire, P215/60R16 BW RIPE STTL
D8N Sensor, Vehicle Speed AL3 94H
D9Z Speedometer Driven Gear QLC Tire, P245/50ZR 16/N BL R/PE ST TL
EXP Export l.E.S. HW4
E7Z Sensor, Vehicle Speed - Delete QMT Tire, P235/55R 16/N BL R/PE ST TL
FE2 Suspension System, Ride Handling AL2
F41 Suspensions System, Firm Ride QPE Tire, P2 l 5/60R 16/N BL RIPE ST TL
Handling, Front and Rear AL2
GU2 Axle, Rear 2. 73 Ratio STE Plant Code-St. Therese, PQ, GM of
GUS Axle, Rear 3.23 Ratio Canada
GU6 Axle, Rear 3.42 Ratio TR7 Headlamps, Automatic Control
080 Axle, Rear Positraction (Limited Slip) Leveling System
092 Axle, Rear Ratio Performance TUB Lamp, Interior, Stop, High Level -
ILD Trim, Interior Design Delete
IL2 Trim, Interior Design T2H Ornamentation, Exterior, Export
IPB Trim, Interior Design T2J Ornamentation, Interior, Export
IP2 Seat, Leather Sport Front Bucket, T39 Lamp Turn Signal, Auxiliary
Driver and Passenger, Reclining T61 Lighting - Daytime Running
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·21

T72 Headlamps, Left Hand Rule of Road, VL5 License Plate, Front Mounting Package,
Export Export
T79 Lamps, Fog, Rear VP6 Noise Control
T84 Headlamps, RH Rule Of Road VR7 Hook Tow~Rear, Second
T90 Lamp Signaling and Marker, Export V73 Vehicle Statement, US/Canada
T96 Lamp, Fog V76 Hook, Tow
UB3 Instrument Cluster, Oil, Coolant, V78 Vehicle Statement - Delete
Temperature, Volts, Trip Odometer, WS9 Model Conversion Formula
Tachometer WX7 Wiring Provisions
UD4 Alarm Vehicle Speed, 120 km/h W66 Merchandised Package - Formula
UD6 Alarm, Exhaust Temperature YA7 Emission Test - California Assembly
UKl Japanese Radio Frequencies Line
UK2 Lever, Directional Signal, Multifunction YE8 Vehicle Test, Engineering
UK3 Electronic System Accessory Control YF5 Emission Certification - California
UL2 European Radio Frequencies Y81 Merchandised Package - Firebird
UM6 Radio, AM/FM Stereo, Seek/Scan, Auto Y83 Merchandised Package - Trans Am
Reverse Cassette, Clock, ETR Z28 Merchandised Package - Special
UN6 Radio, AM/FM Stereo, Seek/Scan, Auto Performance
Reverse Music Search Cassette, Clock, Z49 Canadian Modifications
ETR OlU Primary Color Exterior, Special
UP3 Radio, AM Stereo and FM Stereo, 05P Wheel Color Argent
Seek/Scan, Compact Disc, Equalizer, ISA Package Option O1
Clock, ETR lSB Package Option 02
UQO Speaker System 4, Dual Front Door lSC Package Option 03
Mounted, Standard Range Quarter/Shelf lSD Package Option 04
UT6 Radio AM Stereo and FM Stereo, lSE Package Option 05
Seek/Scan, Auto Reverse Music Search lSF Package Option 06
Cassette, Equalizer, Clock, ETR lOQ Molding Color - Arctic White
UU8 Radio, AM/FM Stereo, Seek/Scan, Auto IOU Primary Color - Exterior, Arctic White
Reverse Music Search Cassette, HPS, 12B Trim Combination - Cloth, Graphite
Clock, ETR 120 Trim Combination - Cloth, Graphite
UW2 Speaker System 10, Quad Front Door 121 Interior Trim - Graphite
Mounted, Dual Rear Sail Panel, 122 Trim Combination - Leather, Graphite
Amplifier 14B Trim Combination - Cloth, Lt. Gray
UW6 Premium 6 Speaker System 140 Trim Combination - Cloth, Lt. Gray
UXl Radio, AM Stereo and FM Stereo, 141 Interior Trim - Lt. Gray
Seek/Scan, Auto Reverse Music Search 142 Trim Combination - Leather, Lt. Gray
Cassette, Equalizer, Clock, ETR 17P Wheel Color - Silver
UlC Radio, AM/FM Stereo, Seek/Scan, 18U Primary Color - Exterior, Dark Green
Compact Disc, Clock, ETR Gray Metallic
UlT Radio, AM/FM Stereo, Seek/Scan, 40P Wheel Color - White
Compact Disc, HPS, Clock, ETR 41Q Molding Color - Black
U18 Speedometer Instrument, Kilometers 41U Primary Color - Exterior, Black
U19 Speedometer Instrument, Kilometers 48Q Molding Color - Dark Yellow Green
and Miles, Kilometer Odometer Metallic
U73 Antenna, Fixed 48U Primary Color - Exterior, Dark Yellow
U75 Antenna, Power Green Metallic
U82 Speaker System 3, Dual Door Mounted, 54Q Molding Color- Sunfire Yellow
Rear Package Shelf 54U Primary Color - Exterior, Sunfire
VAS Language Label, English Yellow
VBl Shipping Label, Japan 6DN Suspension - Computer Selected.
VCl Label, Price/Fuel Economy FRT,LH
VC3 Label, Price/Fuel Economy, US 6DR Suspension - Computer Selected,
Territories FRT,LH
VC4 Label, Price/Fuel Economy, Puerto Rico 6DS Suspension - Computer Selected,
VG8 Vehicle Buyer Notice Label FRT,LH
VG9 Protector Wax, Exterior Body, Export 6DT Suspension - Computer Selected,
VHS Plate, Vehicle Identification FRT, LH
VK3 License Plate, Front Mounting Package 6DV Suspension - Computer Selected,
VK4 License Plate, Front Mounting Package, FRT,LH
EEC 6DX Suspension - Computer Selected,
VL4 License Plate, Front Mounting Package, FRT,LH
EEC, Export
OA·22 GENERAL INFORMATION 1994 CAMARO AND FIREBIRD

6DY Suspension - Computer Selected, 7EB Suspension - Computer Selected,

FRT, LH FRT,RH
6EA Suspension - Computer Selected, 7ED Suspension - Computer Selected,
FRT,LH FRT,RH
6EB Suspension - Computer Selected, 7EG Suspension - Computer Selected,
FRT, LH FRT,RH
6ED Suspension - Computer Selected, 7EH Suspension --' Computer Selected,
FRT,LH FRT,RH
6EG Suspension - Computer Selected, 7EJ Suspension - Computer Selected,
FRT, LH FRT,RH
6EH Suspension - Computer Selected, 7EK Suspension - Computer Selected,
FRT,LH FRT,RH
6EJ , Suspension - Computer Selected, 7EL Suspension - Computer Selected,
FRT, LH FRT,RH
6EK Suspension - Computer Selected, 7EV Suspension - Computer Selected,
FRT,LH FRT,RH
6EL Suspension - Computer Selected, 7EW Suspension - Computer Selected,
FRT, LH FRT,RH
6EV Suspension - Computer Selected, 7EX Suspension - Computer Selected,
FRT, LH FRT,RH
6EW Suspension - Computer Selected, 7EY Suspension - Computer Selected,
FRT, LH FRT,RH
6EX Suspension - Computer Selected, 7GA Suspension - Computer Selected,
FRT, LH FRT,RH
6EY Suspension - Computer Selected, 7GB Suspension - Computer Selected,
FRT, LH FRT,RH
6GA Suspension - Computer Selected, 7GD Suspension - Computer Selected,
FRT, LH FRT, RH
6GB Suspension - Computer Selected, 7GE Suspension - Computer Selected,
FRT, LH FRT, RH
6GD Suspension - Computer Selected, 7GG Suspension - Computer Selected,
FRT, LH FRT,RH
6GE Suspension - Computer Selected, 7GH Suspension - Computer Selected,
FRT, LH FRT, RH
6GG Suspension - Computer Selected, 7GJ Suspension - Computer Selected,
FRT, LH FRT,RH
6GH Suspension - Computer Selected, 7GK Suspension - Computer Selected,
FRT, LH FRT,RH
6GJ Suspension - Computer Selected, 71Q Molding Color - Red
FRT, LH 71U Primary Color - Exterior, Medium
6GK Suspension - Computer Selected, Patriot Red
FRT, LH 8TA Suspension - Computer Selected,
6Z3 Speed Recorder RR,LH
64B Trim Combination - Cloth, Lt. Beige 8TB Suspension - Computer Selected,
64D Trim Combination-Cloth, Lt. Beige RR,LH
641 Interior Trim - Lt. Beige 8TC Suspension - Computer Selected,
642 Trim Combination - Leather, Lt. Beige RR,LH
7DN Suspension - Computer Selected, STD Suspension - Computer Selected,
FRT, RH RR,LH.
7DR Suspension - Computer Selected, 8TF Suspension - Computer Selected,
FRT, RH RR,LH
7DS Suspension - Computer Selected, 8TH Suspension - Computer Selected,
FRT, RH RR,LH
7DT Suspension - Computer Selected, 8TJ Suspension - Computer Selected,
FRT,RH RR,LH
7DV Suspension - Computer Selected, 8TK Molding Color - Medium Quasar Blue
FRT,RH Metallic
7DX Suspension - Computer Selected, 8TM Primary Color - Exterior, Medium
FRT,RH Quasar Blue Metallic
7DY Suspension - Computer Selected, 80Q Molding Color - Bright Red
FRT,RH Primary Color - Exterior, Bright Red
7EA Suspension - Computer Selected, 80U Suspension - Computer Selected,
FRT,RH RR,RH
1994 CAMARO AND FIREBIRD GENERAL INFORMATION OA·23

81Q Suspension - Computer Selected, 9TF Suspension - Computer Selected,

RR.RH RR,RH
81U Suspension - Computer Selected 9TH Suspension - Computer Selected,
RR,RH RR,RH
9TA Suspension - Computer Selected, 9TJ Suspension - Computer Selected,
RR,RH RR,RH
9TB Suspension - Computer Selected, 9TK Suspension - Computer Selected,
RR,RH RR,RH
9TC Suspension - Computer Selected, 9TM Suspension - Computer Selected,
RR,RH RR,RH
9TD Suspension - Computer Selected, 91Q Molding Color - Purple Pearl
RR.RH 91U Primary Color - Exterior, Purple Pearl

A Service Parts Identification DO NOT REMOVE

1G4BN5371 NW400001 4BN69
AG9 A90 848 COS 033 E92 LC3 N81 TR9 UF7 U26 U81 ZX5 42T 609
AUE BMD 884 C49 864 F40 MX 1 MNI TT5 UN3 U29 VE5 41 A 6PA
A01 BSI 893 C60 085 GU2 M31 POI T63 UN9 U35 N30 42L 608 BXY
A42 832 896 DF3 E52 K 19 NA5 DJW T87 UP8 U76 YT9 420 601 9XY
C A52 833 CD4 DIC E6E K64

l
WA8358 SILVER LOWER
WA7686 DARK BLUE UPPER
PAINT ALANTIC PROMOTION TWO TONE

/BASE COAT - CLEAR COAT

WA-i18118 ;~j-2_0~~~1---
K
D E F G J

A VEHICLE IDENTIFICATION NUMBER (VIN) F UPPER EXTERIOR PAINT COLOR

B ENGINEERING MODEL NUMBER (CAR DIVISION, G ACCENT COLOR
CARLINE AND BODY STYLE) J INTERIOR TRIM AND DECOR LEVEL
C SPECIAL ORDER PAINTS K OPTION CONTENT
D TYPE OF PAINT TECHNOLOGY
E LOWER EXTERIOR PAINT COLOR
PC1004-0A-B-RP

Figure 24 - Service Parts Identification Label

 MAINTENANCE AND LUBRICATION 08-1

SECTION OB

MAINTENANCE AND LUBRICATION

CONTENTS
Scheduled Maintenance Service . . . . . . . . . . . . . . OB-1 Fuel Tank, Cap and Lines Inspection ....... OB-5
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . . OB-1 Owner Inspection and Services . . . . . . . . . . . . . . . OB-5
Schedule I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-1 While Operating the Vehicle . . . . . . . . . . . . . . . OB-5
Schedule II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-1 At Each Fuel Fill ........................ OB-5
Explanation of Scheduled At Least Monthly . . . . . . . . . . . . . . . . . . . . . . . . OB-6
Maintenance Services .................. OB-1 At Least Twice a Year . . . . . . . . . . . . . . . . . . . . OB-6
Engine Oil and Oil Filter Change . . . . . . . . . OB-1 At Least Annually . . . . . . . . . . . . . . . . . . . . . . . OB-6
Chassis Lubrication . . . . . . . . . . . . . . . . . . . . OB-4 Each Time Oil Is Changed . . . . . . . . . . . . . . . . . OB- 7
Tire and Wheel Assembly Inspection Recommended Fluids and Lubricants . . . . . . . . . . OB-8
and Rotation . . . . . . . . . . . . . . . . . . . . . . . OB-4 Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . OB-8
Serpentine Drive Belt Inspection .......... OB-4 Approximate Fluid Capacities . . . . . . . . . . . . . . . . OB-9
Cooling System Service . . . . . . . . . . . . . . . . . OB-4 Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . OB-9
Front Wheel Bearing Assembly Repack .... OB-4 Rear Axle Filler Plug Torque . . . . . . . . . . . . . . . . . OB-9
Transmission Service . . . . . . . . . . . . . . . . . . . OB-4 Belt Tension Specifications . . . . . . . . . . . . . . . . . . OB-9
Spark Plug Assembly Replacement ........ OB-5 Tire Pressure Specifications . . . . . . . . . . . . . . . . . . OB-9
Spark Plug Wire Assembly Inspection ..... OB-5
Air Cleaner and Crankcase Ventilation
Filter Replacement . . . . . . . . . . . . . . . . . . . OB-5

SCHEDULED MAINTENANCE • Towing a trailer. Do not exceed trailering limits. See

the Owner's Manual for details.
SERVICE
• Operating in dusty areas.
NORMAL VEHICLE USE • The vehicle is used in delivery service, police, taxi
or other commercial applications.
The maintenance instructions contained in the Main-
tenance Schedule are based on the assumption that the
vehicle will be used as designed: SCHEDULE II
• To carry passengers and cargo within the limitation
indicated on the Tire Placard located on the edge of
the driver's door. Figure 2
• On reasonable road surfaces within legal operating Follow Schedule II ONLY if none of the driving
limits. conditions specified in Schedule I apply.

• On unleaded gasoline.
SCHEDULE I
Figure 1
Follow Schedule I if the vehicle is operated under
one or more of the following conditions:
• When most trips are less than 6 km (4 miles).
• Operating when outside temperatures remain below
freezing and when most trips are less than 16 km
(10 miles).
• When most trips include extended idling and/or
frequent low-speed operation as in stop-and-go
traffic.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
Refer to Figures I and 2 for the schedules of time
and/or mileage intervals. The following text and
illustrations (Figures 3 and 4) give details of the required
maintenance services.
Engine Oil and Oil Filter Change
ALWAYS USE SH QUALITY ENERGY CON-
SERVING II OILS OF PROPER VISCOSITY. Oils
designated "SH" will protect better than SG, SF/CC or
SF/CD oils. The "SH" designation may be shown alone
or in combination with other designations such as SH/SG,
etc.
 0
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SCHEDULED MAINTENANCE SERVICES z-I

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SCHEDULE I z
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Follow Schedule I if your vehicle is MAINLY driven under one or more of the following conditions: z
()
• When most trips are less than 6 kilometers (4 miles). m
)>
• When most trips are less than 16 kilometers (IO miles) and outside temperatures remain below freezing .
• When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic. t a
• Towing a trailer.**
• Operating in dusty areas .
'
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WHEN TO PERFORM
0
Kilometers (Miles) or Months,, The services shown in this schedule up tp 80 000 km (48,000 miles) ~
are to be performed after 80 000 km (48,000 miles) at the same intervals.
0
Whichever Occurs First z
ITEM TO BE SERVICED KILOMETERS (000) 5 IO 15 20 25 30 35 40 45 50 55 60 65 7!) 75 80
Tl NO.
(0. MILES (000) 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48
c
ro 1. Engine Oil & Oil Filter Change' Every 5 000 km (3,000 mi.) or 3 mos. • • • • • • • • • • • • • • • •
I
2. Chassis Lubrication Every other oil change • • • • • • • •
s:: 3. Tire & Wheel Assembly Inspection & Rotation At 10 000 km (6.000 mi.) and then every
~-
:::, 25 000 km ( 15.000 mi.) • • •
cii
:::, 4. Serpentine Drive Belt Inspection
!l)
:::, 5. Cooling System Service*
Every 50 000 km (30,000 mi.) or 24 mos. •
0
CD
6. Transmission Service
(/) See explanation for service interval.
0
:::, 7. Spark Plug Assembly Replacement'
CD
a.
c 8. Spark Plug Wire Assembly lnspection't •
ii> 9. Air Cleaner & Crankcase Ventilation Filter Replacement* Every 50 000 km (30.000 mi.) •
10. Fuel Tank, Cap & Lines lnspection't •
t Note: Schedule I should also be followed if the vehicle is used for delivery service, police, taxi or other commercial applications.
The U.S. Environmental Protection Agency has determined that the failure to perform this maintenance Item will not nullify the emission warranty or limit recall liability prior to the completion of
* vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded in section E of the owner's

... maintenance schedule •

An Emission Control Service
Do not exceed trailering limits. See your Owner's Manna! for details•

PC2001-0B-F-RP
 "

'

SCHEDULED MAINTENANCE SERVICES

SCHEDULE II
Follow schedule II ONLY if none of the driving conditions specified in Schedule I apply.

WHEN TO PERFORM
Kilometers (Miles) or Months, The.services shown in this schedule up to75 000 km (45,000 miles)
Whichever Occurs First are to be performed after 75 000 km (45,000 miles) at the same intervals.
ITEM TO BE SERVICED KILOMETERS (000) 12..S 25 37.S so 62.5 75
NO. MILES (000) - 7.5 15 22.S 30 37.S 45
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I. Engine Oil Change* Every 12 500 km (7,500 mi.) or 12 mos. • • • • • •
co Oil Filter Change* At first and then every other oil change • • •
I\J
I
2. Chassis Lubrication Every 12 500 km (7,500 mi.) or 12 mos. • • • • • •
:s::: 3. Tire & Wheel Assembly Inspection & Rotation At 12 500 km (7,500 mi.) and then
II)
s· every 25 OOOkm (15,000mi.) • • •
cii
::::, 4. Serpentine Drive Belt Inspection
II)
::::,
(') ' 5.. Cooling System Service*
Every 50 000 km (30,000 mi.) or 24 mos.
•
CD
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6. Transmission Service
See explanation for service interval.
::,: 7. Spark Plug Assembly Replacement*
CD
a.
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8. Spark Plug Wire Assembly lnspection*:j: •
9. Air Cleaner & Crankcasse Ventilation Filter Replacement* Every 50 000 km (30,000 mi.) •
10. Fuel Tank Cap & Lines Inspection*:j: •
:s::::
t The U.S. Environmental Protection Agency has determined that the failure to perform this maintenance item ,rill not nullify the emission warranty or limit recall liability prior to the completion of vehicle useful life. )>
General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded in section E of the owner's maintenance schedule.
• An Emission Control Service. ~
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PC2002-0B-F-RP 0
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08·4 MAINTENANCE AND LUBRICATION
HOT LOOK FOR
WEATHER ONE Of THESE
Of oc LABELS
-100 +31
-80 ·27
·60
..
+16
-40
-20 -7
-11
SAE lOW-30
SAE5W-30
PREFERRED
COLD
WEATHER
IF NEITHER SAE 5W-30 NOR SAE lOW-30
GRADE OILS ARE AVAILABLE, SAE 30 GRADE
MAY BE USED AT TEMPERATURES ABOVE
40 DEGREES F (4 DEGREES C).
DO NOT USE SAE 10W-40, SAE 20W·50 OR
ANY OTHER GRADE OIL NOT RECOMMENDED. RCOOOt-OB-F-RP
Figure 3 - Engine Oil Viscosity Recommendation
Engine oil viscosity (thickness) has an effect on fuel
economy and cold-weather operation (starting and oil
flow). Lower viscosity engine oils can provide better fuel
economy and cold-weather performance; however, higher
temperature weather conditions require higher viscosity
engine oils for satisfactory lubrication. Using oils of any
viscosity other than those viscosities recommended
could result in engine damage.
When choosing an oil, consider the range of
temperatures the vehicle will be operated in before the
next oil change. Then, select the recommended oil
viscosity from the chart (Figure 3).
Chassis Lubrication
Lubricate transmission shift linkage.
Lubricate all grease fittings in the suspension and
steering linkage as described by the following.
Lubricating Joints that Have Grease Fittings
Wipe off all dirt from the grease fitting before
lubricating the joint. Use a low-pressure grease gun on all
joints to prevent seal damage.
Steering tie rod assemblies - Apply grease until
grease flows out between seal and tie rod end housing.
Lower ball stud assemblies - Lower ball stud as-
semblies should not be lubricated unless their temperature
is -12 °C (10°F) or warmer. During cold weather, the ball
stud assembly should be allowed to warm up as necessary
before being lubricated. Apply grease slowly while
watching grease seal. Apply grease until the seal expands
or grease is seen bleeding from the seal. If the seal
expands but no grease is seen, do not apply any more
grease. Allow time for the grease to bleed from the seal.
All joints - Wipe off all excess grease.
Tire and Wheel Assembly Inspection and
Rotation
Figure 4
Check tires for abnormal wear or damage. To
equalize wear and obtain maximum tire life, rotate as
shown in Figure 4.
If the vehicle is equipped with P245/50ZR16 size
tires, special rotation provisions must be followed
because the tires are directional. See Figure 4 for the
recommended rotation. Directional tires have color-coded
arrows on both sides of the sidewall pointing in the
direction the tires must roll for the correct performance.
Follow these steps:
1. Dismount tires from the wheel assemblies.
2. Rotate the tires (not the wheel assemblies) in the
rotation pattern shown in Figure 4. Make sure the
tires rotate in the direction of the arrows as they are
remounted on the wheel assemblies.
3. Rebalance the tires.
4. Replace wheel a.ssemblies in their original position.
If irregular or premature wear exists, check wheel
alignment. Also, check for damaged wheel assemblies.
Do not include the compact spare tire in rotation.
While the tire and wheel assemblies are removed,
perform the brake systems inspection specified. Refer to
"Each Time Oil ls Changed" in this section.
Serpentine Drive Belt Inspection
Inspect drive belt for cracks or fraying. If sections
of the drive belt are missing, the drive belt should be
replaced. Refer to SECTION 6A2A or SECTION 6A3A.
Cooling System Service
Drain, flush and refill system with new or approved
recycled coolant. Refer to "Recommended Fluids and
Lubricants" in this section, or SECTION 6B.
Front Wheel Bearing Assembly Repack
The front wheel bearing assemblies are not service-
able. Complete replacement of the front wheel bearing
assembly hubs is required.
Transmission Service
For the manual transmission, fluid does not require
changing.
For the automatic transmission, change both the
fluid and the filter every 25 000 km (15,000 miles) if the
vehicle is mainly driven under one or more of these
conditions:
• In heavy city traffic where outside temperature
regularly reaches 32°C (90°F) or higher.
• On hilly or mountainous terrain.

A
I I
...
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LL
11 11
I B
I before operating the vehicle.
A NORMAL FOUR-WHEEL ROTATION PATIERN FOR TIRES
DESIGNED TO ROLL IN EITHER DIRECTION
B SPECIAL FOUR-WHEEL ROTATION PATIERN FOR
DIRECTIONAL TIRES DESIGNED TO ROLL MAINLY IN ONE
DIRECTION
IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE
ASSEMBLY IN ROTATION.
PC0004-3E·F·RP
Figure 4 - Recommended Tire Rotation Pattern
• Frequent trailer pulling. Do not exceed trailering
limits. See the Owner's Manual or 1993 dealership
trailering brochure for details.
• Used for delivery service, police, taxi or other
commercial applications.
If the vehicle is not used under any of these
conditions, change both the fluid and filter (or service the
screen) every 160 000 km (100,000 miles). Refer to
SECTION 7A for more information.
Spark Plug Assembly Replacement
Replace spark plug assemblies every 50 000 km
(30,000 miles) on the 3.4L L32 engine and every 160 000
km (100,000 miles) on the 5.7L LTl engine with type
listed. Refer to "Maintenance Items" in this section.
Spark Plug Wire Assembly Inspection
Clean wire assemblies and inspect for burns, cracks
or other damage. Check the wire assembly boot fit at the
ignition distributor assembly and/or ignition distributor
coil assembly, and at the spark plug assemblies. Replace
the wire assemblies as needed.
MAINTENANCE AND LUBRICATION OB·S
Air Cleaner and Crankcase Ventilation Filter
Replacement
Replace the air cleaner filter every 50 000 km
(30,000 miles}_or 36 months, whichever comes first.
Replace more often under dusty conditions.
Fuel Tank, Cap and Lines Inspection
Inspect fuel tank, cap and lines for damage or leaks.
Inspect fuel cap gasket for an even filler neck imprint or
any damage. Inspect injection assemblies. Replace parts
as needed. Periodic replacement of the fuel filter is not
required.
OWNER INSPECTION AND SERVICES
Listed below are vehicle inspections and services
that should be made by either the owner or a qualified
technician at the frequencies indicated to help ensure
proper safety, emission systems performance and
dependability of the vehicle. Whenever repairs are
necessary, have them completed at once.
Any safety related or emissions related components
that could have been damaged in an accident should be
inspected and all needed repairs should be performed
WHILE OPERATING THE VEHICLE
Automatic transmission shift indicator operation
- Make sure the indicator points to the gear chosen.
Horn assembly operation - Blow the hofu
assembly occasionally to make sure it works. Check all
button locations.
Brake system operation - Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if the brake warning lamp or
antilock brake system warning lamp goes on or flashes,
something may be wrong with part of the brake system.
Exhaust system operation - Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
Have it inspected and repaired at once.
Tires, wheel assemblies and alignment operation
- Be alert to a vibration of the steering wheel or seat at
normal highway speeds. This may mean a wheel assembly
balance is needed. Also, a pull right or left on a straight
and level road may show the need for a tire pressure
adjustment or a wheel alignment.
Steering system operation - Be alert to changes in
steering action. An inspection is needed when the steering
wheel is harder to turn, or has too much free play, or if
unusual sounds are noted when turning or parking.
Headlamp capsule assembly aim - Take note of
the light pattern occasionally. If beams seem to be
improperly aimed, headlamps should be checked and
adjusted as necessary.
AT EACH FUEL FILL
A fluid loss in any system (except windshield
washer) may indicate a problem. Have the system
inspected and repaired at once.
Engine oil level - Check level and add oil if
necessary. The best time to check the engine oil level is
08·6 MAINTENANCE AND LUBRICATION
wh~n the oil is wann. After stopping the engine with the
vehicle on a level surface, wait a few minutes for the oil to
drain back to the oil pan. On the 5.7L LTl engine, pinch
!he. end of the oil level indicator (dipstick) and pull the
md.1c~tor out. The oil level indicator will be wiped clean
as 1t 1s removed. On the 3.4L L32 engine, pull out the oil
level indicator and wipe it clean. Push the oil level inciator
back _down all the way. Pull out the oil level indicator
(without pinching the holder on the 5.7L LTl), keeping
the t_ip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above the
"ADD" line and within the cross-hatched operating range
are~. Avoid overfilling the engine since this may cause
engme damage. Push the oil level indicator back down all
the way after taking the reading.
If you check the oil level when the oil is cold, do not
run the engine first. The cold oil will not drain back to the
pan fast enough to give a true oil level.
Engine coolant level and condition - Check engine
coolant level in the coolant reservoir and add coolant if
necessary.
Windshield washer solvent level - Check washer
solvent level in reservoir and add solvent if necessary.
Hood latch operation - When opening the hood,
note the operation of the secondary latch. It should keep
!he hood from opening all the way when the primary latch
1s released. Make sure that the hood closes firmly.
AT LEAST MONTHLY
Tire and wheel assembly inspection and pressure
check - Check tires for abnormal wear or damage. Also
check for damaged wheel assemblies. Pressure should be
checked when tires are "cold." Maintain pressures as
shown in "Tire Pressure Specifications" in this section, or
the Tire Placard on the driver's door.
Lamp operation - Check operation of the license
plate lamp, sidemarker lamps, headlamps (including high
beams), fog lamps, parking lamps, taillamps, brake lamps
(including the center high-mounted stoplamp ), tum sig-
nals, backup lamps, hazard warning flasher and interior
lamps.
Fluid leak check - Periodically inspect the surface
beneath the vehicle for water, oil, fuel or other fluids after
the vehicle has been parked for a while. Water dripping
from the air conditioning system after use is normal. The
cause of fuel leaks or fumes should be found and
corrected at once.
AT LEAST TWICE A VEAR
Power steering system reservoir level - Check and
keep at proper level. Refer to SECTION 3B 1B.
Brake master cylinder reservoir level - Check
fluid. Refer to SECTION SA. Keep fluid at proper level.
A low ·fluid level can indicate worn disc brake pads which
may need to be serviced. Also refer to SECTION 5El.
Weatherstrip lubrication - Clean the surface and
then apply a thin film of silicone grease, GM P/N
12345579 or equivalent, using a clean cloth.
AT LEAST ANNUALLY
CAUTION: Before checking the holding
ability of the parking brake and auto-
matic transmission park mechanism,
park on a fairly steep hill with enough
room for movement in the downhill
direction. To reduce the risk of person-
al injury or property damage, be pre-
pared to apply the regular brakes
promptly if the vehicle begins to move.
Parking brake and transmission park mecha-
nis'!1 operation - To check the parking brake, with the
engine running, parking brake set and transmission in
"NEUTRAL," slowly remove foot pressure from the
regular brake pedal until the vehicle is held only by the
parking brake.
To check the automatic transmission park mecha-
nism holding ability, release all brakes after shifting the
transmission to "PARK."
CAUTION: Before performing the fol-
lowing transmission neutral start
switch check, be sure to have enough
room around the vehicle. Then, firmly
apply both the parking brake and the
regular brakes. Do not use the acceler-
ator pedal. If the engine starts, be ready
to turn off the ignition promptly. Take
these precautions because the vehicle
could move without warning and possi-
bly cause personal injury or property
damage.
Transmission neutral start switch operation - On
automatic transmission vehicles, try to start the engine in
each gear. The starter should crank only in "PARK" or
"NEUTRAL."
On manual transmission vehicles, place the shift
lever in "NEUTRAL," push the clutch pedal halfway and
try to start. The starter should crank only when the clutch
pedal is fully depressed.
Steering column lock operation - While parked,
try to turn the key to "LOCK" in each gear range. On
vehicles with automatic transmissions, the key should
tum to "LOCK" only when the gear selector is in
"PARK." On vehicles with key release button, try to turn
to "LOCK" without depressing the .button. The key
should turn to "LOCK" only with the key button
depressed.
Seatback latch operation - Be sure seatbacks latch
on those vehicles with folding seats using mechanical
latches.
Lap and shoulder belts condition and operation -
Inspect belt system, including webbing, buckles, latch
plates, retractor, guide loops and anchors.
Movable head restraint operation - Make sure
movable head restraints stay in the desired position.
Seat back recliner operation (if equipped) - Make
sure the recliner is holding by pushing and pulling on the
top of the seatback while it is reclined.

Spare tire and jack storage - Be alert to rattles in
rear of the vehicle. Make sure the spare tire, all jacking
equipment and any covers or doors are securely stowed at
all times. Oil the jack screw mechanism after each use.
Key lock service - Lubricate the key lock cylinder
(except instrument panel compartment lock).
Body lubrication service - Lubricate all body door
hinges, including the hood, fuel door and rear
compartment hinges and latches, the instrument panel
compartment door, and any folding seat hardware.
Lubricate all pivot points in the headlamp door
assembly, including the spring links for each door.
Underbody flushing - At least every spring, flush
from the underbody any corrosive materials used for ice
and snow removal and dust control. Use plain water. Take
care to thoroughly clean any areas where mud or other
debris can collect. Sediment packed in closed areas of the
vehicle should be loosened before being flushed.
Engine cooling system - Inspect coolant and freeze
protection. Keep coolant at the proper mixture for proper
freeze protection, corrosion inhibitor level and best
engine operating temperature. Inspect hoses and replace if
cracked, swollen or deteriorated. Clean outside of radiator
and air conditioning condenser. Wash filler cap and neck.
To help ensure proper operation, a pressure test of both the
cooling system and cap is also recommended.
EACH TIME OIL IS CHANGED
Automatic transmission fluid level - Maintain
level within operating range on the oil level indicator.
Refer to SECTION 7A.
Manual transmission - Check fluid level and add
as required. Refer to SECTION 7B.
Brake systems inspection - For convenience, the
following should be done when wheel assemblies are
removed for rotation: Inspect lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc. Inspect disc
brake pads for wear and rotors for surface condition. Also
inspect drum brake linings for wear and cracks. Inspect
MAINTENANCE AND LUBRICATION 08·7
other brake parts, including drums, wheel cylinders,
parking brake, etc., at the same time. The parking brake is
self-adjusting and no manual adjustment is required.
Inspect brakes more often if habit or conditions
result in frequent braking.
Steering and suspension inspection - Inspect front
and rear suspension and steering system for damaged,
loose or missing parts, signs of wear or lack of lubrication.
Inspect power steering lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc.
Exhaust system inspection - Inspect complete
system, including catalytic converter. Inspect body near
the exhaust system. Look for broken, damaged, missing
or out-of-position parts as well as open seams, holes,
loose connections and other conditions which could cause
a heat buildup in the floor pan or could let exhaust fumes
seep into the trunk or passenger compartment. Check heat
shields. Tighten connections or replace parts as necessary.
Throttle linkage inspection Inspect for
interference, binding, and damaged or missing parts.
Serpentine drive belt - Inspect drive belt for
cracks, fraying, wear and proper tension. Drive belts
cannot be adjusted. Replace tensioner or drive
belt as needed. Refer to SECTION 6A2A or SECTION
6A3A.
Rear axle assembly - Check fluid level and add if
needed. To check or add fluid, hoist vehicle at suspension
contact points. Refer to SECTION OA. Keep vehicle
level. Clean dirt or foreign material from around filler
plug opening before removing the filler plug. Maintain
fluid level from flush with bottom of opening to no lower
than 6 mm (1/4 inch) below opening. Always replace
filler plug. Tighten to 35 N•m (26 lb. ft.).
If the vehicle is used to pull a trailer, change
lubricant every 12 500 km (7,500 miles) in either type
differential.
Limited slip differentials should have fluid drained
and refilled at the first 12 500 km (7,500 miles). Be sure to
add limited slip additive.
08-8 MAINTENANCE AND LUBRICATION

RECOMMENDED FLUIDS: AND LUBRICANTS

Engine oil - GM Good wrench motor oil or equivalent for API service SHISG of recommended viscos-
ity.
Engine coolant - 50150 mixture of water (preferably distilled) and good quality ethylene glycol base
antifreeze or approved recycled coolant conforming to GM Specification 1825M (GM PIN 1052753 or
equivalent).
Hydraulic brake system - Delco-Supreme 11 ®brake fluid (GM PIN 1052535) DOT-3 brake fluid.
Hydraulic clutch system - Hydraulic clutch fluid (GM PIN 12345347 or equivalent).
Power steering system - Power steering fluid meeting requirements of GM 9985010 (GM PIN
1050017, GM PIN 1052884 or equivalent). In cold climates use GM PIN 12345867, GM PIN 12345866
or equivalent. (System should be drained and refilled prior to using this fluid).
Automatic transmission- DEXRON®-IIE or DEXRON®-III automatic transmission fluid.
Automatic transmission shift linkage - Engine oil. Clutch linkage pivot points - Engine oil.
Manual transmission - DEXRON®-IIE automatic transmission fluid.
Manual transmission shift linkage - Chassis lubricant meeting requirements of NLGI Grade 2,
Category LB or GC-LB (GM PIN 1052497).
Key lock cylinders (except instrument panel compartment lock) - Lubricate with Multi-Purpose
Lubricant (GM PIN 12345120 or equivalent) or synthetic SAE 5W-30 engine oil or silicone lubricant
(GM PIN 1052276 or 1052277). Do not use aerosols.
Weatherstrips - Dielectric silicone grease (GM PIN 12345579 or equivalent).
Chassis lubrication - Chassis lubricant meeting requirements of NLGI Grade 2, Category LB or GC-
LB (GM PIN 1052497 or equivalent).
Standard differential rear axle assembly - SAE 80W-90 GL-5 gear lubricant or axle lubricant (GM
PIN 12345977, or equivalent).
Limited slip differential rear axle assembly - All models require 118 ml (4 fl. oz.) of limited slip
differential additive lubricant (GM P/N 1052358 or equivalent) and axle lubricant (GM P/N 12345977,
or equivalent) or SAE 80W-90 GL-5 gear lubricant.
Windshield washer solvent - GM Optikleen® Washer Solvent (GM P/N 1051515 or equivalent).
Hood latch assembly and pivots - Engine oil.
Hood latch assembly release pawl - Chassis lubricant meeting requirements of NLGI Grade 2,
Category LB or GC-LB (GM PIN 10524?7). .
Hood and. door hinges, hatchback lid· binge and linkage. Headlamp door assemblies, if equipped.
Rear folding seat. Fuel door hinge. Rear compartment lid hinges. - Engine oil or Lubriplate lubri-
cant (GM PIN 1050104).

MAINTENANCE ITEMS
Air Cleaner Filter
All VIN ...............•. , .· ..... ; ., .. :'.. '. ..... ·. . . . . . . . . . . . . . . . . . . . . . AC Type A1163C
Engine Oil Filter
3.4L (VIN S) ................ , ........ ,. .............................. AC Type PF47
5.7L (VIN P) ........................................................ AC Type PF25
Fuel Filter
All VIN .............. ,. ·... :· .: ........... :·· . •.. ·......... ,. ................ AC Type GF578
~v~~ . . .
3.4L (VIN S) .................................................... AC Type CV789C
5.7L (VIN P) ..................................................... AC Type CV895C
Spark Plug Assemblies and Gap
3.4L (VIN S) .......................................... AC.R43TSK 1.14 mm (0.045")
5.7L (VIN P) .......................................... AC.R45LTSP 1.27 mm (0.050")
 MAINTENANCE AND LUBRICATION 08·9

APPROXIMATE FLUID CAPACITIES

Air Conditioning
R-134a ............................................................ 0.91 kg (2.0 lb.)
Engine Crankcase
Without Filter Change (All VIN) ...................................... 3.8 liters (4.0 qt.)
With Filter Change
3.4L (VIN S) .................................................... 3.8 liters (4.0 qt.)
5.7L (VIN P) .................................................... 4.7 liters (5.0 qt.)
Fuel Tank ........................................................ 58.7 liters (15.5 gal.)
Transmission
Manual - Drain and Refill and Overhaul
Five-Speed ..................................................... 2.8 liters (5.9 pt.)
Six-Speed ...................................................... 3.8 liters (8.0 pt.)
Automatic (HYDRA-MATIC 4L60-E)
3.4L (VIN S) Drain & Refill ........................................ 4.7 liters (10.0 pt.)
3.4L (VIN S) Overhaul ............................................ 7.9 liters (16.7 pt.)
5.7L (VIN P) Drain and Refill ....................................... 4.7 liters (10.0 pt.)
5.7L (VIN P) Overhaul ............................................ 10.6 liters (22.4 pt.)
Cooling System
3.4L (VIN S)
With Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6 liters (12.3 qt.)
With Manual Transmission ....................................... 11.8 liters (12.5 qt.)
5.7L (VIN P)
With Automatic Transmission .................................... 14.3 liters (15.1 qt.)
With Manual Tranmission ........................................ 14.5 liters (15.3 qt.)

Rear Axle - Drain and Refill ........................................... 1.7 liters (3.5 pt.)
Rear Axle -Additive ............................................ 118 milliliters (4 fl. oz.)

The capacities shown here are approximate. Add fluid as necessary to bring to appropriate level.

WHEEL NUT TORQUE

Wheel Nuts ...................................................... 140 N•m (100 lb. ft.)

REAR AXLE FILLER PLUG TORQUE

Filler Plug ......................................................... 35 N•m (26 lb. ft.)

BELT TENSION SPECIFICATIONS

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

TIRE PRESSURE SPECIFICATIONS

Compact Spare ..................................................... 420 kPa (60 psi)
Front and Rear - All ................................................. 210 kPa (30 psi)
 HEATER AND VENTILATION 1A·1

SECTION 1

HEATING -AND AIR COND~TION-ING

CONTENTS
Heater and Ventilation ................................................... Section IA
Heater, Ventilation and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1B
Manual Control Air Conditioning ......................................... Section lBl
HD6(HR6-HE Air Conditioning Compressor Service or Unit Repair R-134a ....... Section 1D2

SECTION 1A

HEATER AND VENTILATION

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

CONTENTS
General Description ........................ IA-I On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . IA-9
Base Heater System . . . . . . . . . . . . . . . . . . . . . . lA-1 Replacement Procedures .................. IA-9
Control Assembly . . . . . . . . . . . . . . . . . . . . . . . lA-2 Control Assembly and Vacuum Selector
Temperature Control Knob .............. lA-2 Valve and/or Blower Motor Assembly
Mode Control Knob . . . . . . . . . . . . . . . . . . . . lA-2 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . lA-9
Blower Motor Assembly Speed Control Control Assembly Lamp Bulb ........... lA-15
Knob .............................. lA-5 Temperature Control Cable Assembly ..... lA-16
Air Distribution System ................... lA-5 Blower Motor Resistor Assembly . . . . . . . . 1A-17
Vacuum System . . . . . . . . . . . . . . . . . . . . . . . lA-5 Blower Motor Assembly and Blower
Temperature Valve and Heater Core ....... lA-5 Motor Fan ........................ lA-17
Mode Valve Housing ................... lA-5 Vacuum Harness ...................... lA-18
AirOutlets ........................... lA-6 Vacuum Tank ........................ lA-18
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . lA-6 Vacuum Actuators .................... lA-19
Diagnosis ................................ lA-6 Air Deflectors ....................... IA-19
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . lA-6 Heater Hose Assembly and Heater
Heater Output Temperature Check .......... lA-8 Hose Pipes ........................ lA-19
Insufficient Heating or Defrosting . . . . . . . . . . . lA-8 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . lA-20
High or Low Heater Control Effort .......... lA-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . lA-23
Blower Motor Assembly Noise . . . . . . . . . . . . . lA-9 Fastener Tightening Specifications . . . . . . . . . lA-23
Excessive Heat .......................... lA-9 Electrical Specifications . . . . . . . . . . . . . . . . . lA-23

GENERAL DESCRIPTION Within the heater module assembly (1), the air is
heated as required and then routed through ducts to the
proper outlets for discharge into the passenger compart-
BASE HEATER SYSTEM ment. A control assembly (2) in the instrument panel
assembly allows the operator to control blower motor
Figures 1 through 5 assembly speed, mode of operation and the temperature of
The base heater system provides heating, ventila- the air coming from the heater system.
tion, side window defogging and windshield defrosting. The heater module assembly (I) contains compo-
Outside air is drawn from the plenum at the base of the nents that heat the air flowing through it and direct the air
windshield assembly into the heater module assembly (1) to the proper ducts and outlets. The heater module assem-
by the blower motor fan ( 18). bly ( 1) is a single unit, including the blower motor assem-
1A·2 HEATER AND VENTILATION
bly ( 6), that is mounted to the rear surface of the dash front Temperature Control Knob
panel in front of the instrument panel assembly.
Hot coolant from the engine's cooling system is
directed through the heater core (14) and returned to the · air being discharged into the passenger compartment from
cooling system when the engine is running. The heater
core ( 14) transfers heat from the coolant to the air passing
through the heater core fins. There is no hot water valve in
the heater system to prevent flow of coolant through the
heater core (14).
CONTROL ASSEMBLY
Figures 1 through 5
Three knobs in the instrument panel allow a front
seat occupant to operate the heating and ventilation. These
knobs are in the control assembly, in the center of the
instrument panel, just above or below the radio, depend-
ing on the vehicle. To the left of the blower motor speed
control knob is the control button for the electric rear win-
dow defogger (Pontiac only).
The controls are lit when the headlamps a.re on.
Electrical power is provided by the instrument panel light-
ing circuit. The control assembly lamp is in parallel with
the instrument cluster bulbs, the radio dial bulb and cer-
tain other interior illumination bulbs. Brightness .of the
dial illumination is controlled by the dimmer control of
the headlamp switch. For electrical circuit diagrams and
more infonnation, refer to SECTION 8A.
1 MODULE ASSEMBLY, HEATER
2
3
CONTROL ASSEMBLY
VALVE, VENT MODE
4 VALVE, Bl-LEVEL MODE
6 MOTOR ASSEMBLY; BLOWER
7 KNOB,MODECONTROL
8 KNOB, TEMPERATURE CONTROL
9 KNOB, BLOWER MOTOR ASSEMBLY SPEED CON1ROL
10 ACTUATOR, Bl-LEVEL MODE VALVE
11 ACTUATOR, DEFROSTER/HEATER VALVE
12 OUTLET, FLOOR AIR
13 HARNESS, VACUUM
RCOOOMA·f.RP
Figure 1 - Heater Module Assembly and Controls
The temperature control knob is the middle knob in
the control assembly. It regulates the temperature of the
the heater or ventilation system. The temperature control
knob controls the position of a "door" called the tempera-
ture valve in the heater module assembly. The temperature
valve governs the relative amounts of heated and un-
heated air discharged from the heater system. Full warm,
full cool or any intermediate temperature mixture can be
selected by moving the knob to the right (red area) for
warm air and to the left (blue area) for cool air or any-
where in between.
Mode Control Knob
The right knob, called the mode control knob, is a
rotary vacuum switch that regulates airflow from the out-
lets by routing engine vacuum to vacuum actuators at the
heater module assembly. The mode control knob also con-
trols an electrical switch that supplies power to operate the
blower motor assembly for specific mode selections.
A choice of six operating modes can be selected by
turning the mode control knob in the control assembly.
From left to right, the six modes are "OFF," '!.....,;" (vent),
"~,i" (bi-level), '~,.i " (heater), "~,i' (blend) and "@"
(defrost).
"OFF" Mode
When the mode control knob is in the "OFF" posi-
tion, no electrical power is supplied to the blower motor
assembly. A limited flow of air, caused by movement of
the vehicle, may come from the defrost outlet and the
floor outlets. This is the only mode in which the blower
motor assembly will not operate.
·:...,; " (Vent) Mode
With the mode control knob in the "..._;" position,
outside air is delivered through the instrument panel out-
lets to ventilate the vehicle. If preferred, the air may be
warmed by setting the temperature control knob to the
desired temperature.
~,.i "(Bi-level) Mode
With the mode control knob in the ·~,;" position,
electrical power is supplied to the blower motor assembly.
Outside air is drawn in and heated (depending on the posi-
tion of the temperature control knob). Then the airflow is
split between the_ instrument panel outlets and _th~_floor
outlets. Blower motor assembly speed may be varied.
,,.,
" · " (Heater) Mode
With the mode control knob in the ·:.._; " position,
outside air is drawn into the vehicle, heated (depending on
the position of the temperature control knob) and directed
to the floor air outlets. A small amount of air is routed to
the windshield assembly through the defrost outlet.
Blower motor assembly speed may be varied as in
other operating modes.
This mode is the normal selection for cold weather
operation unless the windshield assembly must be cleared
of heavy frost.
 HEATER AND VENTILATION 1A·3

156

7 KNOB, MODE CONTROL

8 KNOB, TEMPERATURE CONTROL
9 KNOB, BLOWER MOTOR ASSEMBLY SPEED CONTROL
156 KNOB, REAR WINDOW DEFOGGER RC2002·1A·f·RP

Figure 2 - Control Assembly- (Pontiac)

157 KNOB, MODE CONTROL 157

158 KNOB, TEMPERATURE CONTROL 158
159 KNOB, BLOWER MOTOR ASSEMBLY SPEED CONTROL RC1003·1A·f.RP

Figure 3 - Control Assembly - (Chevrolet)

\ E
G G
1 MODULE ASSEMBLY, HEATER
3 VALVE, VENT MODE
4 VALVE, Bl·LEVEL MODE
A OUTSIDE AIR E TO INSTRUMENT PANEL OUTLETS 6 MOTOR ASSEMBLY, BLOWER
B PLENUM F TO FLOOR OUTLETS 14 CORE, HEATER
CHEATED AIR G TO WINDSHIELD DEFROSTER OUTLETS 15 VALVE, DEFROSTER/HEATER
D UNHEATED AIR H TO SIDE WINDOW DEFOGGER OUTLETS 16 VALVE, TEMPERATURE
RC0012·1A·f·RP

Figure 4 - Heater Module Assembly Schematics

1A-4 HEATER AND VENTILATION

11

10
15
A

A COMPONENT LOCATIONS L TO SIDE WINDOW DEFOGGER OUTLETS

B uBI-LEVEL" MOOE AIRFLOW 3 VALVE, VENT MODE
C uVENT" MOOE AIRFLOW 4 VALVE, Bl-LEVEL MODE
0 "HEATER" MODE AIRFLOW 10 ACTUATOR, Bl-LEVEL MODE VALVE
E "DEFROST" MOOE AIRFLOW 11 ACTUATOR, DEFROSTER/HEATER VALVE
F uBLENO" MOOE AIRFLOW 15 VALVE.DEFROSTER/HEATER
G OUTSIDE AIR 17 HEATERASSEMBLY
H TO INSTRUMENT PANEL OUTLETS 18 FAN, BLOWER MOTOR
J TO FLOOR AIR OUTLET 1~ ACTUATOR, VENT MODE VALVE
K TO WINDSHIELD DEFROSTER NOZZLES RC0003·1A·f.RP

Figure 5 - Operating Mode Airflow Distribution


....
"® ·" ,,
(Blend) Mode
With the mode control knob in this position, outside
air is drawn into the vehicle, heated (depending on the
position of the temperature control knob) and split
between the defrost outlet and the floor air outlets.
"@" (Defrost) Mode
With the mode control knob in the "@" position,
outside air is drawn into the vehicle, heated (depending on
the position of the temperature control knob) and directed
to the defrost outlet. A small amount of air is routed to the
floor air outlets. Blower motor assembly speed may be
varied.
Side Window Defogging
In all modes except "OFF" and "..,;" (vent), air is
supplied to the side window defrost outlets, located at the
end of the instrument panel upper trim pad assembly.
Blower Motor Assembly Speed Control Knob
With the ignition switch in the "RUN" position, the
blower motor assembly runs in all mode control knob
positions except "OFF." Blower motor assembly speed is
controlled by a four-position electrical blower switch at
the left side of the control assembly. The blower switch
provides a choice of low blower motor assembly speed,
two medium blower motor assembly speeds and a high
blower motor assembly speed.
The circuit to the blower motor assembly is com-
pleted to ground at the instrument panel assembly through
the instrument panel wiring harness. Refer to SECTION
SA.
AIR DISTRIBUTION SYSTEM
Air enters the heater module assembly where it is
heated as necessary before being sent to the proper outlets
for discharge into the passenger compartment. Within the
heater module, valves ("doors") guide the airflow in
response to the positions of the temperature control knob
and the mode control knob in the control assembly.
Vacuum System
Figure 6
All valves in the heater module assembly except the
temperature valve are controlled by engine vacuum drawn
from the vacuum tank in the engine compartment. The
vacuum is routed by a vacuum selector valve in the con-
trol assembly to spring-loaded vacuum actuators on the
heater module assembly. Vacuum stored in the vacuum
tank is prevented from bleeding back to its source during
conditions of low engine manifold vacuum (acceleration,
hard pulling, etc.) by a check valve in the vacuum line.
The vacuum selector valve in the control assembly is
controlled by the mode control knob. For each mode con-
trol knob position, the vacuum selector valve directs vacu-
um to specific hoses to overcome the force of the spring
within the appropriate vacuum actuators. The vacuum
selector valve also vents (to normal air pressure) the hoses
to each remaining vacuum actuator, allowing the actua-
tor's external spring to expand. This results in the valves
HEATER AND VENTILATION 1A-5
being properly positioned for the selected operating
mode.
The bi-level and vent valves have two-position vac-
uum actuators. When vacuum is directed to either actua-
tor's vacuum chamber, the vacuum pulls in a flexible
diaphragm that forms one wall of the chamber. This draws
a movable shaft attached to the diaphragm. The shaft is
linked to the corresponding valve, and it operates the
valve when vacuum is applied.
When the vacuum chamber is vented to normal air
pressure, an external spring moves the shaft back to its
original position. The shaft, in turn, returns the valve to its
original position.
The defroster/heater valve has a three-position mode
valve actuator with two vacuum hoses and two vacuum
chambers, one at each end of the actuator. In effect, the
three-position mode valve actuator acts like a pair of two-
position actuators placed end-to-end. When vacuum is
directed to either chamber, that chamber's diaphragm
moves the mode valve operating linkage from its centered
position to one extreme of travel. Venting that chamber
while directing vacuum to the opposite chamber causes
the linkage to move to its opposite extreme. Venting both
chambers allows external torsion springs to center the
linkage. The center position of the defroster/heater valve
creates the blend mode.
Temperatl,lre Valve and Heater Core
Figure 4
The temperature of the air discharged from the heat-
er system is regulated by controlling the relative amounts
of warm and cool air that are mixed together downstream
from the heater core area. The part of the total airflow that
is allowed to pass through the heater core ( 14) is governed
by the position of the temperature valve (16).
Hot coolant from the engine's cooling system is
directed through the heater core (14). The heater core (14)
transfers heat from the coolant to the air passing through
the heater core fins.
Mode Valve Housing
After the heated and unheated airflows are mixed,
the combined airflow comes to the mode valve housing.
In vent mode "...; ", the vent mode valve actuator is en-
gaged as well as the bi-level mode valve actuator. This
directs all the air to the instrument panel outlets.
In bi-level mode '~,i ", the vent mode valve remains
closed (allowing air to the defroster/heater door), while
the bi-level mode valve opens, allowing air to the instru-
ment panel outlets. The defroster/heater door directs air to
the floor air outlets. A small amount of air goes to the side
window defrost outlets.
In heater mode ','...,i ", both the vent and bi-level
doors remain closed and the defroster/heater door moves
up, directing most of the air to the floor air outlets.
In blend mode "~,.i", both chambers of the heater/
defrost actuator are vented and the heater/defrost valve
moves to a mid-position allowing air up to the defroster
and down to the heater outlet. Both the vent and bi-level
doors remain closed.
 1A·6 HEATER AND VENTILATION

A
B

B
E A H

A BLACK HOSE
B ORANGE HOSE
D YELLOW HOSE
E GREEN HOSE
F VIOLET HOSE
G TO VACUUM SOURCE
H RED HOSE
2 CONTROLASSEMBLY
10 ACTUATOR, Bl-LEVEL MODE VALVE
11 ACTUATOR, DEFROSTER/HEATER VALVE
19 ACTUATOR, VENT MODE VALVE
20 TANK, VACUUM RC0004-1A-F-RP

Figure 6 - Vacuum Circuit

In defrost mode "@", the heater/defrost valve pressure within the passenger compartment. The pressure
moves down and forces the air up to the defroster outlet. A forces stale air to leave the vehicle through a pressure
small amount of air still flows to the heater outlet because relief valve near the base of the rear compartment after it
of a fixed bleed. has circulated through the passenger compartment.

Air Outlets
Figures 7 and 8
There are five adjustable high-level air outlets in the
instrument panel assembly. Three near the center and one
at each extreme end of the panel assembly. In addition,
there are two side window defrost outlets, one at each end
· of the instrument panel upper trim pad assembly (Pontiac)
or in the "A" pillar trim (Chevrolet). All seven outlets are
fed by the air distributor assembly.
Heated air can be discharged from the floor outlets
centered on the transmission tunnel in the front floor pan
and from the defrost outlet.
Ventilation
Figure 9
The air distribution system provides fresh air ven-
tilation for the passenger compartment in all operating
modes. Even in the "OFF" mode, fresh outside air is
forced into the air distribution system by the forward
movement of the vehicle.
After being warmed or cooled to the desired temper-
ature, the air is discharged from the outlets appropriate to
the selected operating mode. When all windows are
closed, the addition of outside air builds a slight positive
DIAGNOSIS
FUNCTIONAL TEST
The following operational test sequence will aid in
determining whether the heater system is working prop-
erly. Coolant temperature should be close to 90°C
(194°F).
Preparation
• Engine should be started and allowed to idle for
about 20 minutes or until thermostat is open.
Test
I. Set mode control knob to ·~;" (bi-level), tempera-
ture control knob all the way to the left and blower
switch to "HIGH."
• Air at nearly the same temperature as outside
air should come from all outlets.
2. Set mode control knob to ''....; " (vent).
• Air at nearly the same temperature as outside
air should come from instrument panel outlets.
• Air should not come from floor outlets,
defroster nozzle or side window defogger
outlets.
 HEATER AND VENTILATION 1A·7

24

21

12
12 OUTLET, FLOOR AIR
21 OUTLET, LEFT-HAND
22 DEFOGGER, SIDE WINDOW
23 OUTLET, CENTER
24 OUTLET, RIGHT-HAND
PC2002-1A-F-RP

Figure 7 - Air Outlets - (Pontiac)

160 163 164

12
12 OUTLET, FLOOR AIR
160 DEFOGGER, SIDE WINDOW
161 OUTLET, LEFT-HAND EYEBROW
162 OUTLET, LEFT-HAND DRIVER
163 OUTLET, RIGHT-HAND EYEBROW
164 OUTLET, RIGHT-HAND PASSENGER
165 OUTLET, LEFT-HAND PASSENGER RC0011-1 A-F-RP

Figure 8 - Air Outlets - (Chevrolet)

1A·8 HEATER AND VENTILATION
3. Move mode control knob to the ':.._) " (heater)
position.
• Most of the air should come from floor outlets
with remainder coming out of defroster
nozzles and defogger outlets.
• Air should not come from instrument panel
outlets in '~,.i" (heater) position.
• All air from heater system should be at nearly
the same temperature as outside air.
4. Move the mode control knob from ·~,; " (heater)
position to the ":;" (blend) position: Air should
come equally from the defroster nozzle and the
heater outlet with some air coming from the side
window defogger.
5. Move mode control knob from ·~;" (blend) posi-
tion to "@" (defrost) position.
• Most of the air should be discharged onto
windshield from defroster nozzles.
• A small amount of air should also be dis-
charged from floor outlets.
6. Move mode control knob back to ·~~" (bi-level)
position and move temperature control knob all the
way to the right.
• Air should come from instrument panel out-
lets, and its temperature should climb rapidly
to approximately 55°C (131 °F) or higher, de-
pending upon outside air temperature. For a
more precise heater output temperature check,
refer to "Heater Output Temperature Check"
in the following procedure.
• Defroster nozzle airflow should diminish and
airflow from floor outlets may increase
slightly.
7. Move temperature control knob all the way to the
left and check to be sure air temperature drops back
to nearly the temperature of the outside air once
again.
8. Slowly turn blower motor assembly speed control
knob toward "OFF," stopping briefly at each inter-
mediate position to notice force of airflow coming
from instrument panel center outlets and sound of
blower.
A PLENUM
25 VALVE, PRESSURE RELIEF
PC2003·1A·f·RP
Figure 9 - Flow-Through Ventilation (Typical)
• Both airflow and blower noise should reduce
noticeably at each intermediate step.
HEATER OUTPUT TEMPERATURE CHECK
Figure 10
The heat output of the heater system can be checked
with the following procedure.
Preparation
With the engine sufficiently cool, the radiator cap
should be removed and the engine started and allowed to
idle (3.4L V6 engine only). Heater controls should be set
to " ; " (heater) mode, temperature control knob turned
all the way to the right and "HIGH" blower speed. ~hen
coolant flow in the radiator is visible through the filler
neck, the radiator cap should be installed (3.4L V6 engine
only).
Temperature Check
When the engine is warmed up (after approximately
20 minutes of operation), the vehicle should be driven. An
accurate thermometer should be used to determine the
temperature of the outside air and t~e temperat~re of ~he
air discharged at the floor outlets with the vehicle bemg
driven at 48 km/h (30 mph). Minimum acceptable heater
output temperatures at four different outside air tempera-
tures are shown in Figure 10.
Minimum acceptable heater output temperatures for
outside air temperatures other than those shown in Figure
10 can be approximated by using the Fahrenheit scale and
rounding off the outside air temperature to the nearest 5 ~.
For every additional 5 ° of outside temperature, an addi-
tional 1.8 ° of heater output temperature should be
allowed when the outside temperature is below 50°F. An
additional 1.6° of heater output temperature should be
allowed for every 5 ° of outside temperature when the
outside temperature is above 50°.
INSUFFICIENT HEATING OR DEFROSTING
The most likely causes of insufficient heating out-
side the heater system include a low coolant level, a faulty
thermostat, a partially or fully clogged heater core or heat-
er hose, an obstruction to air circulation (often under the
front seat) or an air leak past a faulty seal into the passen-
ger compartment. For an organized diagnosis procedure,
refer to Figures 11 and 12.
OUTSIDE AIR -18°C -4°C 10°C 24°C
TEMPERATURE (0°FI (25°Ft (50°Ft (75°Ft
HEATER AIR 43°C 50°C 60°C 66°C
TEMPERATURE* (110°F) (125°F) (140°F) (150°F)
* Temperature at floor air outlet assembly controls at •H1•
blower, •HEATER• mode and fullwarm, engine at
operating temperature and vehicle speed of 48 km/h (30 mph).
l'C0005-1A·f·RP
Figure 1O - Heater Output Temperature Chart

HIGH OR LOW HEATER CONTROL EFFORT
A kinked control cable, a binding valve or a faulty
control assembly are possible causes of excessive temper-
ature control knob effort. For an organized diagnosis pro-
cedure, refer to Figure 13.
BLOWER MOTOR ASSEMBLY NOISE
A constant air rush noise is typical of alJ heater sys-
tems when operating on "HIGH" blower speed. Some
!L'l'I Inspect
systems and modes may be worse than others. If possible,
check a similar vehicle to determine whether the noise is
typical or excessive. For diagnosis of excessive blower
motor assembly noise, refer to Figures 14 and 15.
EXCESSIVE HEAT
The most likely cause of excessive heat from the
heater system is a disconnected or nonfunctional tempera-
ture control cable assembly. Refer to "Temperature Con-
trol Cable Assembly" in this section. A hot air leak from
!++I Install or Connect
the engine compartment to the blower inlet is also a re-
mote possibility.
ON-VEHICLE SERVICE
REPLACEMENT PROCEDURES
Control Assembly and Vacuum Selector
Valve and/or Blower Motor Assembly Switch
Figures 2, 3, 16 and 17
!.,+I Remove or Disconnect
I. Control assembly trim plate (Pontiac only).
• Pull control assembly trim plate rearward and
off instrument panel lower trim pad.
2. Upper instrument panel cover panel (Chevrolet
only).
3. Cluster trim plate (Chevrolet only). Refer to SEC-
TION 8C.
4. Heater and air conditioning control bolts/screws
(26).
5. Control assembly (2 or 162).
• PulJ control assembly (2 or 162) out far enough
to reach the vacuum, electrical and tempera-
ture control cable connections.
6. Blower motor assembly switch connector.
7. Vacuum harness connector from vacuum selector
valve.
8. Temperature control cable assembly from control
assembly (2 or 162).
A. Release temperature control cable clips from
control assembly.
B. Pry temperature control cable with small
screwdriver from control assembly (2 or 162).
9. Vacuum selector valve, if necessary.
HEATER AND VENTILATION 1A·9
• Remove two retaining screws and remove vac-
uum selector valve.
10. Blower motor assembly switch, if necessary.
A. Remove blower motor assembly speed control
knob (9 or 159) and retaining bolt/screw.
B. Remove blower motor assembly switch.
• Electrical terminals for corrosion. Remove corro-
sion or replace component as necessary
• Temperature and mode knobs for freedom of move-
ment. Lubricate, repair or replace as necessary.
• Temperature control cable assembly for kinks, bind-
ing and other damage. Adjust, repair or replace as
necessary.
NOTICE: See "Notice" on page lA-1 of this
section.
1. Blower motor assembly switch, if removed.
A. Hold blower motor assembly switch in posi-
tion and install bolt/screw.
B. Install blower motor assembly speed control
knob (9 or 159).
2. Vacuum selector valve and retaining screws, if
removed.
3. Temperature control cable assembly.
A. Slip temperature control cable assembly into
position on lever arm. Align shaft with temper-
ature control cable slot.
B. Press temperature control cable clip into slot in
control assembly (2 or 162). Make sure all
three clips are in place.
4. Vacuum harness connector to vacuum selector
valve.
5. Blower motor assembly switch connector.
6. Control assembly (2 or 162).
7. Heater and air conditioning co.ntrol bolts/screws
(26).
• Install lower right bolt/screw (26) first to align
control assembly (2 or 162) properly.
!~I Tighten
• Heater and air conditioning control bolts/
screws (26) to 1.9 N•m (17 lb. in.).
8. Control assembly trim plate (Pontiac only).
• Hold control assembly trim plate in position
and press it forward to engage four retaining
clips.
9. Cluster trim plate (Chevrolet only). Refer to SEC-
TION 8C.
10. Upper instrument panel cover panel (Chevrolet
only).
1A·10 HEATER AND VENTILATION

INSUFFICIENT HEATING OR DEFROSTING

CHECK FOR LOW COOLANT LEVEL, LOOSE OR WORN BELTS, LEAKING

OR KINKED HOSES, LOSS OF RADIATOR CAP PRESSURE SEAL.
. -
- ADJUST THE HEATER CONTROLS TO "HEATER" MODE, "HIGH"
BLOWER SPEED AND FULL "WARM."
-
-
- -
WITH VEHICLE IDLING, CHECK THE AIR FLOW OUT OF THE
FLOOR AIR OUTLET AND CHECK OUTLET ATIACHMENT.
I
I
HIGH AIRFLOW. I LOW OR NO AIRFLOW.
I
CHECK BLOWER SPEEDS RUN THE FUNCTIONAL TEST IN THIS
- FOR AIRFLOW CHANGE. SECTION. IF THE PROBLEM IS NOT
I RESOLVED, CHECK THE AIRFLOW FROM
I I DEFROSTER AND VENT OUTLETS.
I SPEED CHANGE. I NO SPEED I I
CHANGE.
I HIGH AIRFLOW FROM LOW OR NO AIRFLOW
DEFROSTER OR VENT FROM DEFROSTER OR
OUTLETS. VENT OUTLETS.
CHECK BLOWER
SWITCH AND I
RESISTOR ASSEMBLY. SWITCH THE MODE
REPAIR AS CHECK VACUUM SYSTEM. CONTROL KNOB TO
NECESSARY. REPAIR AS REQUIRED. "DEFROST" AND CHECK
AIRFLOW.

r
DEFROSTER LOW OR NO
AIRFLOW CORRECT. DEFROSTER AIRFLOW.
I

REMOVE
FLOOR AIR CHECK BLOWER
OUTLET AND SPEEDS FOR
CHECK FOR AIRFLOW
OBSTRUCTIONS. CHANGE.
I I
RUN.THE HEATER OUTPUT
TEMPERATURE CHECK IN THIS NO SPEED I SPEED CHANGE.
SECTION. CHANGE.
I
I

CHECK BLOWER SWITCH CHECK FOR AIRFLOW

AND RESISTOR ASSEMBLY. OBSTRUCTIONS AT
REPAIR AS NECESSARY. BLOWER INLET AND
PLENUM.

HEAl"ER OUTPUT HEATER OUTPUT

TEMPERATURE CORRECT. TEMPERATURE LOW.
I I I CONTINUED I
I CONTINUED I CONTINUED I ,l,
~ ,-l, PC0006-1A·F·RP

Figure 11 - Insufficient Heating or Defrosting Diagnostic Procedure (1 of 2)

 HEATER AND VENTILATION 1A·11

INSUFFICIENT HEATING OR DEFROSTING (Continued)

HEATER OUTPUT HEATER OUTPUT CHECKFO RAIRFLOW

TEMPERATURE CORRECT. TEMPERATURE LOW. OBSTRUCTIONSAT
BLOWER I NLETAND
PLE NUM.

CHECK VEHICLE FOR
COLD AIR LEAKS AT COWL,
HEATER CASE AND
VENTS. CHECK UNDER
SEAT FOR OBSTRUCTIONS.
WITH THE IGNITION SWITCH IN "RUN" AND NO OBST RUCTIONS
THE BLOWER ON LOW, ROTATE THE ATBLO WERINLET
ORPL ENUM.
TEMPERATURE CONTROL KNOB TO THE
MID-POSITION, THEN RAPIDLY TO FULL
"HOT." LISTEN FOR VALVE SLAM AT THE
END OF CONTROL KNOB ROTATION.

I I
WITH THE BLOWER ON
I NO VALVE SLAM. I I VALVE SLAM. I "HIGH," MOVETHE TE.MP-
I ERATURE CO NTROL KNOB
CHECK THE TEMPERA- WITH THE TEMPERATURE FROM FULL II WARM"TO
TURE CONTROL CABLE VALVE FULL "WARM," START THE FULL "COOL" AND LISTEN
ASSEMBLY FOR PROPER VEHICLE. CHECK THE TEMPER- FOR AIRFLO WCHANGE.
ATURE OF THE HEATER INLET
ATIACHMENT AT CONTROL I
AND OUTLET HOSES BY FEEL.
ASSEMBLY AND HEATER
THE AIR TEMPERATURE NO AIRFLOW
MODULE ASSEMBLY. AROUND THE HOSES MUST CHANGE.
REPAIR AS NECESSARY. BE AT LEAST 24°C (85°F).
I
STILL NO VALVE SLAM. I AIRFL OW CHANGE.
I
REPLACE TEMPERATURE
CONTROL CABLE ASSEMBLY. CHECK THE TE MPERA-
TURE VALVE, CA BLES AND
I CONTROL. REPLACE
HOT INLET AND WARM OUTLET. I BOTH WARM. I AS REOUI RED.

I
CHECK THE THERMOSTAT
FOR PROPER INSTALLA- CHECKFO RAIRFLOW
TION AND SEATING. OBSTR UCTION
BETW EENTHE
I BLOWE RAND THE
I I
SYSTEM OUTLETS.
INCORRECT. I I CORRECT.
I I BACK FLUSH HEATER
REINSTALL REPLACE CORE, DRAIN AND
AND RECHECK. THERMOSTAT. REPLACE COOLANT. RETEST.
I
I

BOTH HOSES HOT INLET AND WARM

WARM. OUTLET HOSES.

I
REPLACE HEATER CORE. RETEST AND
VERIFY SYMPTOMS.
PCOOOMA·f·RP

Figure 12 - Insufficient Heating or Defrosting Diagnostic Procedure (2 of 2)

1A·12 HEATER AND VENTILATION

TEMPERATURE CONTROL EFFORT

I CHECKTEMPERATURE
CONTROL EFFORT.
I
·-
I
I
I EXCESSIVE EFFORT. I I PROPER
EFFORT.
I'.
EFFORT TOO LOW.
TEMPERATURE VALVE
'. MOVES ON HIGH BLOWER.
I
I NO CONTROL PROBLEM.
REMOVE CABLE FROM CONTROL
CHECK CABLE FOR ROUTING, A KINK, AND CHECK TO SEE THAT
WIRING INTERFERENCE OR OTHER INSTRUMENT CONTROL HAS DETENTS.
PANEL INTERFERENCE.

I
I I
0 PROBLEM NOT FOUND. PROBLEM FOUND. I I NO DETENTS. I I DETENTS. I
I I
REMOVE CABLE
FROM TEMPERATURE
REPAIR AS
I REPLACE CONTROL. I I REPLACE
CABLE.
I
NECESSARY.
VALVE AND CYCLE
VALVE MANUALLY.
CHECK FOR VALVE
BINDING.

I NO VALVE BIND. I
I VALVE BINDS. I
CHECK FOR
CONTROL BINDING.

ICONTROL BINDS. I
l
NO CONTROL I LUBRICATE VALVE
AND RECHECK. .
I
BIND.
I I
REMOVE CABLE AND REINSTALL AND I OK. I
RECHECK CONTROL RECHECK CLEAR· I STILL
BINDS. I
FOR BINDING. ANCES TO DASH
COMPONENTS.

. I
I CONTROL BINDS. I NO CONTROL BIND. CHECK TEMPERATURE
VALVE FOR SHAFT
I ALIGNMENT, BENT SHAFT

I
OR VALVE, WARPED CASE.
REPLACE
CONTROL. I REPLACE CABLE(S).
REPAIR AS NECESSARY.

RC0005-1A·F·RP

Figure 13 - Temperature Control Effort Diagnostic Procedure

 HEATER AND VENTILATION 1A·13

. SLOWl:R-MOTORASSEMSLYNOISE--

CHECK ALL ELECTRICAL CONNECTIONS AND GROUNDS FOR PROPER CONNECTIONS. IF IN DOUBT, USE
VOLTMETER TO CHECK FOR CONSTANT VOLTAGE AT BLOWER MOTOR ASSEMBLY.

SIT IN VEHICLE WITH DOORS AND WINDOWS CLOSED, WITH IGNITION SWITCH ASSEMBLY IN "RUN" AND
ENGINE "OFF." RUN BLOWER MOTOR ASSEMBLY ON HIGH SPEED WITH TEMPERATURE SET FOR MAXIMUM
COOLING. CYCLE THROUGH BLOWER MOTOR ASSEMBLY SPEEDS, MODES ANO TEMPERATURE SETTINGS TO
FIND WHERE NOISE OCCURS AND WHERE NOISE DOES NOT OCCUR. TAY TO DEFINE TYPE OF NOISE: AIR
RUSH, WHINE, TICK/CLICK, SQUEAUSCREECH, FLUTTER, RUMBLE OR SCRAPE. CHECK ANOTHER VEHICLE IF
POSSIBLE (SAME MODEL) TO DETERMINE IF NOISE IS TYPICAL.

I
I I 1

NOISE IS CONSTANT BUT NOISE IS ONLY AT START-UP OR IS NOISE IS CONSTANT AT HIGH

LESSENS WITH BLOWER INTERMITTENT. MAY OCCUR AT BLOWER MOTOR ASSEMBLY
MOTOR ASSEMBLY SPEED COLD AMBIENTS AND LOW BLOWER SPEEDS IN CERTAIN MODES BUT
REDUCTION. TYPICAL NOISES MOTOR ASSEMBLY SPEEDS. CAN BE ELIMINATED AT LOWER
ARE WHINE, TICK/CLICK, TYPICAL NOISE IS AN BLOWER MOTOR ASSEMBLY
FLUTTER OR SCRAPE. OBJECTIONABLE SQUEAUSCREECH. SPEEDS OR IN OTHER MODES.
TYPICAL NOISES ARE FLUTTER OR
RUMBLE. REFER TO FIGURE 6.
I
I
CHECK FOR MOTOR ASSEMBLY AND BLOWER IMPELLER VIBRATION AT
EACH BLOWER MOTOR ASSEMBLY SPEED BY FEELING THE BLOWER
MOTOR COVER.
I I

NO EXCESS VIBRATION. I I VIBRATION EXCESSIVE.

I
REMOVE BLOWER MOTOR ASSEMBLY AND
BLOWER IMPELLER AND CHECK FOR
FOREIGN MATERIAL AT THE ORIFICE OF
THE BLOWER INLET.
I

I
I I

I
PROBLEM
FOUND.
I
I PROBLEM
STILL EXISTS.
I
REPAIR OR EXAMINE BLOWER IMPELLER FOR WEAR
REPLACE AS SPOTS, CRACKED BLADES OR HUB, AND
NECESSARY AND ALIGNMENT. EXAMINE BLOWER CASE
RECHECK. FOR WEAR SPOTS.

I
I -.
I PROBLEM STILL EXISTS. I I PROBLEM FOUND. l
I
I
I CONTINUED I REPLACE
BLOWER IMPELLER

l AND RECHECK.

RC0013·1A-F-RP

Figure 14 - Blower Motor Assembly Noise Diagnostic Procedure ( 1 of 2)

1A·14 HEATER AND VENTILATION

BLOWER MOTOR ASSEMBLY NOISE (Continued)

I CONTINUED I NOISE IS CONSTANT AT HIGH

I BLOWER MOTOR ASSEMBLY
SPEEDS IN CERTAIN MODES BUT
REPLACE BLOWER MOTOR

I ASSEMBLY AND BLOWER

IMPELLER AND RECHECK.
I
CAN BE ELIMINATED AT LOWER
BLOWER MOTOR ASSEMBLY
SPEEDS OR IN OTHER MODES.

PROBLEM PROBLEM
FOUND.
I I STILL EXISTS.

REINSTALL ORIGINAL
BLOWER MOTOR
- - ASSEMBLY.

AT HIGH BLOWER MOTOR ASSEMBLY SPEED, CHECK FOR

NOISE AT TEMPERATURE SELECTIONS
(INCLUDING DEFROSTER OPERATION).

I
I I I I

NOISE IN ALL NOISE IN ALL NOISE ONLY NOISE ONLY

MODES AND MODES BUT IN "DEFROST" IN "VENT"
IN ALL NOT ALL OR "HEATER" MODE.
TEMPERATURE TEMPERATURE MODE.
SETIINGS. SE'irlNGS.

I
CHECK SYSTEM FOR
I
CHECK
I
CHECK DUCTS FOR CHECK DUCTS FOR
OBSTRUCTIONS OR TEMPERATURE OBSTRUCTIONS OR OBSTRUCTIONS OR
FOREIGN MATERIALS VALVE SEALS. FOREIGN MATERIALS AND FOREIGN MATERIALS AND
BETWEEN THE REPAIR OR REMOVE. CHECK REMOVE. CHECK
BLOWER IMPELLER REPLACE AS DEFROSTER VALVE DEFROSTER VALVE
AND THE NECESSARY AND FUNCTION. REPAIR OR SEALS. REPAIR OR
TEMPERATURE VALVE. RECHECK. REPLACE AS NECESSARY REPLACE AS NECESSARY
REMOVE, REPAIR OR AND RECHECK. AND RECHECK.
REPLACE AS
NECESSARY AND
RECHECK.

PC0010-1A·F-RP

Figure 15 - Blower Motor Assembly Noise Diagnostic Procedure (2 of 2)

 HEATER AND VENTILATION 1A~15

2 CONTROL ASSEMBLY
26 BOLT/SCREW, HEATER AND AIR CONDITIONING
CONTROL

RC20CJ6.1A-F·RP

Figure 16 -Control Assembly Removed - (Pontiac)

169

26 BOLT/SCREW, HEATER AND AIR CONDITIONING 162

CONTROL
162 CONTROL ASSEMBLY
169 TRIM PLATE, CLUSTER
26
RC1-1A-F-RP

Figure 17 - Control Assembly Removed - (Chevrolet)

11. Test operation of temperature control knob, mode 5. Bulb and socket by twisting socket.
control knob and blower motor assembly switch. 6. Bulb from socket.
• Pull bulb straight out from socket.
.Control Assembly Lamp Bulb
Figures 16 and 17
!l'l'! Inspect
• Control assembly lamp bplb socket for corrosion
!+-+! Remove or Disconnect and damage. Clean or replace as necessary.
I. Control assembly trim plate' (Pontiac only). • Wires for damage and secure connection to bulb
socket. Repair or replace as necessary.
• Pull control assembly trim plate forward and
off instrument panel lower trim pad.
2. Cluster trim plate (Chevrolet only). Refer to SEC-
!+•! Install or Connect

TION 8C. NOTICE: See "Notice" on page lA-1 of this

3. Heater and air conditioning control bolts/screws
(26).
4. Control assembly (2 or 162).
• Pull control assembly (2 or 162) out. far enough
to reach control assembly lamp bulb socket.
section.
1. New bulb.
• Push bulb straight into socket.
2. Bulb and socket by twisting socket into place.
3. Control assembly (2 or 162).
1A· 16 HEATER AND VENTILATION
4. Heater and air conditioning bolts/screws (26).
l~J Tighten
• Heater and air conditioning control bolts/
screws (26) to 1.9 N•m ( 17 lb. in.).
5. Control assembly trim plate (Pontiac only).
· • Hold control assembly trim plate in position
and press it rearward to engage four retaining
clips.
6. Cluster trim plate (Chevrolet only). Refer to SEC-
TION 8C.
7. Test operation of control assembly lamp bulb.
Temperature Control Cable Assembly
Figures 16 through 18
!++! Remove or Disconnect
I. Ri'ght instrument panel sound insulator assembly.
Refer to SECTION 8C.
2. Temperature control cable assembly (5) at heater
module assembly (I).
• Remove temperature control cable bolt/screw
(29).
3. Control assembly trim plate (Pontiac only).
• Pull control cable assembly trim plate rearward
and off instrument panel lower trim pad.
4. Cluster trim plate (Chevrolet only). Refer to SEC-
TION 8C.
A SNAPS
1 MODULE ASSEMBLY, HEATER
2 CONTROL ASSEMBLY
5 CABLE ASSEMBLY, TEMPERATURE CONTROL
28 RETAINER, TEMPERATURE CONTROL CABLE
29 BOLT/SCREW, TEMPERATURE CONTROL CABLE
Figure 18 - Temperature Control Cable Assembly
5. Heater and air conditioning control bolts/screws
(26).
6. Control assembly (2 or 162).
• Pull control assembly (2 or 162) out far enough
to reach temperature control cable assembly
connection.
7. Temperature control cable assembly (5).
• Release temperature control cable clips from
control assembly (2 or 162).
• Pry temperature control cable with small
screwdriver from control assembly (2 or 162).
I++! Install or Connect
NOTICE: See "Notice" on page IA-I of this
section.
1. Temperature control cable assembly (5) to control
assembly (2 or 162).
A. Slip temperature control cable into position
over lever arm. Align shaft with temperature
control cable slot.
B. Press temperature control cable clip into slot in
control assembly (2 or 162). Make sure all
three clips are in place.
2. Control assembly (2 or 162).
. 3. Heater and air conditioning control bolts/screws
(26).
• Install lower right bolt/screw (26) first to align
control assembly (2 or 162) properly.
5
PC001 MA·F-RP

l~I Tighten
• Heater and air conditioning control bolts/
screws (26) to 1.9 N•m (17 lb. in.).
4. Control assembly trim plate (Pontiac only).
• Hold control assembly trim plate in position
and press it forward to engage four retaining
clips. · 3. Right instrument panel sound insulator assembly.
5. Cluster trim plate (Chevrolet only). Refer to SEC-
TION 8C.
6. Temperature control cable assembly (5) at heater
module assembly (I) with temperature control cable
bolt/screw (29).
l~I Tighten
• Temperature control cable bolt/screw (29) to
1.9 N•m (17 lb. in.).
7. Right instrument panel sound insulator assembly.
Refer to SECTION 8C.
Blower Motor Resistor Assembly
Figure 19
l++I Remove or Disconnect
1. Key from ignition to assure that switch will remain
in "OFF."
2. Right instrument panel sound insulator assembly.
Refer to SECTION 8C.
3. Pull carpet assembly away from heater module
assembly.
4. Blower motor resistor bolt/screw (31 ).
5. Blower motor resistor assembly (30).
!++! Install or Connect
NOTICE: See "Notice" on page lA-1 of this
section.
©) 30 v
• 31
30 RESISTOR ASSEMBLY, BLOWER MOTOR
31 BOLT/SCREW, BLOWER MOTOR RESISTOR
RC0007-1A·F·RP
Figure 19 - Blower Motor Resistor Assembly Removed
. HEATER AND VENTILATION 1A·17
1. Blower motor resistor assembly (30) and blower
motor resistor bolt/screw (31).
l~L!~ghten
• Blower motor resistor bolt/screw (31) to 2
N•m (18 lb. in.).
2. Carpet assembly.
Refer to SECTION 8C.
4. Test blower motor operation at all four speeds.
Blower Motor Assembly and Blower Motor
Fan
Figure 20
!++I Remove or Disconnect
1. Key from ignition switch to assure that switch will
remain "OFF."
2. Right instrument panel sound insulator assembly
and side trim panel. Refer to SECTION 8C.
3. Blower motor bolts/screws (32).
• Blower motor assembly (6) and blower motor
fan (18) will drop down.
!L"'I Inspect
• Blower motor terminals for corrosion. Clean corro-
sion from terminals or replace blower motor assem-
bly (6) as necessary.
• Flange of blower motor assembly (6) for damage or
distortion that could cause an air leak. Repair as
necessary.
• Blower motor fan (18) for damage and distortion.
Repair or replace as necessary.
!++I Install or Connect
NOTICE: See "Notice" on page lA-1 of this
section.
1. Blower motor assembly (6).
• Guide blower motor assembly (6) and blower
motor fan (18) into position, being careful not
to catch blower motor fan (18) on protruding
parts.
2. Blower motor bolts/screws 32 .
MOTOR ASSEMBLY, BLOWER
FAN, BLOWER MOT.PR
BOLT/SCREW, BLOWER MOTOR
Figure 20 - Blower Motor Assembly and Blower Motor Fan
Removed
1A-18 HEATER AND VENTILATION

3. Pry apart connector and remove harness through

I©-! Tighten
• Blower motor bolts/screws (32) to 2.J N•m
(20 lb. in.).
3. Right instrument panel sound insulator assembly
and side trim panel. Refer to SECTION 8C.
4. Check blower operation.
Vacuum Harness
Figure 21
It is not necessary to replace an entire vacuum har-
ness in case of a localized leakage or hose collapse. A
repair can be made by cutting the hose and inserting a
plastic retainer.
If an entire hose must be replaced in the harness that
connects to the round vacuum selector valve on the con-
trol assembly, cut off all hoses at the connector and then
attach all the hoses (including the replacement hose)
directly to the vacuum selector valve.
!+-+! Remove or Disconnect
I. Open instrument panel compartment and push in on
both sides of compartment. This will cause compai1-
ment to "drop" open completely for access to
vacuum harness.
2. Vacuum hose connectors at vacuum actuators.
• Trace each vacuum hose to its actuator on
heater module assembly ( 1), noting its routing
for reference during installation.
instrument panel compartment.
!l'l'I Inspect
• Vacuum hoses for leaks by attempting to blow
through hose while covering opposite end with a fin-
gertip. Replace any hose that leaks.
• Vacuum switches and connecting hose at control
assembly for leaks and proper function. Replace
faulty components.
!-++I Install or Connect
1. Vacuum harness.
2. Vacuum hose connectors to vacuum actuators.
• Be sure connectors are snapped securely in
place. ·
3. Push in on sides of instrument panel compartment
and return it to its normal position.
Vacuum Tank
The vacuum (ank that supplies the heater vacuum
system is an oblong-shaped tank mounted on the front
outer engine rail.
!+-+I Remove or Disconnect
I. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Right lower side air baffle.
3. Vacuum line from lower connection.

13

A VACUUM HARNESS CONNECTORS, MAIN HARNESS

TO ENGINE COMPARTMENT HARNESS
B CONNECTOR , ELECTRICAL B
1 MODULE ASSEMBLY; HEATER
2 CONTROL ASSEMBLY
10 ACTUATOR, Bl-LEVEL MODE
11 ACTUATOR, DEFROSTER/HEATER VALVE
13 HARNESS, VACUUM
19 ACTUATOR, VENT MODE VALVE

RC0009-1A·f.RP

Figure 21 - Vacuum Harness

 HEATER AND VENTILATION 1A-19

4. Two vacuum tank mounting bolts/screws from top 4. Front floor console assembly. Refer to SECTION
of vacuum tank. 8C.
5. Vacuum tank. Vent Mode Valve
!++I Install or Connect j++! Remov.e or Disconnect
NOTICE: See "Notice" on page lA-1 of this
1. Instrument panel. Refer to SECTION 8C.
section.
2. Vent mode valve linkage bolt/screw.
I. Vacuum tank and vacuum tank mounting bolts/
screws. 3. Vent mode valve actuator (19).
• Disconnect linkage from vent mode valve
l~I Tighten actuator ( 19).

• Vacuum tank mounting bolts/screws to 2.5

N•m (22 lb. in.).
li++I Install or Connect
NOTICE: See "Notice" on page lA-1 of this
2. Vacuum line to lower connection.
section.
3. Right lower side air baffle. 1. Vent mode valve actuator (19).
4. Lower vehicle. • Conn~ct linkage to vent mode valve actuator
(19).
Vacuum Actuators 2. Vent mode valve linkage bolt/screw.
Figure 21
!~! Tighten
Defroster/Heater Valve • Vent mode valve linkage bolt/screw to 2.3
N•m (20 lb. in.).
!+-t! Remove or Disconnect 3: Instrument panel. Refer to SECTION 8C.
I. Instrument panel. Refer to SECTION 8C. Air Deflectors
2. Defroster/heater valve actuator ( 11) from linkage. The right (passenger's side) and three center air de-

!++! Install or Connect

flectqrs of the heater system can be removed by closing
the deflector and then pulling it out. The left (driver's
side) deflector can be removed by inserting a screwdriver
I. Defroster/heater valve actuator ( 11) to linkage.
or similar object into the locking tabs. Gently pry up to
2. Instrument panel. Refer to SECTION 8C. remove the deflector. The deflectors can be installed by
pressing them into place.
Bi-Level Mode Valve
Heater Hose Assembly and Heater Hose
j+-t! Remove or Disconnect ·. .P.ipes
I. Front floor console assembly. Refer to SECTION Figures 22 a:nd 23
8C. .
. The heater hose. inlet pipe (37) and heater hose outlet
2. Floor air outlet. · gipe(36)extendforward from the dash front panel next to
3. Bi-level mode valve linkage bolt/screw from the heater module assembly. The heater hose inlet pipe
linkage. (37) is toward the left side of the vehicle from the heater
h(1se outlet pipe (36),
4. Bi-level mode valve actuator (I 0).
.· On the 3AL L32 engine, the heated coolant supply
• Unsnap bi-level mode valve actuator (10). for the heater comes from a fitting at the front of the lower
inlet manifold, ;j,ust below the throttle body air inlet. A
!++I Install or Connect pipe from the fitting extends across the front of the engine
and connects to a heater inlet hose assembly (33) that
NOTICE: See "Notice" on page JA-1 of this
leads to a pipe mounted on the right side rail in the engine
section. compartment. The rear end of the pipe is connected to a
I. Bi-level mode valve actuator (I 0). . short' inlet hose that leads to the heater hose inlet pipe
• Snap bi-level mode valve actuator (I 0) into (37). The fitting on the pipe across the front of the engine
place. has two hose nipples that connect to short inlefand outlet
hoses which heat the fuel injection system throttle body
2. Bi-level mode valve linkage bolt/screw to linkage.
air inlet.
!~I Tighten On the 5.7L LTl engine, the heated coolant supply
for the heater comes from a fitting at the water pump
• Bi-level mode valve linkage bolt/screw to 2.3 assembly.
N•m (20 lb. in.). On botb engines, the heater hose outlet pipe (36) dis-
3. Floor air outlet. charges coolant to a short heater outlet hose that is con-
1A-20 HEATER AND VENTILATION
nected to a pipe mounted on the right side rail in the
engine compartment. The forward end of the pipe is con-
nected to an outlet hose that crosses in front of the engine
and feeds the coolant into the water pump assembly.
The hoses are attached at each end with a spring ten-
sion clamp (34 and 35 or 151 and 152).
!+-+I Remove or Disconnect
1. Engine coolant.
• Drain enough coolant into a clean container for
reuse.
NOTICE: The heater core can be damaged if exces-
sive force is applied on the core pipes during hose
removal.
2. Heater hose assembly (33).
A. Squeeze clamps with pliers and slide clamps
(34 and 35 or 151 and 152) away from fittings.
B. Remove heater hose assembly (33) by twisting
and pulling. If hose will not come off heater
hose inlet pipe (37) or outlet pipe (36) easily
with this method, cut off hose forward of heat-
er hose pipes. Then cut hose remaining on
pipes lengthwise to remove it.
C. Remove and discard hose clamps (34 and 35 or
151 and 152) if hose assembly (33) is to be
reused.
!++! Install or Connect
I. Heater hose assembly (33). If old hoses are being
reused, replace original hose clamps with worm-
gear clamps.
A. Cut replacement hose(s) to same length as
original hose(s), if necessary.
B. If replacing rubber hoses, remove aluminum
crimp and replace it with worm-gear clamps.
C. Apply rubber lubricant to inside diameter of
hose(s), if desired.
D. Squeeze clamp ends and slip new hose clamp
(34, 35, 151 or 152) over one end of heater
hose. Push hose onto fitting with twisting mo-
tion. Hose end should be 1.0 mm (0.04 inch)
away from touching nearest surface (dash front
panel, fitting hex head, etc.).
E. Install clamp (34, 35, 151 or 152) beyond any
bead around fitting, but not closer than 3.0 mm
(0.12 inch) to nearest surface (dash front panel,
fitting hex head, etc.).
F. Repeat hose and clamp installation procedure
at other end of hose.
2. Engine coolant.
• Use coolant drained earlier only if it is uncon-
taminated. Discard contaminated coolant and
add fresh 50/50 coolant and water mixture.
IL"'! Inspect
• Be sure installed hose does not sag or rub against
other components. Adjust or support hose as neces-
sary to correct hose position.
• Operate engine and check hose installation for leaks.
• Check coolant level after engine has been warmed
up. Add coolant as necessary.
Heater Core
Figure 24
!+-+I Remove or Disconnect
1. Open instrument panel compartment. Push in on
sides of compaitment to release it to reach heater
core.
NOTICE: Heater core can be damaged if too much
force is applied to heater core pipes during hose re-
moval.
2. Heater module bolts/screws (41 ).
3. Heater module assembly cover.
• For vehicles equipped with A/C, remove air
conditioning evaporator temperature sensor
assembly from heater and air conditioning
cover.
4. Heater core bolt/screw (42) and heater core clamp
(43).
5. Hose pipe clamp bolt/screw (45) and hose pipe
clamp (44).
• Clamp off heater hoses.
6. Heater hose assembly from heater hose pipes.
7. Heater core (14).
• Carefully pull heater core toward you.
l++I Install or Connect
NOTICE: See "Notice'' on page lA-1 of this
section.
I. Heater core (14).
2. Heater hose assembly to heater hose pipes.
m Important
• Lubricate heater pipes for good seal.
• Be sure seals around heater pipes remain in
place when installing.
• To verify that seal is installed correctly, observe
seal from inside engine compartment. If seal
leaks, apply sealer GM P/N 3012078. between
heater core pipes and evaporator housing.
3. Hose pipe clamp bolt/screw (45) and hose pipe
clamp (44).
• Unclamp heater hoses.
I~! Tighten
• Hose pipe clamp bolt/screw (45) to 1.8 N•m
(16 lb. in.).
4. Heater core bolt/screw (42) and heater core clamp
(43).
l~I Tighten
• Heater core bolt/screw to 1.8 N•m (16 lb. in.).
5. Heater module assembly cover.
 HEATER AND VENTILATION 1A·21

148

33

33 HOSE ASSEMBLY, HEATER INLET

34 CLAMP, HEATER OUTLET FRONT HOSE
35 CLAMP, HEATER INLET FRONT HOSE
36 PIPE, HEATER HOSE OUTLET
37 PIPE, HEATER HOSE INLET
146 HOSE ASSEMBLY, HEATER OUTLET
147 HOSE, THROTILE BODY HEATER RETURN
148 CLAMP, THROTILE BODY HEATER RETURN HOSE
149 PIPE, HEATER OUTLET

PC0016-1A·F·RP

Figure 22 - Heater Hose Assembly and Heater Hose Pipes (3.4L L32 Engine)
1A-22 HEATER AND VENTILATION

150

36 PIPE, HEATER HOSE OUTLET

37 PIPE, HEATER HOSE INLET
38 VALVE, FLOW CONTROL
39 HOSE, THROTILE BODY HEATER RETURN
40 VALVE, BLEED
150 HOSE ASSEMBLY, HEATER INLET
151 CLAMP, HEATER OUTLET FRONT HOSE
152 CLAMP, HEATER INLET FRONT HOSE
153 PIPE, HEATER INLET
154 PIPE, HEATER OUTLET
155 HOSE ASSEMBLY, HEATER OUTLET

PC0017·1A·f·RP

Figure 23 - Heater Hose Assembly and Heater Hose Pipes (5.7L LT1 Engine)
 HEATER AND VENTILATION 1A·23

~5~
. ~

41

A A
A SEALS
1 MODULE ASSEMBLY, HEATER
14 CORE, HEATER
41 BOLT/SCREW, HEATER MODULE
42 BOLT/SCREW, HEATER CORE
43 CLAMP, HEATER CORE
44 CLAMP, HEATER HOSE PIPE
45 BOLT/SCREW, HEATER HOSE PIPE

RC0010-1A-F-RP

Figure 24 - Heater Core Removed

6. Heater module bolts/screws (41 ). A. Fill cooling system.

!~! Tighten
B. Operate engine and check for leaks at heater
core pipes.
• Heater module bolts/screws (41) to 2 N•m C. Check coolant level after engine has been
(18 lb. in.). warmed up. Add coolant as necessary.
7. Coolant. 8. Instrument panel compartment.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Bi-Level Mode Valve Linkage Bolt/Screw ............................... 2.3 N•m (20 lb. in.)
Blower Motor Bolt/Screw ............................................ 2.3 N•m (20 lb. in.)
Blower Motor Resistor Bolt/Screw ....................................... 2 N•m (18 lb. in.)
Heater and A/C Control Bolt/Screw .................................... 1.9 N•m (17 lb. in.)
Heater Core Bolt/Screw ............................................. 1.8 N•m (16 lb. in.)
Heater Hose Pipe Bolt/Screw ......................................... 1.8 N•m (16 lb. in.)
Heater Module Bolt/Screw ............................................. 2 N•m (18 lb. in.)
Hose Pipe Clamp Bolt/Screw ......................................... 1.8 N•m (16 lb. in.)
Temperature Control Cable Bolt/Screw ................................. 1.9 N•m (17 lb. in.)
Vacuum Tank Mounting Bolt/Screw .................................... 2.5 N•m (22 lb. in.)
Vent Mode Valve Linkage Bolt/Screw .................................. 2.3 N•m (20 lb. in.)

ELECTRICAL SPECIFICATIONS
Blower Motor Fuse (Labeled "HVAC") .................................. 25 Amp. (White)
Control Assembly Dial Fuse (Labeled "IP DIMMER") ......................... 5 Amp. (Tan)
Control Assembly Dial Lamp Bulb Number ........................................... 37
 HEATER, VENTILATION AND AIR CONDITIONING 18·1

SECTION 18

HEATER, VENTILATION AND AIR

CONDITIONING
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . lB-3
Heater, Ventilation and Air Conditioning
System Operation . . . . . . . . . . . . . . . . . . . . . . 1B-3
Heater System .............. Refer to Section IA
Air Distribution . . . . . Refer to Sections 1A and 1B 1
Refrigeration System . . . . . . . . . . . . . . . . . . . . . 1B-3
Refrigerant- I 34a . . . . . . . . . . . . . . . . . . . . . . 1B-3
Air Conditioning Receiver and
Dehydrator Assembly . . . . . . . . . . . . . . . . 1B-4
Air Conditioning Compressor Assembly .... lB-4
Air Conditioning Condenser Assembly . . . . . 1B-4
Electric Engine Coolant Fan Assembly ..... lB-4
Thermostatic Expansion Valve Assembly . . . 1B-4
Air Conditioning Evaporator . . . . . . . . . . . . . 1B-4
High Pressure Relief Valve .............. lB-5
Relays and Switches . . . . . . . . . . . . . . . . . . . . . 1B-5
Blower Motor Assembly Relay . . . . . . . . . . . 1B-5
Air Conditioning Compressor Relay . . . . . . . 1B-5
Air Conditioning Refrigerant Pressure
Sensor Assembly . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning Evaporator Temperature
Sensor Assembly . . . . . . . . . . . . . . . . . . . . 1B-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Air Distribution System ...... Refer to Section lBl
Blower Motor Assembly .... Refer to Section 8A-63
Compressor Assembly
Circuit . . . . . . . . . . . . . Refer to Section 6E3-Cl0
Refrigeration System/Insufficient
Cooling . . . . . . . . . . . . . . . . . Refer to Section 1B 1
Heater System/Insufficient
Heating . . . . . . . . . . . . . . . . . . Refer to Section IA
Leak-Testing the Refrigeration System . . . . . . . 1B-5
Electric Halogen Leak Detector . . . . . . . . . . . 1B-5
Fluorescent Leak Detector . . . . . . . . . . . . . . . 1B-6
Liquid Leak Detectors and Pressure Testing . I B-6
Eliminating Air Conditioning Odor . . . . . . . . . . 1B-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . I B-7
Refrigeration System Services . . . . . . . . . . . . . . I B-7
Replacing 0-Rings . . . . . . . . . . . . . . . . . . . . . 1B-7
Handling Refrigerant-134a . . . . . . . . . . . . . . 1B-8
Handling Refrigerant Lines and Fittings . . . . 1B-8
Maintaining Chemical Stability in the
Refrigeration System ................. lB-9
Refrigerant Recovery and Recycling, Adding Oil,
Evacuating and Recharging Procedures . . . . . 1B-9
General Description . . . . . . . . . . . . . . . . . . . . 1B-9
Station (ACR4) Setup and Maintenance ... lB-10
Refrigerant Recovery . . . . . . . . . . . . . . . . . . lB-11
Evacuation .......................... lB-12
A/C System Oil Charge Replenishing ..... lB-13
Refrigerant Oil Distribution ............. lB-14
Refrigerant Oil Loss Due to a Large Leak .. lB-14
Compressor System ................... lB-14
Charging the A/C System (Engine Off) .... lB-14
Replacement Procedures . . . . . . . . . . . . . . . . . 1B-15
Blower Motor and
Fan Assembly .......... Refer to Section IA
Air Ducts and
Deflector Outlets ........ Refer to Section lA
Vacuum Tank . . . . . . . . . . . . . Refer to Section lA
Heater Hoses and Pipes . . . . . Refer to Section lA
Air Conditioning Compressor and
Condenser Hose Assembly ........... lB-15
Air Conditioning Receiver
Dehydrator Tube ................... lB-16
Air Conditioning Evaporator Tube . . . . . . . 1B-18
Air Conditioning Thermostatic
Expansion Valve Assembly ........... lB-18
Air Conditioning Receiver and
Dehydrator Assembly ............... lB-19
Air Conditioning Refrigerant Pressure
Sensor Assembly ....... Refer to Section lBl
Air Conditioning Condenser Assembly . . . . 1B-20
Air Conditioning Compressor Assembly . . . 1B-20
Air Conditioning Refrigerant Service Valve 1B-22
Generator and Air Conditioning Compressor and
Power Steering Pump Bracket
Assembly (5.7L LTl Engine) ....... lB-23
Generator and Air Conditioning Compressor
Bracket Assembly (3.4L L32 Engine) ... lB-23
18-2 HEATER, VENTILATION AND AIR CONDITIONING

33

RC0001· 1B·F-RP

Figure 1 - Refrigeration System Components


Compressor Assembly On-Vehicle Minor
Component Replacement . . . . . . . . . . . . . 1B-24
Specifications .............. , . . . . . . . . . . . . . 1B-24
General Specifications . . . . . . . . . . . . . . . . . . . 1B-24
GENERAL DESCRIPTION
HEATER, VENTILATION AND AIR
CONDITIONING SYSTEM OPERATION
NOTICE: The refrigeration system on this vehicle
uses R- I 34a which is not compatible with refriger-
ant R-12. Before servicing the system al ways make
sure the proper servicing equipment is used or the
system could become severely damaged. Always
refer to the service text and manufacturer instruc-
tions included with service equipment before pro-
ceeding.
The air conditioning system (C60) delivers air that
has been heated or cooled and dehumidified for occupant
comfort. It also provides power ventilation, windshield
assembly and side window defrosting.
During most operating conditions, outside air is
drawn through the heater and air conditioning module
assembly by the blower motor assembly. Additional out-
side air is also forced into the vehicle by forward move-
ment of the vehicle.
Within the evaporator module assembly, air is
pushed by the blower motor assembly through the evapo-
rator, then through the heater core depending on the tem-
perature valve position, then into the passenger
compartment. For air conditioning or defroster operation
at ambient temperatures above 7°C (45°F), the refrigera-
1 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING
EVAPORATOR
2 COMPRESSOR ASSEMBLY, AIR CONDITIONING
3 CONDENSER ASSEMBLY, AIR CONDITIONING
4 RECEIVER AND DEHYDRATOR ASSEMBLY, AIR
CONDITIONING
5 EVAPORATOR, AIR CONDITIONING
6 VALVE ASSEMBLY, AIR CONDITIONING
THERMOSTATIC EXPANSION
7 HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR
AND CONDENSER
8 TUBE, AIR CONDITIONING EVAPORATOR
9 TUBE. AIR CONDITIONING RECEIVER DEHYDRATOR
10 BRACKET, AIR CONDITIONING RECEIVER DEHYDRATOR
11 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR CLAMP
12 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR BRACKET
13 0-RING, AIR CONDITIONING RECEIVER DEHYDRATOR
TUBE
14 0-RING, AIR CONDITIONING EVAPORATOR TUBE
15 SEAL, AIR CONDITIONING EVAPORATOR TUBE
16 SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
17 O·RING, AIR CONDITIONING CONDENSER FITTING
18 SEAL, AIR CONDITIONING COMPRESSOR HOSE
19 SEAL, AIR CONDITIONING REFRIGERANT SERVICE
VALVE
Figure 2 - Refrigeration System Components - Legend
HEATER, VENTILATION AND AIR CONDITIONING 18-3
Fastener Tightening Specifications . . . . . . . . . 1B-24
Fitting Tightening Specifications . . . . . . . . . . . 1B-25
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-26
tion system will chill the evaporator to almost freezing.
As the air passes through the evaporator, the air tempera-
ture drops which causes the moisture in the air to con-
dense on the evaporator core fins. This moisture leaves
the vehicle by gravity feed through a drain hole, dehumid-
ifying the vehicle.
From the evaporator, some or all of the air may pass
through the heater core assembly, which is warmed by
engine coolant. Any of the air which is not to be heated
will mix with the heated air before entering the passenger
compartment.
When maximum air conditioning mode is selected,
most of the air entering the blower motor assembly is
taken from the passenger compartment (recirculated)
where it is most likely to be cooler than the outside air.
Only outside air is used in all other modes.
REFRIGERATION SYSTEM
Figures 1 and 2
Refrigerant-134a
CAUTION: Avoid breathing A/C Refrig-
erant-134a and lubricant vapor or mist.
Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C
system, use service equipment certi-
fied to meet the requirements of SAE
J2210 (R-134a recycling equipment). If
20 0-RING , AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR
21 VALVE, AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR
22 SENSOR ASSEMBLY, AIR CONDITIONING
REFRIGERANT PRESSURE
23 CORE, AIR CONDITIONING REFRIGERANT SERVICE
VALVE
24 CAP, AIR CONDITIONING REFRIGERANT CHARGE
VALVE (SERVICE VALVE)
. 25 VALVE, AIR CONDITIONING REFRIGERANT SERVICE
26 CAP, AIR CONDITIONING REFRIGERANT CHARGE
VALVE
27 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR TUBE
28 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
29 BOLT/SCREW, AIR CONDITIONING THERMOSTATIC
EXPANSION VALVE
30 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP BRACKET
32 BRACKET, AIR CONDITIONING COMPRESSOR HOSE
CLIP (5.7L LT1 ENGINE)
33 RETAINER, RADIATOR AIR UPPER BAFFLE
34 STRAP, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
38 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
RCOOOZ· 1B-f.RP
1B-4 HEATER, VENTILATION AND AIR CONDITIONING
accidental system discharge occurs,
ventilate work area before resuming
service. Additional health and safety in-
formation may be obtained from refrig-
erant and lubricant manufacturers.
Like the coolant in the engine cooling system, the
refrigerant is the substance in the air conditioning system
that absorbs, carries and then releases heat. Although vari-
ous substances are used as refrigerants in other types of
refrigeration systems, past automotive air conditioning
systems used a type called Refrigerant-12 (R-12).
This vehicle uses a new type of refrigerant called
Refrigerant-l 34a (R- J34a). It is a non-toxic, non-flam-
mable, clear, colorless, liquefied gas.
While the R-134a A/C system is very similar to an
R-12 A/C system, the differences in the refrigerant, lubri-
cants, and service equipment are important.
NOTICE: R-134a refrigerant is not compatible with
R-12 refrigerant in an air conditioning system. R-12
in a R-134a system will cause compressor failure,
refrigerant oil sludge or poor air conditioning sys-
tem performance.
Refrigerant-134a carries a charge of a special lubri-
cating oil, polyalkylene glycol (PAG) refrigerant oil.
GM PAG refrigerant oil will have a slight blue tint.
The oil is hydroscopic (absorbs water from the
atmosphere) and should be stored in closed contain-
ers.
Use only polyalkylene glycol (PAG) synthetic
refrigerant oil for internal circulation through the
R- I 34a A/C system and only mineral base 525 vis-
cosity refrigerant oil on fittings threads and 0-rings.
If lubricants other than those specified are used,
compressor failure and/or fitting seizure is likely to
occur.
Air Conditioning Receiver and Dehydrator
Assembly
The receiver and dehydrator assembly is located on
the right side wheelhouse panel,just downstream from the
conde11ser assembly. It functions as a moisture separator
that receives refrigerant liquid and refrigerant oil from the
condenser. It only allows refrigerant liquid and a small
amount of oil to continue on to the thermostatic expansion
valve assembly.
At the bottom of the receiver and dehydrator assem-
bly is the desiccant, which acts as a drying agent for mois-
ture that may have entered the system. A filter is also
located near the bottom of the receiver and dehydrator
assembly outlet pipe to keep any particles from plugging
the thermostatic expansion valve assembly.
Air Conditioning Compressor Assembly
The air conditioning compressor assembly is driven
by a belt from the engine crankshaft through the compres-
sor clutch pulley. The compressor pulley rotates freely,
without turning the compressor shaft, until an electromag-
netic clutch coil is energized. When voltage is applied to
energize the clutch coil, a clutch plate and hub assembly is
drawn rearward toward the pulley. The magnetic force
locks the clutch plate and pulley together as one unit to
drive the compressor shaft. For unit repair information,
refer to SECTION 1D2.
Air Conditioning Condenser Assembly
The air conditioning condenser assembly in front of
the radiator assembly is made up of coils, which carry the
refrigerant and cooling fins to provide rapid transfer of
heat. The air passing through the condenser assembly
cools the high-pressure refrigerant vapor, causing it to
condense into a liquid.
Electric Engine Coolant Fan Assembly
Coolant fan assembly operation is crucial to the
proper operation of the air conditioning system. The cool-
ant fan assembly ensures the proper amount of air flow
across the condenser throughout the vehicle operating
range.
Fan assembly operation should be checked during
any air conditioning diagnosis procedure. Special atten-
tion should be given to the fan assembly whenever exces-
sive high side pressures are encountered.
Thermostatic Expansion Valve Assembly
Figure 3
The purpose of the thermostatic expansion valve
assembly is to regulate the flow of refrigerant through the
evaporator to optimize its cooling performance. This is
accomplished by monitoring the refrigerant conditions at
the evaporator outlet and adjusting the inlet flow accord-
ingly. This assures that all the liquid is evaporated before
it is returned to the compressor assembly.
The refrigerant flow is controlled by the movement
of a shaft that pushes a ball from its seat. As the ball is
unseated, more flow is allowed through the evaporator.
Shaft movement is controlled by the power dome which
has two separate sides. The thermal side of the power
dome is sealed and charged with refrigerant. The system
side of the power dome is exposed to the pressure of the
evaporator outlet or low side. Refrigerant exiting the
evaporator flows over part of the thermal side of the
power dome. The sealed refrigerant in the thermal side
responds to the temperature changes of the refrigerant
flowing out of the evaporator. As the refrigerant tempera-
ture rises, the pressure of the thermal side increases.
If the pressure on the thermal side of the power
dome is greater than the pressure on the system side (the
evaporator outlet or low-side pressure), the shaft moves
down and pushes the ball off the seat allowing more
refrigerant flow through the evaporator. When the oppo-
site is true, the shaft moves up and reseats the ball reduc-
ing flow. A spring at the bottom of the thermostatic
expansion valve assembly is not adjustable.
Although the thermostatic expansion valve assem-
bly controls evaporator refrigerant flow, air conditioning
capacity control (to prevent ice build-up) is managed by
compressor cycling which is controlled by the powertrain
control module (PCM).
Air Conditioning Evaporator
The evaporator is a device which cools and dehu-
midifies the air before it enters the vehicle. High-pressure
refrigerant flows through the thermostatic expansion
valve assembly and becomes low-pressure refrigerant

F G
E
A POWER DOME
B THERMAL-SIDE PRESSURE
C AIR CONDITIONING SYSTEM LOW-SIDE PRESSURE
D FROM AIR CONDITIONING RECEIVER AND
DEHYDRATOR ASSEMBLY (HIGH SIDE)
E TO AIR CONDITIONING EVAPORATOR (LOW SIDE)
F FROM AIR CONDITIONING EVAPORATOR
G TO AIR CONDITIONING COMPRESSOR ASSEMBLY
PC0003·1B·f·RP
Figure 3 - Thermostatic Expansion Valve Assembly
before entering the evaporator. The heat in the air passing
through the evaporator core is Jost to the cooler surface of
the core, thereby cooling the air. As ~h.e process of heat
Joss from the air to the evaporator core surface is taking
place, any moisture (humidity) in the aiq:ondenses on the
outside of the evaporator core and is drained off as water.
High Pressure Relief Valve
The compressor assembly is equipped with a pres-
sure relief valve which is placed in the system as a safety
factor. Under certain conditions, the refrigerant on the dis-
charge side may exceed the designedoperating pressure.
To prevent system damage, the valve is .designed to open
automatically at approximately 3036 kPa (440 psi). Any
condition that causes this valve to open should be cor-
rected, and the refrigerant oil should be replaced as neces-
sary. The air conditioning refrigerant pressure sensor
should also be checked for proper calibration. Refer to
SECTION 6E3 (DTC 61 ).
RELAYS AND SWITCHES
Blower Motor Assembly Relay
The blower motor assembly relay is used to provide
battery voltage to the blower motor assembly only during
high blower motor assembly speed. The blower motor
resistor assembly is used to prnvide power to the blower
motor assembly in all other speed settings. The .blower
motor relay is located under the instrument panel. Refer to
SECTION SA-63 for more information.
Air Conditioning Compressor Relay
The air conditioning compressor relay is used to pro-
vide battery voltage to the compressor clutch coil. The
HEATER, VENTILATION AND AIR CONDITIONING 1B-5
relay is controlled by the powertrain control module
(PCM) only. The relay is located in the underhood electri-
cal center. Refer to SECTION SA-64 for more informa-
tion.
Air Conditioning Refrigerant Pressure
Sensor Assembly
The A/C refrigerant pressure sensor assembly
attached to the air conditioning evaporator liquid line,
senses refrigerant pressure on the air conditioning system
high-side. The refrigerant pressure status is sent to the
PCM. The purpose of this sensor is to inform the PCM of
high-side pressure status so the PCM can:
• Control cooling fan assembly operation.
• Prevent compressor assembly operation if ambient
temperatures are too cold.
• Disable the compressor assembly before high-side
pressure becomes too high.
Refer to SECTION SA-64 for more information.
Air Conditioning Evaporator Temperature
Sensor Assembly
The air conditioning evaporator temperature sensor
assembly mounted to the heater and air conditioning
evaporator module assembly has a probe inserted into the
evaporator which measures evaporator temperature and
sends a signal to the PCM. Within the probe is a thermis-
tor which varies output according to. temperature. The
purpose of this sensor assembly is to inform the PCM of
the evaporator temperature so the compressor assembly
can be disabled before the evaporator freezes. The evapo-
rator temperature sensor assembly is a solid state device,
do not attempt to measure resistance. Measuring resis-
tance across pins can cause sensor damage. Refer to SEC-
TION 8A-64 for more information.
DIAGNOSIS
LEAK-TESTING THE REFRIGERATION
SYSTEM
A refrigerant leak test should be performed on the
system whenever a leak is suspected due to system indica-
tion of low charge or after any service operation which
disturbs the components, Jines, or connections. Many
methods and special tools are available for this purpose;
however, no matter which tool is used, care and diligence
are the biggest keys to success.
Electric Halogen Leak Detector
Figures 4 and 5
Tool Required:
J 39400 Halogen Leak Detector
This type of leak detector has been found to be the
most useful tool in locating refrigerant leaks. The J 39400
is a small unit which operates on 12 volts DC and provides
an audible signal which increases in frequency when leak-
ing refrigerant is detected. There are three settings: one
for R-12, one for R-134a, and one for gross leaks. The
gross leak setting is for isolating very large leaks already
found at one of the other two settings. Care must be taken
that the instrument is properly calibrated, per the included
1B-6 HEATER, VENTILATION ANO AIR CONDITIONING

J 39400

)
PC6015-1 B-D-RP

Figure 4 - Electric Halogen Leak Detector A SERVICE FITIING VALVE

instructions, and that it is used at the proper setting for the

type of refrigerant in the system being tested.

Evaporator Core
Because the evaporator core is contained in a closed J 39400
module and is inaccessible to leak detectors, it is one of
the most difficult parts of the air conditioning system to
check for leaks. To leak-test the evaporator core:
1. Turn the blower motor assembly on to high for 15 or
more seconds then shut it off.
2. Wait IO minutes.
3. Remove blower motor resistor assembly. Refer to
SECTION lA. B REFRIGERANT LINE

4. Insert the leak detector probe into the resistor open-

ing. If the detector goes to a solid alarm, a leak has
been found.

Compressor and Block Fitting

I. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Probe the compressor area. Jf the detector goes to a
solid alarm, a leak has been found.
c
Fluorescent Leak Detector
Fluorescent detection additive is now approved by
GM for use in R-134a systems.
C REFRIGERANT PRESSURE SENSOR ASSEMBLV OR
COMPRESSOR LOW PRESSURE CUT-OFF SWITCH
ASSEMBLY
Liquid Leak Detectors and Pressure Testing
Due to their lack of sensitivity, liquid/bubble leak PC0004-1B·f.RP
detectors have very limited usefulness and are not recom-
mended. Figure 5 - Checking for Refrigerant Leaks

CAUTION: R-134a service equipment or
vehicle A/C systems should not be
pressure tested or leak-tested with
con,pressed_ air. Some mixtur~~ _<>f
air/R134a have been shown to be com-
bustible at elevated pressures. These
mixtures are potentially dangerous and
may result in fire or explosion causing
injury or property damage. Additional
health and safety information may be
obtained from refrigerant and lubricant
manufacturers.
ELIMINATING AIR CONDITIONING ODOR
Tool Required:
J 36645 A/C Evaporator Cleaning Gun
Some vehicles may experience odors emitted from
the air conditioning system primarily at start up in hot,
humid climates. This odor may be the result of debris in
the evaporator module case and/or microbial growth on
the evaporator core. To eliminate this condition, the fol-
lowing equipment and procedure should be used.
CAUTION: This procedure should only
be performed on a cold vehicle to pre-
vent the disinfectant from coming in
contact with hot engine components
which could cause irritating vapors to
form.
Disinfectant can cause substantial, but
temporary, eye injury. Do not get in
eyes or on clothing. Wash thoroughly
with soap and water after handling dis-
infectant. If disinfectant gets into eyes,
hold eyelids open and flush with a
steady, gentle stream of water for fif.
teen minutes. Obtain medical attention
if irritation persists.
rn Important
• This procedure will eliminate debris or micro-
bial growth which can cause odors but will not
keep such debris or microbes present in the
environment from causing a recurrence of the
problem.
I. Remove heater core assembly. Refer to SECTION
lA.
2. Check evaporator module assembly case for debris,
remove any debris present. If debris is imbedded
into evaporator core face and cannot be removed,
the core will have to be removed from vehicle and
cleaned. If a large amount of debris is present in
evaporator module assembly case, the air inlet
screen will require sealing around the windshield
wiper post holes and fender edges.
3. Place drain pan with at least a two-liter (two-quart)
capacity below evaporator drain hole to collect dis-
infectant and rinse water runoff.
• The evaporator drain hole is located at the bot-
. tom of the evaporator lower case approxi-
mately 25 mm ( 1 inch) from the dash panel
assembly (engine compartment side).
HEATER, VENTILATION AND AIR CONDITIONING 18-7
4. Connect battery charger to avoid draining battery
assembly during cleaning procedure.
5. Position pedestal fan and turn it on high speed to
provjdecross ventilation durjng cleaning procedure.
6. Turn ignition switch to the "RUN" position but do
not start vehicle.
7. Set heater and air conditioning control assembly to
"LOW" blower motor speed, full "HOT" and
"HEATER."
8. Open all windows and doors and exit vehicle.
9. Put on rubber gloves, safety goggles (ordinary safety
glasses are not sufficient), and NIOSH-approved
acid gas/organic vapor respirator with chlorine diox-
ide cartridges, 3M PIN C1842 or equivalent.
I 0. Pour small bottle of two-part GM Good wrench air
conditioning system disinfectant kit, GM PIN
25533404 or equivalent, into large bottle. Seal and
invert large container once or twice to mix contents.
11. Use J 36645 or equivalent siphon-type parts-clean-
ing spray gun capable of delivering 60 ml (2 ounces)
per minute of liquid when driven with 552 to 621
kPa (80 to 90 psi) of compressed air. Insert nozzle of
spray gun through heater core opening and insert
siphon hose into container of disinfectant. Direct
spray toward evaporator face taking extra care to
ensure adequate coverage of the corners and edges,
completely saturating the entire core. Use entire
container of solution.
I 2. Turn ignition switch to the ''OFF" position and
allow core to soak for five minutes.
13. Check underneath vehicle to verify proper drain
operation. If necessary, unclog and increase drain
plug hole with a rat-tail file.
14. Turn the ignition switch to the "RUN" position but
do not start vehicle.
15. Thoroughly rinse evaporator core with one liter (one
quart) of clean water using spray gun to remove any
disinfectant residue ..
16. Turn ignition switch to the "OFF" position and
install heater core assembly. Refer to SECTION IA.
17. Dispose of disinfectant and rinse water runoff col-
lected in drain pan in an approved manner.
ON-VEHICLE SERVICE
REFRIGERATION SYSTEM SERVICES
Replacing 0-Rings
Install new GM-approved service replacement air
conditioning 0-rings when a joint or a fitting is installed,
except when the 0-rings are provided on new replacement
components. Unless service replacement 0-rings of the
specified part numbers are used, excessive leakage of
Refrigerant-134a may occur. Refer to the part number for
identification, not to the former color-coating method of
identification, because some formerly color-coated ser-
vice replacement 0-rings may be black.
Air conditioning 0-rings should be coated with min-
eral base 525 viscosity refrigerant oil just before installa-
tion and should be slipped onto the flange tube to assure
proper locating and sealing. To prevent the possibility of
1B-8 HEATER VENTILATION AND AIR CONDITIONING
swelling and a reduction in sealing effectiveness, 0-rings
should not be allowed to soak in refrigerant oil. Before
installation, the 0-rings and the fittings should be
examined to ensure that they have not been nicked or
deformed. Nicked or deformed parts must be replaced or
excessive refrigerant leakage may result.
Handling Refrigerant-134a
The air conditioning system in this vehicle contains
Refrigerant-134a (R-_J 34a). This chemic~] mixture
requires special handlmg procedures to avoid personal
injury.
Always wear goggles a~d wrap a clean clo~h around
fittings, valves, and connections. when performmg work
that involves opening the refngerant system. Always
work in a well ventilated area and avoid breathing any
refrigerant fumes. Do n?t weld _o_r st.earn ~lean on or near
any vehicle-installed air cond1t1onmg Imes or compo-
nents.
If R-134a should come in contact with any part of
the body, flush the exposed area with water and immedi-
ately seek medical attention.
CAUTION: Avoid breathing A/C refrig-
erant and lubricant vapor or mist. Expo-
sure may irritate eyes, nose, and throat.
To remove R-134a from the A/C system,
use service equipment certified to meet
the requirements of SAE J2210 or SAE
J2209. If accidental system discharge
occurs ventilate work area before
resumi~g service. Additional health
and safety information may be
obtained from refrigerant and lubricant
manufacturers.
Do not store or heat refrigerant contain-
ers above 125°F (52°C).
Do not heat a refrigerant container with
an open flame; if container warming is
required, place the bottom of the con-
tainer in a pail of warm water.
Do not intentionally drop, puncture, or
incinerate refrigerant containers.
Refrigerant will displace oxygen, there-
fore be certain to work in well ventilated
areas to prevent suffocation.
If it is necessary to carry a container of
"Dot CFR" Refrigerant-134a in a
vehicle it should not be carried in the
passenger compartment. Only contain-
ers that meet DOT SPEC 4BA or 4BW
should be used.
NOTICE: R-12 refrigerant and R-134a refrigerant
must never be mixed, even in the smallest of
amounts, as they are incompatible with each ?ther. !f
the refrigerants are mixed, compressor failure 1s
likely to occur.
Use only polyalkylene glycol (PAG) synthetic
refrigerant oil for internal circulation through the
R- I 34a A/C system and only mineral base 525 vis-
cosity refrigerant oil on fitting threa~s. and 0-rings.
If lubricants other than those spec1f1ed are used,
compressor failure and/or fitting seizure is likely to
occur.
Do not introduce compressed air to any refrigerant
container or refrigerant component, because con-
tamination will occur.
Before attempting any service which requires open-
ing refrigeration system Jines or components, refer to
"Handling of Refrigerant Lines and Fittings" and "Main-
taining Chemical Stability" that follow. Carefully follow
the instructions for refrigerant recovery and recycling,
adding oil, evacuating, and recharging the refrigeration
system.
All Refrigerant-134a disposable (colored blue) con-
tainers are shipped with a heavy metal screw cap to pro-
tect the valve and safety plug of the container from
damage. It is good practice to replace the cap after each
use of the container to continue protection.
Handling Refrigerant Lines and Fittings
CAUTION: For personal protection,
goggles should be worn and a clean
cloth wrapped around fittings, valves
and connections when doing work that
includes opening the refrigeration sys-
tem. If Refrigerant-134a comes in con-
tact with any part of the body, severe
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and
prompt medical help should be
obtained.
• All metal tubing lines should be free of dents or
kinks to prevent loss of system capacity due to line
restriction.
• The flexible hose lines should never be bent to a
radius of less than four times the diameter of the
hose.
• The flexible hose lines should never to allowed to
come within a distance of 63.5 mm (2 1/2 inches) of
the exhaust manifold.
• Flexible hose lines should be inspected regularly for
leaks or brittleness and replaced with new lines if
deterioration or leaking is found.
• When disconnecting any fitting in the refrigeration
system, the system must first be discharged of all
Refrigerant- l 34a. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
• Once a refrigerant line is opened to the atmosphere,
it should be capped or taped immediately to prevent
entry of moisture and dirt.
• The use of the proper wrenches when making con-
nections on 0-ring fittings is important. The oppos-
ing fitting should always be backed up with a
wrench to prevent distortion of connecting lines or
components. Tighten all tubing connections to the
specified torque for the fitting. Too little or too much
torque when tightening can result in loose joints or
deformed joint parts. Either condition can result in
refrigerant leakage and an inoperative air condition-

ing system. Refer to "Fitting Tightening Specifica-
tions" at the end of this section.
• 0-rings and seals must be in perfect condition. A
burr or piece of dirt may cause a refrigerant leak.
Install new 0-rings that have been lubricated with
mineral base 525 viscosity refrigerant oil. Do not
use PAG oil.
• Keep polyalkylene glycol (PAG) refrigerant oil off
fitting threads. Long term contact of PAG oil on
threads may cause future disassembly difficulties.
Flush threads of fittings with mineral base 525 vis-
cosity refrigerant oil. Do not use PAG oil. Do not
wipe threads with a cloth.
Maintaining Chemical Stability in the
Refrigeration System
The efficient operation and life of the air condition-
ing system is dependent upon the chemical stability of the
refrigeration system. When foreign materials such as dirt,
air, or moisture, contaminate the refrigeration system, the
stability of the Refrigerant-134a and polyalkylene glycol
(PAG) synthetic refrigerant oil will change. Contaminants
will also affect pressure-temperature relationship, reduce
efficient operation and possibly cause interior corrosion
and abnormal wear of moving parts.
The following general practices should be observed
to ensure the chemical stability in the system:
• Before breaking a refrigerant connection, wipe away
any dirt or oil to reduce the possibility of dirt enter-
ing the system. Both sides of the connection should
be capped, plugged or taped as soon as possible to
prevent the entry of dirt, foreign material and mois-
ture.
• Keep tools clean and dry. This includes the manifold
gage set and replacement parts.
• When adding polyalkylene glycol (PJ\G) synthetic
refrigerant oil, the transfer device and container
should be exceptionally clean and dry to assure that
refrigerant oil remains as moisture-free as possible.
• When it is necessary to "open" an A/C system, have
everything needed ready and handy so that as little
time as possible will be required to perform the
operation. Do not leave the A/C system open any
longer than is necessary.
• Any time the A/C system has been "opened," it
should be properly evacuated before recharging with
Refrigerant-134a.
• All service parts are dehydrated and sealed prior to
shipping. They should remain sealed until just prior
to making connections. All parts should be at room
temperature before uncapping. This prevents con-
densation of moisture from the air entering the sys-
tem. If for any reason caps are removed but the
connections are not made, parts should be resealed
as soon as possible.
HEATER, VENTILATION AND-AIR CONDITIONING 18·9
REFRIGERANT RECOVERY AND
RECYCLING, ADDING OIL, EVACUATING
AND RECHARGING PROCEDURES
General Description
.Figure 6
The J 39500 air conditioning refrigerant recovery,
recycling and recharging (ACR 4 ) system removes Refrig-
erant-l 34a from the vehicle A/C system, recycles and
recharges all with one hook-up.
Single pass filtering during recovery cycle, plus
automatic multiple pass filtering during evacuation cycle
assures constant supply of clean/dry refrigerant for A/C
system charging.
NOTICE: R-12 and R-134a require separate and
non-interchangeable sets of recovery, recycling, and
recharging equipment, because the refrigerants and
lubricants are not compatible and cannot be mixed
even in the smallest amounts. Do not attempt to use
one set of equipment for both R-12 and R-134a, as
all equipment contains residual amounts of refriger-
ant and/or lubricant, which will result in contamina-
tion, and damage to the recovery/recycle equipment.
Adaptors to convert from one size fitting to the other
must never be used; refrigerant/lubricant contamina-
tion will occur and system failure may result.
M A
J
G
E
A BOTILE, OIL STORAGE
B VALVE, OIL DRAIN
C HOSE, BLUE
D HOSE, RED
E BOTILE, OIL CATCH
F HOSE, YELLOW
G BOTILE, SELECTED OIL
H HOSE, LOW SIDE (BLUE)
I COUPLER, QUICK DISCONNECT, LOW SIDE
J COUPLER, QUICK DISCONNECT, HIGH SIDE
K HOSE, HIGH SIDE (RED)
L GROMMETS
M VALVE, OIL INJECTION
PC0005-1B-F-RP
Figure 6 - Complete Operational Setup
18-10 HEATER, VENTILATION AND AIR CONDITIONING

Station (ACR 4 ) Setup and Maintenance

Initial Setup A B C D

'~~~~
Refer to the manufacturer instructions for all initial
setup procedures.

Operation Setup
Figure 6 0008

8~~8 I-~~
CAUTION: Always wear goggles and
gloves when doing work that involves
opening the refrigeration system. If liq-
uid refrigerant comes into contact with
the skin or eyes, injury may result. H G F E
CAUTION: Use only authorized 23 kg
(SO-pound) refillable refrigerant tanks
(J 39500-50). Use of other tanks could
cause personal injury and void the war- A DISPLAY, DIGITAL
ranty. B GAGE, LOW SIDE
NOTICE: Refrigerant-l 34a systems have special C BEEPER
D GAGE, HIGH SIDE
fittings (per SAE specifications) to avoid cross-con- E VALVE, HIGH SIDE
tamination with Refrigerant-12 systems. Do not F INDICATOR, MOISTURE
attempt to adapt this unit to Refrigerant-12 systems G VALVE, LOW SIDE
as severe system failure will result. H KEYPAD
I SWITCH, MAIN POWER
Connect high-side (red) and low-side (blue) hoses to
the ACR 4 unit. Be sure to route hoses through hose reel
bracket grommets. RC0003· 1B-f·RP

Control Panel Functions Figure 7 - Control Panel

Figures 7 and 8
This section explains the functions of the various
components of the unit control panel (Figure 7).
• Main Power Switch - supplies electrical power to
the control panel.
• FILTER - automatically recovers and evacuates to
• Beeper - emits an audible tone to alert the operator 57 kPa ( 17 inches Hg) vacuum from the filter and
to unit operating functions. low side of the unit.
• Digital Display - shows the time programmed for
vacuum and the weight of refrigerant programmed • CHG - automatically charges the A/C system with
for recharging. the programmed amount of refrigerant.
• Low-Side Manifold Gage - when connected to an • HOLD/CONT - interrupts the automatic cycle in
A/C system, this gage shows the system low-side the "HOLD" position, and then resumes functions
pressure. in the "CONT" position. Press this button once for
• High-Side Manifold Gage - when connected to an "HOLD" and again for "CONT."
A/C system, this gage shows the system high-side • VACUUM - activates the vacuum and automatic
pressure. recycling sequence.
• Moisture Indicator - shows if the refrigerant is wet
or dry. • ENTER- enters programmed data into the unit con-
trol memory.
• Low-Side Valve - connects the low side of the A/C
system to the unit.
• High-Side Valve - connects the high side of the A/C Digital Display Functions
system to the unit.
In addition to the number keys, the control panel For information regarding the functions of the digi-
contains special keys that accomplish specific operating tal display, refer to the manufacturer instructions.
functions (Figure 8).
• RECYCLE - activates the recycling sequence.
• RECOVER - activates the recovery sequence.
Maintenance
• SHIFT/RESET - activates "shifted" position of Refer to manufacturer instructions for all mainte-
keys on the keypad and resets the program mode. nance procedures.

RECYCLE Fll.ltA
GJ®®B
'51
t.41 '61 Cm)
~ ~ @K)
L:!.J
[z](]J@8
~ 'QI
r"MR) ~ @!!.) (E.NnR)
PC0007-1B-F-RP
Figure 8 - Keypad Functions
Refrigerant Recovery
Figures 6 through 9
Tools Required:
J 39500 Air Conditioning Refrigerant Recov-
ery, Recycling and Recharging (ACR 4 ) System
139500 50 lb. Refillable Recovery Tank
IT] Important
• Use only the 23 kg (50-pound) unit refri§erant
tank (J 39500-50) designed for the ACR . The
unit overfill limitation mechanism has been
calibrated specifically for use with this tank,
and the tank valving is set up specifically for
use with the unit.
• Connect battery charger to vehicle battery
assembly to prevent battery assembly drain.
1. Attach the high-side (red) hose with the quick dis-
connect coupler to the high~side refrigerant service
valve fitting of the vehicle A/C system. This valve is
located in the receiver dehydrator tube, between the
receiver and dehydrator assembly and the condenser
assembly. Open the coupler valve after attachment.
2. Attach the low-side (blue) hose with the quick dis-
connect coupler to the low-side refrigerant charge
valve fitting of the vehicle A/C system. This valve is
located in the compressor and condenser hose
assembly, between the compr~ssor assembly and the
HEATER,VENTILATION AND AIR CONDITIONING 18·11
thermostatic expansion valve assembly. Open the
coupler valve after attachment.
3. Check the high-side and low-side gages on the unit
coot-rnl--panel-to be-sure the A/C s-yst-em haspressure.
If there is no pressure, there is no refrigerant in the
system to recover.
[I] Important
• If there is no refrigerant in the A/C system, do
not continue with the recovery operation. Air
will be drawn into the recovery tank.
4. Open both the high-side and the low-side valves on
the control panel (Figure 7).
5. Open both the red "GAS" (vapor) and the blue
"LIQUID" valves on .the tank.
6. Slowly open the oil drain valve to see if the oil sepa-
rator contains oil (Figure 6).
• If any oil drains into the catch bottle at the bot-
tom of the unit, allow it to drain until there is
no more oil in the separator.
7. Close the oil drain valve.
• Dispose of the oil in the catch bottle in an
appropriate manner and return the bottle to its
place on the unit.
8. Plug the unit into the proper voltage outlet and turn
on the "MAIN POWER" switch.
9. Start engine and run for one minute with A/C system
"ON" in order to stabilize system.
10. Turn ignition switch "OFF," then back to "RUN,"
and blower motor assembly to "HIGH." A battery
charger should be connected to prevent battery
assembly drain.
rn Important
• Blower motor assembly setting to "HIGH"
will increase the rate at which refrigerant can
be recovered.
11. Press "RECOVER" on the keypad. Before recovery
begins, the unit will clear itself of refrigerant.
"CL-L" will appear on the display. The cleaning
process takes from thirty seconds to three minutes to
complete (Figure 9).
[I] Important
• Maintain A/C blower motor assembly on
"HIGH" during recovery operation.
12. When cleaning is complete. The unit will automati-
cally start recovery, and the control panel display
will show the unit is in the "RECOVER" mode of
the "AUTOMATIC" cycle. Also, the weight of
refrigerant being recovered will be displayed.
13. The compressor shuts off automatically when initial
recovery has occurred, at approximately 57 kPa (17
inches Hg) vacuum. ·
18-12 HEATER, VENTILATION AND AIR CONDITIONING

replaced in to the A/C system later when the

system is recharged with refrigerant.
15. Slowly open the oil drain valve and drain the oil into
MAIN POWER -+_.n
SWITCH
D the calibrated oil catch bottle at the bottom of the
unit (Figure 6).
mmrno
©l!ll!l8 16. After the oil is completely drained, close the valve.
(D(!)(!)O
(!)80 17. Read and record the amount of oil removed in the
RECOVER catch bottle.
18. Dispose of the recovered oil in an appropriate man-
ner. Never reuse this oil.
19. Check the control panel "LOW-SIDE GAGE."
• If the A/C system has maintained a vacuum,
CL-L
- the recovery is complete.

-D.DD
20. If the "LOW-SIDE GAGE" pressure rises above
DISPLAY "O," this indicates the presence of more refrigerant

.-
Ill
in the system. In this case, press the "HOLD/
CONT" key on the keypad to recover the additional
refrigerant. Repeat this step as needed until the sys-
tem maintains vacuum for two minutes.

rn
DISPLAY

Important
• If the display flashes "FULL" during the
CPL recovery process, and the unit shuts off, the
OL unit tank is full.
DISPLAY

7.5* .-
Ill
• An empty unit tank (J 39500-50) must be
installed to accommodate additional refriger-
ant, before proceeding to the next step in the
recovery operation. Do not use any other kind
DISPLAY of tank.
("Sample Value)
• It is possible to lower the amount of refrigerant
in the unit tank by charging other vehicles.

PC0008·1B·f·RP
Figure 9 - Refrigerant Recovery
14. At the end of the initial recovery process, the display
shows "CPL" and then alternately flashes the
weight of refrigerant recovered and "OIL/OZ"
("OIL/GMS").
Evacuation
Figures 10 and 11
The ACR 4 unit tank must contain sufficient R-134a
refrigerant for A/C system charging. Check the amount of
refrigerant in the tank by simultaneously pressing
"RESET" and "ENTER" on the keypad to enter the
diagnostic mode. Once in the diagnostic mode, press "7".
When "7" is pressed, the ACR 4 unit will display the
amount of R-134a refrigerant available. in the tank. If less
than 3.6 kg (8 pounds) is displayed, add new refrigerant to

rn Important
• A small amount of A/C system lubricating oil
the tank. Refer to the manufacturer's instructions for
adding refrigerant.
1. With the high side and low side hoses connected to
the vehicle A/C system, open both the high-side
polyalkylene glycol (PAG) might be removed (red) and the low-side (blue) valves on the unit con-
with the refrigerant during recovery. The trol panel.
amount of oil removed (often there will be
none) will vary greatly depending on a variety 2. Open both the red "GAS" (vapor) and the blue
of conditions of the vehicle being serviced. "LIQUID" valves on the tank.
The ACR 4 separates the oil from the refriger-
ant.
• The "OIL/OZ" ("OIL/GMS") flashing is a
rn Important
• To remove all the air and properly dry the A/C
reminder to always drain the recovered oil at system, the unit automatically goes to a pre-
this time. The same amount of oil must be programmed evacuation time.

75.0
DISPLAY
PC0009-1 B-F-RP
Figure 10 - System Evacuation (1 of 2)
• It is possible to evacuate longer. Press keys to
enter time desired. New entry will show on the
display. Press "ENTER," the display will
blink indicating input of data (Figure 10).
3. Press "VACUUM" to start the vacuum pump. The
display counts down the vacuum time to zero to indi-
cate operation time remaining. The display reads
"RECYCLE" five seconds after the vacuum pump
starts and continues while the process takes place.
[I] Important
• Automatic refrigerant recycling during each
evacuation is a feature of the ACR 4 system. No
action is required by the technician.
• The control panel "MOISTURE INDICA-
TOR" must be green during recycling verify-
ing refrigerant moisture content is within
specifications. Yellow indicates a set condition
requiring a filter/drier cartridge change. See
the manufacturer instructions for this proce-
dure.
• Non-condensable gases (mostly air) are auto-
matically vented from the tank during the
recycling process. An audible sound of pres-
sure release may be heard as this happens. This
is a normal function.
4. At approximately the 12-minute mark on the display
(pump has run for three minutes), press "HOLD/
CONT" key to stop vacuum pump (Figure 11 ).
A. A "O" vacuum reading indicates a major sys-
tem leak. Repair leak and restart evacuation
procedure.
B. If a vacuum reading of 91-101 kPa (27-30
inches of Hg) is indicated, close the low-side
and high-side valves. Observe the vacuum
level for a few minutes as a leak check of the
A/C system. If vacuum is not maintained, find
and repair the A/C system leak before continu-
ing.
C. If a vacuum reading of 91-101 kPa (27-30
inches of Hg) is maintained, open the high-side
and low-side valves and press the "HOLD/
CONT" key to restart the vacuum pump.
.HEATER, VENTILATION AND AIR CONDITIONING 19;.13
72.0
DISPLAY
HOLD/CONT
a @Jo@
0
; ;
A B
A LOW SIDE VALVE OPEN
B HIGH SIDE VALVE OPEN
PC0010-1B-F-RP
Figure 11 - System Evacuation (2 of 2)
5. When the vacuum sequence has run the pro-
grammed time, the display shows "CPL" to indicate
that evacuation is complete.
m Important
• The vacuum pump oil must be changed fre-
quently.
• When the pump has run for a total time of ten
hours, the message "OIL" will flash on the
control panel display as a reminder to change
the oil.
• If the "OIL" warning flashes during operation,
press "CONT" and change the oil before the
next operation. See the manufacturer instruc-
tions for this procedure.
A/C System Oil Charge Replenishing
If oil was removed from the AC system during the
recovery process or due to component replacement, it
must be replenished at this time. Refer to "Refrigerant Oil
Distribution" that follows for proper oil capacities.
1. Select the graduated bottle of replenishing polyalky-
lene glycol (PAG) synthetic refrigerant oil (GM PIN
12345923 or equivalent).
2. Adjust the 0-ring around the PAG oil bottle to the
required oil charge level.
Example: If bottle oil level is at 4 ounces and 1/2
ounce of oil is required, adjust 0-rings to 3 1/2
ounces as final level mark.
18-14 HEATER, VENTILATION ANO AIR CONDITIONING
3. Install the bottle on the oil injection system on the
back of the unit.
[I] Important
• Keep the oil bottles tightly capped at all times
to keep out moisture and contamination.
• Do not open the oil injection valve while there
is positive pressure in the A/C system. This
will resu It in oil blow-back through the bottle
vent. A/C system vacuum is required for this
operation.
• Never let the oil level drop below the pick-up
tube .while charging or replenishing. This will
allow air i[\to the A/C system.
4. Open the valve at the top of the plastic container and
watch the level of oil being drawn into the system.
5. Close the valve when the required oil charge has
been pulled into the system.
Refrigerant Oil Distribution
Compressor systems require 240 ml (8 fluid ounces)
of polyalkylene glycol (PAG) synthetic refrigerant oil
(GM P/N 12345923 or equivalent). During component
replacement and conditions stated, new oil quantities
should be added to the system as follows:
• Compressor assembly replaced.
- If less than 30 ml (1 fluid ounce) is drained,
add 60 ml (2 fluid ounces).
- If more than 30 ml (1 fluid ounce) is drained,
add same amount.
• Receiver and dehydrator assembly replaced.
- Add 30 ml (1 fluid ounce) more than what was
drained from old receiver and dehydrator
assembly.
• Evaporator replaced.
- Add 90 ml (3 fluid ounces) oil.
• Condenser assembly replaced.
- Add 30 ml (1 fluid ounce) oil.
Refrigerant Oil Loss Due to a Large Leak
If the refrigerant charge is abruptly lost due to a large
refrigerant leak, approximately 90 ml (3 fluid ounces) of
refrigerant oil will be carried out of the system suspended
in the refrigerant. Any failure that caused an abrupt refrig-
erant discharge will experience this oil loss. Failures that
allow the refrigerant to seep or bleed off over time do not
experience this oil loss.
Upon replacement of a component which caused a
large refrigerant leak, add 90 ml (3 fluid ounces) of new
polyalkylene glycol (PAG) synthetic refrigerant oil (GM
P/N 12345923 or equivalent) plus the required amount of
oil for the particular component (as outlined above).
Add the oil directly to the replaced component if
possible. If the oil cannot easily be added to the replaced
part, add the oil to the receiver dehydrator assembly.
The normal blue tint of the PAG oil may not be seen
once the vehicle's A/C system has been run. Be sure to use
the GM-approved PAG oil for this system.
Compressor System
Up to 120 ml (4 fluid ounces) of oil can collect in the
crankcase. Therefore, it is important when replacing a
compressor assembly that the oil in the old compressor
crankcase be drained and measured (discard the oil after
recording the amount).
All replacement compressor assemblies will be
shipped with approximately 240 ml (8 fluid ounces) of oil
in the crankcase. The oil must be drained and retained.
Then replace the oil in the same amount as previously
recorded from the old compressor assembly.
Charging the A/C System (Engine Off)
Figures 6, 12 and 13
rn Important
• The A/C system must be evacuated prior to
charging.
• Check that the "LB/KG" switch on the back of
the unit to be sure it is set for the desired units
of weight system (operate switch with main
power "OFF").
1. Close the low-side valve on the control panel.
2. Open the high-side valve on the control panel.
3. Press "CHG" on the keypad to be sure the unit is in
the program mode.
4. Enter the amount of refrigerant charge to charge the
A/C system by pressing the appropriate number
keys. Be sure to use correct unit of weight (pounds
or Kg).
rn Important
• Charge A/C system with amounts of R-134a
specified. Do not overcharge.
• Charge A/C system (C60) with 0.91 kg (2.0
pounds).
5. Press "ENTER."
• A blink of the display indicates the charge
amount is in the unit memory.
6. Press "CHG" on the keyboard to begin the charging
process.
7. The display shows "AUTOMATIC" and the
amount of refrigerant programmed for charging.
• The display counts down to zero as the charg-
ing process proceeds.
• At the end of the process, the display shows
"CPL."
[ [ ) Important
• If the transfer of refrigerant stops before com-
plete, refer to "Unsuccessful Transfer" that
follows.
Successful Transfer Complete
I. Close the high-side valve on the unit control panel
(both valves should now be closed).
2. Start the vehicle and the A/C system and let run until
the readings on the high-side and low-side gages sta-
 HEATER, VENTILATION AND AIR CONDITIONING 18·15

bilize. Compare readings, outlet temperatures and
ambient temperature and humidity to the "Air
Conditioning Performance Chart" in SECTION
lBI.
3. With the A/C system running, close the high-side
coupler valve and disconnect the high-side (red)
hose from the vehicle.
4. Open both the high-side and low-side valves on the
control panel.
S. Refrigerant from both hoses will be drawn quickly
into the A/C system through the low-side (blue)
hose.
2. If the transfer will not complete and the display
6. Close the low-side coupler valve and disconnect
from the vehicle.
Unsuccessful Transfer
On rare occasions, the total charge does not transfer
to the vehicle A/C system. There are two reasons why this
can occur.
I. If the transfer is too slow because the pressure in the
unit tank and the vehicle A/C system are about the
3. Add refrigerant to the tank following the manufac-
same, the unit will emit an audible signal and the
display shows the weight remaining for transfer. In
this case:
A. Close t-he-high-si-de valve(Figure 13).
B. Open the low-side valve.
C. Start the vehicle A/C system, and press
"HOLD/CONT" on the keyboard. This will
put the remainder of the charge into the A/C
system.
D. Continue with the previous procedure, "Suc-
cessful Transfer Complete."
shows "CHECK REFRIGERANT," there is not
enough refrigerant in the tank to complete the pro-
cess. This condition requires the recovery of the par-
tial charge of refrigerant in the vehicle A/C system
and another complete evacuation and charge proce-
dure.
A. Press "HOLD/CONT" on the keypad to inter-
rupt the cycle.
B. Press "RESET" to reset the unit.
C. Recover the refrigerant that has been charged
into the system, refer to "Refrigerant Recov-
ery" in this section.
turer instructions, and refer to "Evacuation" in this
section.

REPLACEMENT PROCEDURES
CAUTION: For personal protection,
goggles should be worn and a clean
cloth wrapped around fittings, valves
A B and connections when doing work that
includes opening the refrigeration sys-
tem. If Refrigerant-134a comes in con-
tact with any part of the body, severe
,. do.a ...
Ill
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and
DISPLA'l
prompt medical help should be

--
obtained.
NOTICE: Tighten all tubing connections to the spe-

1.9 ...
Ill
cified torque for the fitting. Too little or too much
torque when tightening can result in loose joints or
deformed joint parts. Either condition can result in
refrigerant leakage and an inoperative air condition-
DISPLAY ing system. Refer to "Fitting Tightening Specifica-
tions" at the end of this section.

Air Conditioning Compressor and

CPL Condenser Hose Assembly

DISPLAY Figures 1, 2 and 14

j++I Remove or Disconnect

A LOW SIDE VALVE CLOSED 1. Recover refrigerant. Refer to "Refrigerant Recovery
B HIGH SIDE VALVE OPEN and Recycling, Adding Oil, Evacuating and
PC0011-1 B·f·RP Recharging Procedures" in this section.
Figure 12 - System Charging ( 1 of 2) 2. Strap (34) from compressor and condenser hose
assembly (7).
18·16 HEATER, VENTILATION AND AIR CONDITIONING

3. Compressor and condenser hose assembly fitting at 3. Compressor and condenser hose assembly (7) into
thermostatic expansion valve assembly (6). position.
• Discard seal (16). 4. Compressor assembly. Refer to "Air Conditioning
4. Raise and suitably support vehicle. Refer to SEC- Compressor Assembly" in this section.
TION OA. 5. 0-ring ( 17) to compressor and condenser hose
5. Compressor and condenser hose assembly fitting at assembly (7).
condenser assembly (3). 6. Compressor and condenser hose assembly fitting to
• Use a back-up wrench to hold condenser condenser assembly (3).
assembly fitting while loosening compressor
and condenser hose assembly fitting.
• Discard 0-ring ( 17).
I~! Tighten
• Compressor and condenser hose assembly fit-
6. Bolt/screw (30). ting to 27 N•m (20 lb. ft.).
7. Compressor assembly. Refer to "Air Conditioning 7. Bolt/screw (30).
Compressor Assembly" in this section.
8. Compressor and condenser hose assembly (7).
• Discard seals (18).
l~I Tighten
• Bolt/screw (30) to 10 N•m (89 lb. in.).

!++! Install or Connect 8. Lower vehicle.

9. Seal (16) to compressor and condenser hose assem-
NOTICE: See "Notice" on page IB-1 of this sec- bly fitting.
tion.
• Lightly coat seal (16) with mineral base 525
1. Clean fittings with mineral base 525 viscosity refrig- viscosity refrigerant oil.
erant oil.
10. Compressor and condenser hose assembly fitting to
• Do not allow refrigerant oil to enter A/C sys-
thermostatic expansion valve assembly (6).
tem.
2. Seals ( 18) to compressor and condenser hose assem-
bly (7).
l~I Tighten
• Lightly coat seals ( 18) with mineral base 525 • Compressor and condenser hose assembly fit-
viscosity refrigerant oil. ting to 37 N•m (27 lb. ft.).
11. Strap (34) to compressor and condenser hose assem-
bly (7).
HOLD/CONT A
12. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
a 13. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
0mm
0@®0 0 Air Conditioning Receiver Dehydrator Tube

SHIFT/ RES:T~µe Figures 1, 2 and 14

l++I Remove or Disconnect

1. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.

II!!_ DISPLAY
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
2. Battery negative cable assembly.
3. Bolt/screw (27).
4. Receiver dehydrator tube fitting at receiver and
A BEEPER dehydrator assembly (4).
B HIGH SIDE VALVE CLOSre
C LOW SIDE VALVE OPEN
• Use a back-up wrench to hold receiver and
dehydrator assembly port while loosening
PC0012-1B-F-RP receiver dehydrator tube fitting.
Figure 13 - System Charging (2 of 2)
5. Receiver dehydrator tube (9).
• Discard 0-rings (13 ).
 HEATER, VENTILATION AND AIR CONDITIONING 18·17

18 2

28

!VIEWC!

A VERTICAL REFERENCE LINE 17 0-RING, AIR CONDITIONING CONDENSER FITIING

2 COMPRESSOR ASSEMBLY, AIR CONDITIONING
3 CONDENSER ASSEMBLY, AIR CONDITIONING
4 RECEIVER DEHYDRATOR ASSEMBLY, AIR
CONDITIONING
6 VALVE ASSEMBLY, AIR CONDITIONING
THERMOSTATIC EXPANSION
7 HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR
AND CONDENSER
8 TUBE, AIR CONDITIONING EVAPORATOR
9 TUBE ASSEMBLY, AIR CONDITIONING RECEIVER
DEHYDRATOR
13 0-RING, AIR CONDITIONING RECEIVER DEHYDRATOR
TUBE
14 0-RING, AIR CONDITIONING EVAPORATOR TUBE
16 SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
18 SEAL, AIR CONDITIONING HOSE
27 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR TUBE
28 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
29 BOLT/SCREW, AIR CONDITIONING THERMOSTATIC
EXPANSION VALVE
30 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP BRACKET
32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
34 STRAP, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
46 VALVE, AIR CONDITIONING REFRIGERANT CHARGE
PC0013·1B·F-RP

Figure 14 - Refrigerant Lines and Hoses

1B-18 HEATER, VENTILATION AND AIR CONDITIONING
!++! Install or Connect
NOTICE: See "Notice" on page IB-1 of this sec-
tion.
l. Clean fittings with mineral base 525 viscosity refrig-
erant oil.
• Do not allow refrigerant oil to enter A/C sys-
tem.
2. 0-rings ( 13) to receiver dehydrator tube (9).
• Lightly coat 0-rings ( 13) with mineral base
525 viscosity refrigerant oil.
3. Receiver dehydrator tube (9).
4. Bolt/screw (27).
• Do not tighten at this time.
5. Receiver dehydrator tube fitting to receiver and
dehydrator assembly (4 ).
!~J Tighten
• Receiver dehydrator tube fitting to 27 N•m (20
lb. ft.).
• Bolt/screw (27) to 16 N •m (12 lb. ft.).
6. Battery negative cable assembly.
7. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
8. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Evaporator Tube
Figures 1, 2 and 14
!++! Remove or Disconnect
1. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
2. Electrical connector at refrigerant pressure sensor
assembly (22).
3. Strap (34) from evaporator tube (8).
4. Receiver dehydrator tube. Refer to "Air Condition-
ing Receiver Dehydrator Tube" in this section.
5. Bolt/screw (12).
6. Evaporator tube fitting at receiver and dehydrator
assembly (4).
• Use a back-up wrench to hold receiver and
dehydrator assembly port while loosening
evaporator tube fitting.
7. Evaporator tube fitting at thermostatic expansion
valve assembly (6).
8. Evaporator tube (8).
• Discard 0-rings (14).
!++! Install or Connect
NOTICE: See "Notice" on page lB-1 of this sec-
tion.
1. Clean evaporator tube fittings with mineral base 525
viscosity refrigerant oil.
• Do not allow refrigerant oil to enter evaporator
tube (8).
2. 0-rings to evaporator tube (8).
• Lightly coat 0-rings with mineral base 525
viscosity refrigerant oil.
3. Evaporator tube fitting at thermostatic expansion
valve assembly (6).
• Do not tighten at this time.
4. Evaporator tube fitting at receiver and dehydrator
assembly (4).
!~! Tighten
• Evaporator tube fitting at receiver and dehy-
drator assembly (4) to 7 N•m (62 lb. in.).
• Evaporator tube fitting at thermostatic expan-
sion valve assembly (6) to 18 N•m (13 lb. ft.).
5. Bolt/screw (12).
I~! Tighten
• Bolt/screw (12) to 14 N•m (10 lb. ft.).
6. Receiver dehydrator tube. Refer to "Air Condition-
ing Receiver Dehydrator Tube" in this section.
7. Strap (34) to evaporator tube (8).
8. Electrical connector at refrigerant pressure sensor
(22).
9. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
10. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Thermostatic Expansion
Valve Assembly
Figures 1, 2 and 14
I++! Remove or Disconnect
1. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
2. Evaporator tube. Refer to "Air Conditioning Evapo-
rator Tube" in this section.
3. Compressor and condenser hose assembly fitting at
thermostatic expansion valve assembly (6).
• Discard seal (16).
4. Bolts/screws (29).
5. Thermostatic expansion valve assembly (6).
6. Seals (15) from evaporator (5).
• Discard seals (15).
!++! Install or Connect
NOTICE: See "Notice" on page 1B-1 of this sec-
tion.
1. Seals (15) to evaporator (5).

• Lightly coat seals with mineral base 525 vis-
cosity refrigerant oil.
2. Thermostatic expansion valve assembly (6).
3. Bolts/screws (29).
!~! Tighten
• Bolts/screws (29) to 7 N•m (62 lb. in.).
4. Clean compressor and condenser hose assembly fit-
ting with mineral base 525 viscosity refrigerant oil.
!++I Install or Connect
• Do not allow refrigerant oil to enter A/C sys-
tem.
5. Seal ( 16) to compressor and condenser hose assem-
bly (7).
• Lightly coat seal with mineral base 525 viscos-
ity refrigerant oil.
6. Compressor and condenser hose assembly fitting to
thermostatic expansion valve assembly (6).
!~! Tighten
, • Compressor and condenser hose assembly fit-
ting to 37 N•m (27 lb. ft.).
7. Evaporator tube. Refer to" Air Conditioning Evapo-
rator Tube" in this section.
8. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
9. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Receiver and Dehydrator
Assembly
Figures 1, 2 and 14
!+-+I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
3. Bolt/screw (27).
4. Receiver dehydrator tube fitting at receiver and
dehydrator assembly (4 ).
• Use a back-up wrench to hold receiver and
dehydrator assembly port while loosening
receiver dehydrator tube fitting.
5. Receiver dehydrator tube (9).
• Discard 0-rings ( 13).
6. Bolt/screw ( 11) at receiver dehydrator bracket
clamp.
HEATER, VENTILATION AND AIR CONDITIONING 18-19
7. Evaporator tube fitting at receiver and dehydrator
assembly (4).
• Use a back-up wrench to hold receiver and
dehydrator assembly port while loosening
evaporator tube fitting.
8. Receiver and dehydrator assembly (4) from bracket
(10).
• Discard 0-ring (14).
NOTICE: See "Notice" on page 1B-1 of this sec-
tion.
1. If receiver and dehydrator assembly is being
replaced, drain and measure amount of PAG oil in
old receiver and dehydrator assembly. Add the
drained amount plus 30 ml (1 fluid ounce) more of
new PAG oil to new receiver and dehydrator assem-
bly.
2. Receiver and dehydrator assembly (4) to bracket
(10).
3. Clean fittings with mineral base 525 viscosity refrig-
erant oil.
• Do not allow refrigerant oil to enter A/C sys-
tem.
4. 0-ring (14) to evaporator tube (8).
• Lightly coat 0-ring (14) with mineral base 525
viscosity refrigerant oil.
5. Evaporator tube fitting to receiver and dehydrator
assembly (4).
!~I Tighten
• Evaporator tube fitting to 7 N•m (62 lb. in.).
6. Bolt/screw ( 11) at receiver dehydrator bracket
clamp.
l~I Tighten
• Bolt/screw (11) to 9 N•m (80 lb. in.).
7. 0-rings (13) to receiver dehydrator tube (9).
8. Receiver dehydrator tube (9).
9. Bolt/screw (27).
• Do not tighten at this time.
10. Receiver dehydrator tube fitting to receiver and
dehydrator assembly (4).
l~I Tighten
• Receiver dehydrator tube fitting to 27 N•m (20
lb. ft.).
• Bolt/screw (27) to 16 N•m (12 lb. ft.).
11. Battery negative cable assembly.
12. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
18-20 HEATER, VENTILATION AND AIR CONDITIONING
13. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Condenser Assembly
Figures 1, 2, 14 and 15
,.,,..! Remove or Disconnect
I. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
2. Air intake duct. Refer to SECTION 6E3.
3. Air cleaner assembly. Refer to SECTION 6E3.
4. Upper radiator shroud assembly. Refer to SECTION
6B.
5. Raise and suitably support vehicle. Refer to SEC-
TION OA.
6. Hose assembly (7) at condenser assembly (3).
• Discard 0-ring ( 17).
7. Lower vehicle.
8. Receiver dehydrator tube. Refer to "Air Condition-
ing Receiver Dehydrator Tube" in this section.
9. Radiator air upper baffle from condenser assembly,
if necessary. Refer to SECTION 6B.
I 0. Condenser assembly (3) from radiator assembly
(47).
• Disconnect retaining tangs from grooves.
3
3 13.
B
47
A TANG, CONDENSER ASSEMBLY RETAINING
B GROOVE
C CONDENSER TUBE
3 CONDENSER ASSEMBLY, AIR CONDITIONING
47 RADIATOR ASSEMBLY
PC0014· 1B·F·RP
Figure 15 - Condenser Assembly
!-++! Install or Connect
NOTICE: See "Notice" on page lB-1 of this sec-
tion.
I. Condenser assembly (3) to radiator assembly (47).
• Retaining tangs must be fully seated in grooves
(Figure 15).
m Important
• If a retaining tang finger breaks, reinstall the
finger by drilling a small hole into the existing
tab and use appropriate screw to fasten finger
to the tab. Make sure not to puncture radiator
coolant tank when doing this procedure.
2. Radiator air upper baffle to condenser assembly, if
removed. Refer to SECTION 6B.
3. Receiver dehydrator tube. Refer to "Air Condition-
ing Receiver Dehydrator Tube" in this section.
4. Raise and suitably support vehicle. Refer to SEC-
TION OA.
5. Clean hose assembly fitting and condenser assembly
fitting with mineral base 525 viscosity refrigerant
oil.
• Do not allow refrigerant oil to enter A/C sys-
tem.
6. 0-ring (17) to hose assembly (7).
• Lightly coat 0-ring with mineral base 525 vis-
cosity refrigerant oil.
7. Hose assembly (7) to condenser assembly (3).
!~! Tighten
• Hose assembly fitting to 27 N•m (20 lb. ft.).
8. Lower vehicle.
9. Upper radiator shroud assembly. Refer to SECTION
6B.
10. Air cleaner assembly. Refer to SECTION 6E3.
11. Air intake duct. Refer to SECTION 6E3.
12. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Compressor Assembly
Figures 1, 2, 16 and 17
!+-+! Remove or Disconnect
1. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Serpentine drive belt. Refer to SECTION 6A2A
(3.4L L32 engine) or SECTION 6A3A (5.7L LTl
engine).
 HEATER, VENTILATION AND AIR CONDITIONING 18·21

32
41
2 COMPRESSOR ASSEMBLY, AIR CONDITIONING
32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
38 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
39 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
40 BRACKET, AIR CONDITIONING COMPRESSOR REAR
41 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
PC0015-1B-F·RP

Figure 16 - Air Conditioning Compressor Assembly Mounting and Bracket (5. 7L LT1 Engine)

4. Drive belt tensioner assembly, 5.7L LTl engine
only. Refer to SECTION 6A3A.
5. Bolt/screw (30).
6. Bolt/screw (28).
7. Hose assembly (7) from compressor assembly (2).
• Discard seals ( 18).
8. Lower transmission oil coo1er pipe assembly at
radiator assembly. Refer to SECTION 7A.
9. Electrical connector at compressor assembly (2).
I0. Bolt/screw (41) on 5. 7L LTl engine o,nly.
11. Bolts/screws (45) on 3.4L L32 engine only.
12. Bolts/screws (38).
13. Compressor assembly (2).
14. Bolts/screws (44) and support (43) on 3.4L L32
engine only, if necessary.
pressor. If measured amount is less than 30 ml
(1 fluid ounce), add 60 ml (2 fluid ounces) to
new replacement compressor. If more that
30 ml (1 fluid ounce) is drained from defective
. compressor add same amount to new compres-
sor. Use PAG refrigerant oil GM PIN
12345923 or equivalent.
2. Bracket (40) and bolts/screws (39) on 5.7L LTl
engine only, if removed.
l~I Tighten
• Bolts/screws (39) to 25 N•m (18 lb. ft.).
3. Support (43) and bolts/screws (44) on 3.4L L32
engine only, if removed.
l~I Tighten

15. Bolts/screws (39) and bracket (40) on 5. 7L LTl • Bolts/screws (44) to 25 N•m (18 lb. ft.).
engine only, if necessary. 4. Compressor assembly (2).
5. Bolts/screws (38).
!+.-I Install or Connect
NOTICE: See "Notice" on page lB-1 of this sec-
tion.
l~I Tighten
• Bolts/screws (38) to 50 N•m (37 lb. ft.).
I. Polyalkaline glycol (PAG) refrigerant oil. . 6. Bolts/screws (45) on 3.4L L32 engine only.
• If compressor assembly (2) is being replaced,
drain refrigerant oil from both defective com-
pressor and new replacement compressor.
l~I Tighten
Measure amount removed from defective com- • Bolts/screws (45) to 50 N•m (37 lb. ft.).
1B-22 HEATER, VENTILATION AND AIR CONDITIONING

45
2 COMPRESSOR ASSEMBLY, AIR CONDITIONING
38 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
43 SUPPORT, AIR CONDITIONING COMPRESSOR lVIEWA!
44 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
45 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
SUPPORT
PC0016-1B-F·RP

Figure 17 -Air Conditioning Compressor Assembly Mounting and Support (3.4L L32 Engine)

7. Bolt/screw (41) on 5.7L LTl engine only.
l~I Tighten
• Bolt/screw (41) to 33 N•m (24 lb. ft.).
8. Electrical connector at compressor assembly (2).
9. Lower transmission oil cooler pipe assembly at
radiator assembly. Refer to SECTION 7A.
10. Seals ( 18) to hose assembly (7).
• Lightly coat seals with mineral base 525 vis-
cosity refrigerant oil.
11. Hose assembly (7) to compressor assembly (2).
12. Bolt/screw (28).
l~I Tighten
• Bolt/screw (28) to 33 N•m (24 lb. ft.).
13. Bolt/screw (30).
17. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
18. Leak-test A/C system. Refer to "Leak-Testing the
Refrigerati'on System" in this section.
Air Conditioning Refrigerant Service Valve
Figures 1 and 2
Tool Required:
J 39037 Octagon Socket
I+-+! Remove or Disconnect
1. Recover refrigerant. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
2. Valve cap (24).
3. Service valve (25).
• Use J 39037 to remove valve.

I~! Tighten l,++I Install or Connect

• Bolt/screw (30) to 10 N•m (89 lb. in.). 1. Service valve (25).
14. Drive belt tensioner assembly, 5.7L LTl engine • Coat seal (19) with mineral base 525 viscosity
only. Refer to SECTION 6A3A. refrigerant oil.
15. Serpentine drive belt. Refer to SECTION 6A2A • Use J 39037 to install valve.
(3.4L L32 engine) or SECTION 6A3A (5.7L LTl
engine). l~I Tighten
16. Lower vehicle. • Service valve to (25) 11 N•m (97 lb. in.).

50
48 BRACKET ASSEMBLY, GENERATOR AND AIR
CONDITIONING COMPRESSOR AND POWER STEERING
PUMP
49 BOLT/SCREW, GENERATOR BRACKET
50 BOLT/SCREW, GENERATOR BRACKET
51 BOLT/SCREW, GENERATOR BRACKET
52 BOLT/SCREW, GENERATOR BRACKET
53 SUPPORT, SPARK PLUG WIRE
54 ENGINE ASSEMBLY (5.7L LT1)
PC0017-1B-f..RP
Figure 18 - Bracket Assembly (5.7L LT1 Engine)
2. Valve cap (24).
3. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
4. Leak-test valve. Refer to "Leak-Testing the Refrig-
eration System" in this section.
Generator and Air Conditioning Compressor
and Power Steering Pump Bracket Assembly
(5.7L LT1 Engine)
Figure 18
!+,.I Remove or Disconnect
1. Generator assembly. Refer to SECTION 603.
2. Power steering pump assembly. Refer to SECTION
3B.
3. Air conditioning compressor assembly. Refer to
"Air Conditioning Compressor Assembly" in this
section.
4. Bolts/screws (49, 50, 51 and 52).
5. Spark plug wire support (53).
6. Bracket assembly (48).
!,.+I Install or Connect
I. Bracket assembly (48).
2. Spark plug wire support (53).
3. Bolts/screws (49, 50, 51 and 52) loosely.
HEATER, VENTILATION AND AIR CONDITIONING 18-23
57
55 BOLT/SCREW. GENERATOR BRACKET
56 BRACKET ASSEMBLY, GENERATOR AND AIR
CONDITIONING COMPRESSOR
57 STUD, GENERATOR BRACKET
58 ENGINE ASSEMBLY (3.4L L32)
PC0018-1 B·f·RP
Figure 19 - Bracket Assembly (3.4L L32 Engine)
l~.J Tighten
• In sequence:
• Bolt/screw (49) to 33 N•m (24 lb. ft.).
• Bolt/screw (50) to 33 N•m (24 lb. ft.).
• Bolt/screw (51) to 33 N•m (24 lb. ft.).
• Bolt/screw (52) to 33 N•m (24 lb. ft.).
4. Air conditioning compressor assembly. Refer to
"Air Conditioning Compressor Assembly" in this
section.
5. Power steering pump assembly. Refer to SECTION
6.
3B.
Generator assembly. Refer to SECTION 603.
7. Bleed power steering system. Refer to SECTION
3B.
8. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
9. Leak-test A/C fitting at rear of compressor assem-
bly. Refer to "Leak-Testing the Refrigeration Sys-
tem" in this section.
Generator and Air Conditioning Compressor
Bracket Assembly (3.4L L32 Engine)
Figure 19
!+,.I Remove or Discon.nect
I. Generator assembly. Refer to SECTION 603.
18·24 HEATER, VENTILATION AND AIR CONDITIONING

2. Air conditioning compressor assembly. Refer to 4. Serpentine drive belt tensioner assembly. Refer to
"Air Conditioning Compressor Assembly" in this SECTION 6A2A.
section.
5. Air conditioning compressor assembly. Refer to
3. Serpentine drive belt tensioner assembly. Refer to "Air Conditioning Compressor Assembly" in this
SECTION 6A2A. section.
4. Bolts/screws (55). 6. Generator assembly. Referto SECTION 6D3.
5. Stud (57). 7. Charge A/C system. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
6. Bracket assembly (56).
Recharging Procedures" in this section.
!++I Install or Connect 8. Leak-test fitting at rear of compressor assembly.
NOTICE: See "Notice" on page lB-1 of this sec- Refer to "Leak-Testing the Refrigeration System"
tion. in this section.

1. Bracket assembly (56).

2. Stud (57). Compressor Assembly On-Vehicle Minor
Component Replacement
• Do not tighten at this time.
Due to the limited clearance on the 5. 7L LTl engine,
3. Bolts/screws (55). it is recommended that the compressor assembly be serv-
I~! Tighten
iced after the compressor assembly is removed from the
vehicle. Vehicles with 3.4L L32 engines have clearance to
service compressor assembly minor components on-ve-
• Bolts/screws (55) to 33 N•m (24 lb. ft.).
hicle. For component replacement procedures, refer to
• Stud (57) to 33 N•m (24 lb. ft.). SECTION 1D2.

SPECIFICATIONS
GENERAL SPECIFICATIONS
A/C System 0-Ring and Fitting Lubricant .......................... 525 Viscosity Mineral Oil,
GM P/N 12301108 or Equivalent
A/C System Internal Lubricant (Including Compressor Assembly) ...... Polyalkylene Glycol (PAG)
SyntheticRefrigerant Oil
GM P/N 12345923 or Equivalent
A/C System R-134a Charge Capacity ...................................... 0.91 kg (2.0 lb.)

FASTENER TIGHTENING SPECIFICATIONS

Air Conditioning Compressor Bolt/Screw (To Main Bracket, All Engines) ...... 50 N•m (37 lb. ft.)
Air Conditioning Compressor (Rear Support) Bolt/Screw
(To Compressor Assembly, 3.4L L32 Engine) ........................... 25 N•m (18 lb. ft.)
Air Conditioning Compressor and Condenser Hose Bolt/Screw ............... 33 N•m (24 lb. ft.)
Air Conditioning Compressor and Condenser Hose Clip Bracket Bolt/Screw .... 10 N•m (89 lb. in.)
Air Conditioning Compressor Low Pressure Cutoff Switch Assembly ........... 6 N•m (53 lb. in.)
Air Conditioning Compressor Rear Bracket Bolt/Screw
(To Compressor Assembly, 5. 7L LTI Engine) ........................... 25 N •m (18 lb. ft.)
Air Conditioning Compressor Rear Bracket Bolt/Screw (To 5.7L LTI Engine) ... 33 N•m (24 lb. ft.)
Air Conditioning Compressor Rear Support Bolt/Screw (To 3.4L L32 Engine) ... 50 N•m (37 lb. ft.)
Air Conditioning Receiver Dehydrator Bracket Bolt/Screw .................. 14 N•m (10 lb. ft.)
Air Conditioning Receiver Dehydrator Bracket Clamp Bolt/Screw .............. 9 N•m (80 lb. in.)
Air Conditioning Receiver Dehydrator Tube Bolt/Screw ..................... 16 N•m (12 lb. ft.)
Air Conditioning Refrigerant Pressure Sensor Assembly ..................... 6 N•m (53 lb. in.)
Air Conditioning Refrigerant Service Valve ............................... 11 N•m (97 lb. in.)
Air Conditioning Thermostatic Expansion Valve Bolt/Screw .................. 7 N•m (62 lb. in.)
Generator Bracket Bolt/Screw ......................................... 33 N•m (24 lb. ft.)
Generator Bracket Stud ............................................... 33 N•m (24 lb. ft.)
 HEATER, VENTILATION AND AIR CONDITIONING 1B-25

FITIING TIGHTENING SPECIFICATIONS

Air Conditioning Compressor and Condenser Hose Assembly Fitting
(At Condenser Assembly) ........................................... 27 N•m (20 lb. ft.)
Air Conditioning Compressor and Condenser Hose Assembly Fitting
(At Thermostatic Expansion Valve Assembly) ................... ~-....... 37 N•m (27 lb. ff:}
Air Conditioning Evaporator Tube Fitting
(At Receiver and Dehydrator Assembly) ................................ 7 N•m (62 lb. in.)
Air Conditioning Evaporator Tube Fitting
(At Thermostatic Expansion Valve Assembly) ........................... 18 N•m (13 lb. ft.)
Air Conditioning Receiver Dehydrator Tube Fitting
(At Receiver and Dehydrator Assembly) ............................... 27 N•m (20 lb. ft.)
18-26 HEATER, VENTILATION AND AIR CONDITIONING

SPECIAL TOOLS

1. 4.

J 39400 J 39500

2. 5.

J 39037 J 36645

3. 6.

J 6742-03 J 39183-C

7.

1. HALOGEN LEAK DETECTOR J 39500-50

2. OCTAGON SOCKET
3. PRECISION THERMOMETER
4. AIR CONDITIONING REFRIGERANT RECOVERY,
4
RECYCLING AND RECHARGING (ACR ) SYSTEM
5. AIR CONDITIONING EVAPORATOR CLEANING GUN
6. R-134a MANIFOLD GAUGE SET
7. 50 LB REFILLABLE RECOVERY TANK

PC0019-1B-F-RP
 MANUAL CONTROL AIR CONDITIONING 181·1

SECTION 181

MANUAL CONTROL AIR CONDITIONING

CAUTION: "fhis v~hicle is equipped with Supplemental Inflatable Restraint (SIR). Ref~r to
CAUTIONS in Section 9J under 'ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location View in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result In possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 1B 1-1
Overview ............................. lBl-1
Control Assembly ...................... lBl-3
Temperature Control .................. lBl-3
Mode Control ........................ lBl-3
Blower Motor Speed Control . . . . . . . . . . . . 1B 1-4
Air Distribution System . . . . . . . . . . . . . . . . . . 1B.1-4
Vacuum System ...................... lBl-4
Other Components . . . . . . . . . . . . . . . . . . . . 1B 1-5
Air Inlet Valve ....................... lBl-5
Blower Motor Assembly and Evaporator .. lBl-5
Temperature Valve and Heater Core
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-5
Bi-Level Valve ....................... lBl-5
Upper and Lower Mode Valve ........... lBl-6
Heater and Defrost Valve ................ lBl-6
Ducts and Outlets . . . . . . . . . . . . . . . . . . . . . 1B 1-6
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-6
Refrigeration System .................... lBl-6
Refrigerant R-134a ................... lBl-9
Compressor Assembly ................ lBl-10
Condenser Assembly ................. lBl-10
Thennostatic Expansion Valve Assembly . lBl-10
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-11
Receiver Dehydrator Assembly . . . . . . . . . lBl-11
Diagnosis .............................. lBl-11
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-11
Insufficient Cooling Check . . . . . . . . . . . . . . 1B 1-11
Improper Air Delivery . . . . . . . . . . . . . . . . . . lBl-11
Air Conditioning Performance Test : ....... IBI-15
Insufficient Heat Check ....... Refer to Section lA
On-Vehicle Service ...................... lBl-15
Refrigeration System
Services . . . . . . . . . . . . . . . . . Refer to Section 1B
Control Assembly and
Components .............. Refer to Section IA
Temperature Control Cable
Assembly . . . . . . . . . . . . . . . . Refer to Section IA
Blower Motor Resistor
Assembly ................ Refer to Section lA
Blower Motor Assembly Relay ........... lBl-15
Air Conditioning Compressor Relay . . . . . . . 1B 1-15
Air Conditioning Evaporator Temperature
Sensor Assembly .................... lBl-15
Air Conditioning Refrigerant Pressure
Sensor Assembly . . . . . . . . . . . . . . . . . . . . 1B 1-15
Vacuum Hose Harness ........ Refer to Section lA
Vacuum Actuator Assemblies ... Refer to Section lA
Heater Core Assembly . . . . . . . . Refer to Section IA
Air Conditioning Evaporator . . . . . . . . . . . . . 1B 1-15
· Specifications ........................... lBl-21
General Specifications .................. lBl-21
Component Tightening Specifications . . . . . . 1B 1-21
Special Tools ........................... lBl-21

GENERAL DESCRIPTION
OVERVIEW
Figures 1 through 3
The air conditioning system (C60) delivers air that
has been heated or cooled and dehumidified for occupant
comfort. It also provides power ventilation, and wind-
shield assembly defrosting and side window defogging.
During most operating conditions, outside air is
drawn through the heater and air conditioning module
assembly by the blower motor assembly. Additional out-
side air is also forced into the vehicle by forward move-
ment of the vehicle.
Within the heater and air conditioning evaporator
module assembly, air is pushed by the blower motor
assembly through the evaporator, then through the heater
core assembly, depending on the temperature valve set-
ting, and into the passenger compartment. For air condi-
tioning or defroster operation at ambient temperatures
above 7°C (45°F), the refrigeration system will chill the
evaporator to almost freezing. As the air passes through
the evaporator, the air temperature drops which causes
moisture in the air to condense on the evaporator core fins.
181·2 MANUAL CONTROL AIR CONDITIONING

A BLOWER MOTOR SPEED CONTROL

B TEMPERATURE CONTROL
C "OFF" MODE
D "MAX A/C" MODE
E "NORMAL A/C" MODE
F "Bl-LEVEL A/C" MODE
G "VENT" MODE .
H "HEATER" MODE
I"DEFROST BLEND" MODE
J "DEFROST" MODE
1 CONTROL ASSEMBLY, HEATER AND AIR
CONDITIONING
PC1001-1B1-F-RP

Figure 1- Heater and Air Conditioning Control Assembly- (Chevrolet)

2
F

A LOWER BLOWER MOTOR SPEED I "Bl-LEVEL A/C" MODE

B MEDIUM 1 BLOWER MOTOR SPEED J "VENT" MODE
C MEDIUM 2 BLOWER MOTOR SPEED K "HEATER" MODE
D HIGH BLOWER MOTOR SPEED L "DEFROST BLEND" MODE
E TEMPERATURE CONTROL M "DEFROST" MODE
F "OFF" MODE 1 CONTROL ASSEMBLY, HEATER AND AIR CONDITIONING
G "MAX A/C" MODE 2 SWITCH ASSEMBLY, REAR WINDOW DEFOGGER
H "NORMAL A/C" MODE

RC2001-181-F-RP

Figure 2 - Heater and Air Conditioning Control Assembly - (Pontiac)


D E
Figure 3 - Air pistribution System
This moisture leaves the vehicle by gravity feed through a
drain hole, dehumidifying the vehicle.
From the evaporator, some or all of the air may pass
through the heater core assembly, which is warmed by
engine coolant. Any of the air which is not to be heated
will mix with the heated air before entering the passenger
compartment.
When maximum air conditioning mode is selected,
most of the air entering the blower motor assembly is
taken from the passenger compartment (recirculated)
where it is most likely to be cooler than the outside air.
Only outside air is used in all other modes.
CONTROL ASSEMBLY
Temperature Control
Figures 1 and 2
The temperature control is mechanically linked to
the air temperature valve (door) by a temperature control
cable. Rotating the temperature control clockwise allows
more of the incoming or recirculated air to flow through
MANUAL CONTROL AIR CONDITIONING 181·3
4 5
A TO WINDSHIELD DEFROST OUTLET
B TO SIDE WINDOW DEFROST OUTLETS
C TO FLOOR OUTLETS
D TO INSTRUMENT PANEL OUTLETS
FROM PLENUM AREA (OUTSIDE AIR)
F FROM INSIDE VEHICLE (RECIRCULATED AIR)
G SMALL PASSAGE
3 EVAPORATOR, AIR CONDITIONING
4 CORE,HEATER
5 MOTOR ASSEMBLY, BLOWER
6 VALVE, TEMPERATURE
7 VALVE, HEATER AND DEFROST
8 VALVE, Bl-LEVEL
9 VALVE, UPPER AND LOWER MODE
10 VALVE, AIR INLET
11 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING
EVAPORATOR
PC0001-1B1·F-RP
the heater core assembly, thus increasing the air tempera-
ture entering the vehicle. Rotating the temperature control
counterclockwise decreases air flow through the heater
core assembly, thus decreasing the air temperature enter-
ing the vehicle.
Mode Control
Figures 1 and 2
The mode control has eight settings: "OFF,"
"MAX," "A/C," "BI-LEVEL A/C," "VENT,"
"HEATER," "DEFROST BLEND," and "DEFROST."
Some settings are symbols on the heater and air condi-
tioning control assembly ( 1). These symbols are identified
in Figures 1 and 2. Each setting is described below.
"OFF" Mode
At this setting, electrical power is not supplied to the
blower motor assembly and A/C is not requested to the
powertrain control module (PCM). A small amount of air
which is forced into the heater and air conditioning
module assembly by forward movement of the vehicle
will still be discharged through the air outlets. This is the
181·4 MANUAL CONTROL AIR CONDITIONING
only mode in which the blower motor assembly does not
operate.
"MAX" A/C Mode
The "MAX" A/C setting is one of five settings
which requests A/C operation to the PCM. At this setting
the blower motor assembly will operate in one of the four
blower motor speed control settings and air will be dis-
charged from the instrument panel air outlets only.
To provide maximum air conditioning, most of the
air entering the heater and air conditioning module assem-
bly is taken from the vehicle interior (recirculated) where
it is most likely cooler than the outside air. This is the only
mode in which air is recirculated, all other modes use
outside air only. This setting would be most useful during
conditions of high temperature and humidity, or when the
outside air may have an objectionable odor.
Normal "A/C" Mode
The normal "A/C" setting functions the same as
"MAX" A/C setting, except only outside air enters the
module. There may be a slight reduction of blower noise
compared to "MAX" A/C mode because the recirculation
valve (door) is closed.
"Bl-LEVEL A/C" Mode
The "BI-LEVEL A/C" setting requests A/C to the
PCM and allows the blower motor assembly to operate in
one of four settings similar to "MAX" A/C, except only
outside air enters the module and air is distributed through
the instrument panel outlets and the floor outlets (bi-
level).
"VENT" Mode
The "VENT" setting does not request A/C to the
PCM but allows the blower motor assembly to operate
normally. This is one of two economy modes (other than
"OFF") in which A/C is not requested. Air is discharged
through the instrument panel outlets only.
"HEATER" Mode
The "HEATER" setting functions the same as the
"VENT" setting, except most of the air is discharged
through the floor outlets with a small amount discharged
through the defroster outlets. The "HEATER" mode is
the normal selection for cold weather operation unless
windshield defrosting or side window defogging is
required.
"DEFROST BLEND" Mode
The "DEFROST BLEND" setting allows operation
of the blower motor assembly and sends an A/C request
signal to the PCM for compressor operation. During this
setting, air is discharged through the defroster and floor
air outlets. This setting allows greater passenger comfort
than "DEFROST" but is not as effective in defrosting the
windshield assembly and side windows.
"DEFROST" Mode
The "DEFROST" setting functions the same as
"DEFROST BLEND" setting except most of the air is
discharged through the defroster outlets with a small
amount going through the heater and side window defog-
gers.
Blower Motor Speed Control
Figures 1 and 2
With the ignition switch in the "RUN" position, the
blower motor assembly runs in all mode control positions
except "OFF." Blower motor assembly speed is con-
trolled by a four-position electrical blower motor speed
control switch at the left side of the control assembly. The
blower motor speed control switch provides a choice of a
low blower motor assembly speed, two medium speeds,
and a high speed.
Electrical power is routed from the HVAC fuse
number 3 in the fuse block to the mode control switch.
The mode control switch breaks the circuit when it is in
the "OFF" position, and closes the circuit in all other
positions.
From the mode control switch, the circuit then goes
to the blower motor speed control switch. When the
blower motor speed control switch is in "LOW," current
is conducted to the resistor assembly. At the resistor
assembly, the current passes through all three resistors and
is reduced to provide the low blower motor assembly
speed.
When the blower switch is in either of the two
medium speed positions, it closes to send current through
either two or one of the resistors in the resistor assembly.
Because the current follows the path of least resistance,
the circuit branch leading directly to all three resistors
becomes ineffective and the current bypasses either one or
two resistors, depending upon which medium speed posi-
tion is selected. The reduced resistance increases current
flow and blower motor assembly speed.
When the blower motor speed control switch is in
the "HIGH" position, it energizes the high blower relay
and power is taken from a separate circuit that is protected
by a fusible link. This separate power circuit is "hot" at
all times and has the capacity to handle the current
demands of the blower motor assembly at high speed.
The circuit to the blower motor assembly is com-
pleted to ground at the instrument panel assembly through
the instrument panel wiring harness. Refer to SECTION
8A for more electrical information.
AIR DISTRIBUTION SYSTEM
Figures 3 through 6
Air enters the heater and air conditioning evaporator
module assembly where it may be cooled for air condi-
tioning or defrost modes, and then heated as necessary
before being sent to the proper outlets for discharge into
the passenger compartment. Within the heater and air
conditioning evaporator module assembly, valves (doors)
guide the airflow in response to the position of the mode
control.
Vacuum System
All valves in the heater and air conditioning evapo-
rator module assembly except the temperature valve are
controlled by engine vacuum drawn from the vacuum
tank assembly, mounted to the right side body rail, just

behind the radiator support. The vacuum is routed by a
vacuum selector valve in the control assembly to spring-
loaded vacuum actuator assemblies on the heater and air
conditioning evaporator module assembly. Vacuum stored
in the vacuum tank assembly is prevented from bleeding
back to its source during conditions of low engine man-
ifold vacuum (acceleration, hard pulling, etc.) by a check
valve in the vacuum source hose.
The vacuum selector valve in the control assembly is
controlled by the mode control. For each mode control
position, the vacuum selector valve directs vacuum to
specific hoses to overcome the force of the spring within
the appropriate vacuum actuator assemblies. The vacuum
selector valve also vents the hoses to each remaining
vacuum actuator assembly to normal air pressure, allow-
ing the actuator spring to expand. This results in the
valves (doors) being properly positioned for the selected
operating mode.
The heater and defrost valve uses a three-position
vacuum actuator. A three-position vacuum actuator has a
diaphragm with a spring on both sides. At rest (no vacuum
applied) the diaphragm will be in a mid-position, allowing
for a "blend" mode. When vacuum is applied to either
end of the diaphragm, the diaphragm will move the heater
and defrost valve to either stop, which will direct airflow
to either the defroster outlets or the floor outlets.
When air is directed to the floor outlets, as in
"HEATER" mode, a small amount of air still bleeds
through the defroster outlets to help eliminate re-fogging
of the windshield.
Other Components
Other components of the air distribution system
include the plenum, the blower motor assembly, the evap-
orator and the heater core assembly. The plenum provides
a source of outside air to the system. The blower motor
assembly draws air from the plenum or.from the vehicle
interior into the heater and air conditioning evaporator
module assembly and forces it through the air distribution
system to the outlets. The evaporator is a part of the
refrigeration system. It cools the air from the blower
motor assembly when operating in an air conditioning or
defrosting mode. The heater core assembly provides heat
which can be used to warm the air downstream from the
evaporator.
Air Inlet Valve
The first valve in the air distribution system is the air
inlet valve. This two-position valve controls the two air
entrances which feed air to the blower motor assembly.
When ''MAX" A/C mode is selected, vacuum is applied
to the air inlet vacuum actuator assembly and the air inlet
valve opens the entrance which supplies inside air from
the passenger compartment. In this position, the air inlet
valve partially closes the entrance for outside air so only a
slight amount can enter. Recirculating the cooled air
inside the passenger compartment when outside tempera-
ture is very high gives a faster cool down to a more com-
fortable temperature.
When any other operating mode (including "OFF")
is selected, the air inlet vacuum actuator assembly is
vented to normal air pressure and the air inlet valve com-
MANUAL CONTROL AIR CONDITIONING 181·5
pletely closes off the entrance for inside air. Only fresh
outside air is used in the system in these modes.
Blower Motor Assembly and Evaporator
In any operating mode except "OFF,''. the blower
motor assembly draws in air from the plenum and pushes
it through the evaporator. When any air conditioning or
defrost mode is selected, the air conditioning refrigeration
system chills the core of the evaporator to slightly above
freezing temperature. This cools the airflow and causes
excess humidity to condense on the fins of the evaporator.
The condensed moisture drips to the bottom of the case
and drains out through a hole that lets the water fall on the
road surface below the vehicle. From the evaporator, the
air flows toward the ternperature valve and heater core
assembly.
Temperature Valve and Heater Core
Assembly
The temperature control in the control assembly is
linked to the temperature valve by a flexible control cable
assembly. When the temperature control is rotated fully
counterclockwise to the full "COOL" position, the tem-
perature valve is held snugly against the ait entrance to the
heater core assembly. This causes all of the airflow from
the evaporator to bypass the heater core assembly and
there is no heat transfer.
As the temperature control is moved clockwise
away from the full "COOL" position, the temperature
valve moves away from the air inlet to the heater core
assembly to allow some air to flow through it. The farther
the temperature control is rotated clockwise, the more the
temperature valve is turned away from the heater cqre air
inlet and the greater the airflow through the heater core
assembly. Heating a greater proportion of the total airflow
in this manner results in a warmer discharge of air becaus.e
the heated and unheated airflows join and are mixed
together thoroughly beyond the heater core.
When the temperature lever is rotated fully clock-
wise to the full "WARM" position, the temperature valve
blocks off the passage that allows air to bypass the heater
core assembly and causes all of the airflow to pass
through the heater core assembly.
Bi-Level Valve
Figure 3
The bi-level valve (8) at its "at rest" (no vacuum)
position, seats against the upper and lower mode valve (9)
and the heater and air conditioning evaporator module
assembly (11). The bi-level valve (8) can be opened by
either the bi-level valve vacuum actuator assembly or the
upper and lower mode valve vacuum actuator assembly.
When opened by the bi-level valve vacuum actuator
assembly, as in "BI-LEVEL A/C" mode air will exit the
instrument panel outlets, floor outlets and a small amount
will exit the defroster outlets.
When the bi-level valve (8) is opened by the upper
and lower mode valve vacuum actuator assembly, as in
''MAX" A/C, normal "A/C" and "VENT" modes both
the upper and lower mode valve (9) and the bi-level valve
(8) move at the same time, directing all airflow through
the instrument panel outlets.
1B1·6 MANUAL CONTROL AIR CONDITIONING
Upper and Lower Mode Valve
Figure 3
The upper and lower mode valve (9), in its "at rest"
(no vacuum) position, seats against the evaporator module
assembly. The upper and lower mode valve (9), when
opened by the upper and lower mode valve actuator
assembly, will also move the bi-level valve (8) at the same
time. When the upper and lower mode valve (9) is opened,
as in "MAX" A/C, normal "A/C" and "VENT" modes
all air is directed to the instrument panel outlets.
Heater and Defrost Valve
Figure.3
The heater and defrost valve (7) is operated by a
three-position heater and defrost vacuum actuator assem-
bly. At its "at rest" (no vacuum applied to either side)
position, the heater and defrost valve (7) is positioned to
allow airflow through both the floor outlets and defroster
outlets, as when in "DEFROST BLEND" mode. During
the "DEFROST" mode, vacuum is applied to one side of
the heater and defrost vacuum actuator assembly, causing
the heater and defrost valve (7) to direct all airflow to the
defroster outlets. A small passage within the heater and air
conditioning evaporator module assembly ( 11) will allow
some air to bleed out the floor outlets. During the
"HEATER" mode, vacuum is applied to the opposite side
of the heater and defrost vacuum actuator assembly caus-
ing the heater and defrost valve (7) to direct all airflow to
the floor outlets with a small bleed to the defroster outlets.
Ducts and Outlets
Figures 4 and 5
There are five adjustable high-level outlets in the
instrument panel assembly, three near the center and one
at each extreme end of the panel assembly. In addition,
there are two side window defrost outlets, one at each end
of the instrument panel upper trim pad assembly. All
seven outlets are fed by the air distributor assembly.
Heated or cooled air can be directed to the wind-
shield assembly through the air distributor assembly and
through the floor air outlet duct.
Ventilation
Figure 7
The air distribution system provides fresh air ven-
tilation for the passenger compartment in all operating
modes. A small amount of the air circulated within the
passenger compartment in the "MAX" A/C mode is
taken from outside the vehicle, and all of the air circulated
in the other modes is from outside. Even in the "OFF"
mode, fresh outside air is forced into the air distribution
system by the forward movement of the vehicle.
After being warmed or cooled to the desired tem-
perature, the air is discharged from the outlets appropriate
to the selected operating mode. When all windows are
closed, the addition of outside air builds a slight positive
pressure within the passenger compartment. The pressure
forces stale air to leave the vehicle through a pressure
relief valve assembly, mounted to the left side quarter
panel, behind the rear fascia after it has circulated through
the passenger compartment.
REFRIGERATION SYSTEM
Figure 8
The refrigeration system cools the air flowing
through the air distribution system during air conditioning
operation. It also operates when the "DEFROST" or
"DEFROST BLEND" mode is selected, dehumidifying
the air to aid in fog removal from the windshield assem-
bly. Refrigeration system components and their functions
are as follows:
• Refrigerant circulates through the refrigeration
system to absorb heat from the air being cooled, and
to give off the heat to the air outside the vehicle. The
refrigerant also carries a polyalkylene glycol (PAO)
refrigerant oil throughout the system, primarily to
lubricate parts of the compressor assembly (28).
• An engine-driven compressor assembly (28) pumps
the refrigerant through the refrigeration system.
• A condenser assembly (29) cools the refrigerant in
the same way that the engine cooling system radiator
assembly cools the engine coolant.
• A receiver dehydrator assembly (30) dries and filters
the refrigerant. It also separates the liquid and the
vapor to provide only liquid to the thermostatic ·
expansion valve assembly.
• Lines (metal tubes and nylon-core composite hoses)
and leak-resistant connectors join the compressor
assembly (28), condenser assembly (29), receiver
dehydrator assembly (30), evaporator (3) and other
components to provide a closed-loop circuit for the
refrigerant.
• The A/C refrigerant pressure sensor assembly (26)
attached to the air conditioning evaporator line and
senses refrigerant pressure on the air conditioning
system high side. The purpose of the A/C refrigerant
pressure sensor assembly (26) is to inform the PCM
of high side refrigerant pressure status so the PCM
can disable the compressor assembly (28) before
high side pressure becomes too high.
• The thermostatic expansion valve assembly (31)
lowers the pressure of the refrigerant from the
receiver dehydrator assembly (30) by restricting the
flow. This prepares the refrigerant to pick up heat.
• An evaporator (3) in the path of the airflow through
the air distribution system absorbs heat from the
moving air and passes it on to the refrigerant inside
the core of the evaporator (3). This causes the refrig-
erant to boil and leave the evaporator (3) as a vapor.
• The air conditioning evaporator temperature sensor
assembly (25) mounted to the heater and air condi-
tioning evaporator module assembly has a probe
inserted into the evaporator (3) which measures
 MANUAL CONTROL AIR CONDITIONING 181·7

60

60

18

53

11

11 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING

EVAPORATOR
12 DUCT, INSTRUMENT PANEL CENTER AIR OUTLET
13 SCREW, INSTRUMENT PANEL CENTER AIR OUTLET
DUCT
18 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
19 DUCT, SIDE WINDOW DEFOGGER OUTLET (LEFT SIDE)
21 DUCT, INSTRUMENT PANEL CENTER AIR OUTLET
23 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
(RIGHT SIDE)
50 GRILLE, SIDE WINDOW DEFOGGER OUTLET
52 OUTLET, INSTRUMENT PANEL CENTER AIR
53 SCREW, AIR DISTRIBUTOR DUCT
54 SCREW, FLOOR AIR OUTLET DUCT
55 DUCT, FLOOR AIR OUTLET
56 SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
DUCT
57 OUTLET, INSTRUMENT UPPER OUTER AIR
58 OUTLET, INSTRUMENT PANEL LOWER OUTER AIR
60 CARRIER ASSEMBLY, INSTRUMENT PANEL
61 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
(LEFT SIDE)
62 OUTLET, INSTRUMENT PANEL CENTER AIR
66 PANEL ASSEMBLY, INSTRUMENT PC1002-1B1-F-RP

Figure 4 -Air Ducts and Outlets - (Chevrolet)

181-8 MANUAL CONTROL AIR CONDITIONING

11 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING

EVAPORATOR
18 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
21 /DUCT, SIDE WINDOW DEFOGGER OUTLET (LEFT SIDE)
23 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
50 GRILLE, SIDE WINDOW DEFOGGER OUTLET
51 OUTLET, INSTRUMENT PANEL OUTER AIR
52 OUTLET, INSTRUMENT PANEL CENTER AIR
53 SCREW, AIR DISTRIBUTOR DUCT
54 SCREW, FLOOR AIR OUTLET DUCT
55 DUCT, FLOOR AIR OUTLET
56 SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
DUCT
60 CARRIER ASSEMBLY, INSTRUMENT PANEL

PCZ002-181·F·RP

Figure 5 - Air Ducts and Outlets - (Pontiac)

 MANUAL CONTROL AIR CONDITIONING 181·9

B MULTl-CONNECTOR
C TO VACUUM SOURCE
32 ACTUATOR ASSEMBLY, HEATER AND DEFROST
c VACUUM
36
33 ACTUATOR ASSEMBLY, Bl-LEVEL VACUUM
37 34 ACTUATOR ASSEMBLY, UPPER AND LOWER MODE
VACUUM
35 ACTUATOR ASSEMBLY, AIR INLET VACUUM
36 VALVE, CONTROL ASSEMBLY VACUUM SELECTOR
37 TANK, VACUUM
38 VALVE, VACUUM CHECK

34 32 33 35

+ 38

P G Y B
U R E R L
R E L E A
P E L D C
L N O K
E W

PC0002-1B1-F-RP

Figure 6 - Vacuum Circuit Diagram

ature so the compressor can be disabled before the

evaporator (3) freezes.

24
A PLENUM AREA
24 VALVE ASSEMBLY, PRESSURE RELIEF
PC1003·1B1-F-RP
Figure 7 - Ventilation Airflow (Typical)
evaporator temperature and sends a signal to the
PCM. Within the probe is a thermistor which varies
resistance according to temperature, as temperature
increases, thermistor resistance decreases. The pur-
pose of this evaporator temperature sensor assembly
(25) is to inform the PCM of the evaporator temper-
Refrigerant-134a
CAUTION: Avoid breathing A/C Refrig·
erant-134a and lubricant vapor or mist.
Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C
system, use service equipment certi-
fied to meet the requirements of SAE
J221 O (R·134a recycling equipment). If
accidental system discharge occurs,
ventilate work area before resuming
service. Additional health and safety
information may be obtained from
refrigerant and lubricant manufacturers.
Like the coolant in the engine cooling system, the
refrigerant is the substance in the air conditioning system
that absorbs, carries and then releases heat. Although
various substances are used as refrigerants in other types
of refrigeration systems, past automotive air conditioning
systems used a type called Refrigerant-12 (R-12).
181-10 MANUAL CONTROL AIR CONDITIONING
This vehicle uses a new type of refrigerant called
Refrigerant-134a (R-134a). It is a non-toxic, non-flam-
mable, clear colorless liquefied gas.
While the R-134a A/C system is very similar to an
R-12 A/C system, the differences in the refrigerant, lubri-
cants, and service equipment are important.
NOTICE: R-134a refrigerant is not compatible with
R-12 refrigerant in an air conditioning system. R-12
in a R-134a system will cause compressor failure,
refrigerant oil sludge or poor air conditioning
system performance.
Refrigerant-134a carries a charge of a special lubri-
cating oil, polyalkylene glycol (PAG) refrigerant
oil. GM PAG refrigerant oil will have a slight
blue tint. The oil is hydroscopic (absorbs water from
the atmosphere) and should be stored in closed
containers.
Use only polyalkylene glycol (PAG) synthetic
refrigerant oil fot internal circulation through the
R-134A A/C system and only mineral base 525
viscosity refrigerant oil on fittings threads and
0-rings. If lubricants other than those specified are
used, compressor failure and/or fitting seizure is
likely to occur.
Compressor Assembly
The compressor assembly (28) is belt driven from
the engine crankshaft through the compressor clutch
pulley. The compressor pulley rotates without driving the
compressor shaft until an electromagnetic clutch coil is
energized. When voltage is applied to energize the clutch
coil, the clutch plate and hub assembly is drawn rearward
toward the pulley. The magnetic force locks the clutch
plate and pulley together as one unit to drive the com-
pressor shaft.
28
29
30
A PROBE, AIR CONDITIONING EVAPORATOR TEMPERATURE
SENSOR
3 EVAPORATOR, AIR CONDITIONING
25 SENSOR ASSEMBLY, AIR CONDITIONING EVAPORATOR
TEMPERATURE
26 SENSOR ASSEMBLY, AIR CONDITIONING REFRIGERANT
PRESSURE
Figure 8 - Refrigeration System Schematic
As the compressor shaft is driven, the compressor
assembly (28) compresses the low-pressure refrigerant
vapor from the evaporator into a high-pressure, high-
temperature vapor. Carried with the refrigerant is the
refrigerant oil which is used to lubricate the compressor
assembly (28).
The compressor assembly (28) has a unique lubrica-
tion system. The crankcase-suction bleed is routed
through the rotating wobble-plate for lubrication of the
wobble-plate bearing. The rotation acts as an oil separator,
which removes some of the oil from the crankcase-suction
bleed, rerouting it to the crankcase where it can lubricate
the compressor mechanism.
Up to 118 ml (4 fluid ounces) of oil can collect in the
crankcase. Therefore, it is important when replacing a
compressor assembly (28) that the oil in the old compres-
sor crankcase be drained and measured (discard after
recording amount).
All replacement compressor assemblies from ser-
vice parts will have 237 ml (8 fluid ounces) of oil in the
crankcase. The oil must be drained and retained. Then
replace the oil in the same amount as previously recorded
from the old compressor assembly. For compressor
assembly overhaul, refer to SECTION 1D2.
Condenser Assembly
The high-pressure refrigerant line from the compres-
sor assembly (28) goes to the condenser assembly (29).
The condenser assembly (29), is made up of coils which
carry hot refrigerant vapor routed from the compressor
assembly (28). Thin cooling fins on the coils transfer heat
to the air passing through the condenser assembly (29).
This cools the high-pressure refrigerant vapor and causes
it to condense into a high-pressure liquid.
Thermostatic Expansion Valve Assembly
The thermostatic expansion valve assembly (31)
controls the flow of refrigerant in the air conditioning
3
31
25
28 COMPRESSOR ASSEMBLY, AIR CONDITIONING
29 CONDENSER ASSEMBLY, AIR CONDITIONING
30 RECEIVER DEHYDRATOR ASSEMBLY, AIR CONDITIONING
31 VALVE ASSEMBLY, AIR CONDITIONING THERMOSTATIC
EXPANSION
RC0002·1B1-F-RP

system. The valve assembly (31) is a mechanical device
and does not control compressor assembly cycling. The
valve assembly (31) replaces the orifice tube used in the
CCOT air conditioning systems. It functions by sensing
pressure and temperature on the low side of the system
and then meters the high side of the system to achieve
optimal refrigeration performance.
Evaporator
Air passing through the evaporator (3) gives off
some of its heat to the evaporator core fins when the
refrigeration system is operating. Refer to "Air Distri-
bution System" in this section. The heat is conducted
through the thin metal walls of the evaporator core to the
low-pressure liquid refrigerant flowing through the
evaporator core tubes, causing the refrigerant to boil and
vaporize. The refrigerant leaves the evaporator as a low-
pressure vapor, carrying off the hear it absorbed from the
evaporator surfaces.
Receiver Dehydrator Assembly
The receiver dehydrator assembly (30) is a sealed
container that serves as a refrigerant storage container. A
bag of desiccant (a moisture absorbing material) in the
base of the receiver dehydrator assembly (30) collects and
holds any traces of moisture in the refrigerant that could
otherwise create problems such ,,s corrosion or freezi11g in
.the ,refrigeration system. · engine assembly is under a heavy load .
Recent improvement in refrigerant hose materials
and the increased use of metal lines have reduced the
chances for entry of moisture into the refrigerant, and an
improvement in desiccant has increased its moisture-
holding capacity. As a result, the receiver dehydrator
assembly (30) should be replaced only if leaking as a
result of p~rforation, a damaged 0-ring seat or damaged
threads, or 1f the system has been opened to outside air for
an extended period.
DIAGNOSIS
FUNCTIONAL TEST
Figure 9
The following operational test sequence will aid in
determining whether the air conditioning electrical, air,
vacuum and refrigeration systems are working properly.
Temperature of the air should be at least 16°C (60°F).
The air conditioning system can not be properly tested
unless it is at least this warm.
The engine should be started and allowed to idle for
about 20 minutes or until the engine cooling system
thermostat is open.
Perform steps 1-9 on Figure 9 and compare vehicle
response to the normal system response shown on the
,chart. If vehicle does not respond correctly during any of
these steps, begin diagnosis as noted below:
• Insufficient heating. Refer to SECTION IA.
• Insufficient _cooling. Refer to "Insufficient
Cooling Check" in this section.
• Improper air delivery. Refer to "Improper Air
Delivery" in this section.
MANUAL CONTROL AIR CONDITIONING 181·11
• Blower motor assembly inoperative or incor-
rect speed. Refer to SECTION 8A.
INSUFFICIENT COOLING CHECK
Figure 10
.. T? help ~!iminate any possible mis-diagnosis,
funct10nal test must be performed first. Insufficient
cooling could be caused by one of several components or
systems such as the air conditioning compressor assem-
bl~, refrigeration system, ajr delivery system or power-
!rall) :C?ntrol i:nodule (PCM). Proper diagnosis of
ms~ff~c1ent co?lmg becaus~ the air conditioning compres-
s.or 1s moperat1ve must begm with an "on board diagnos-
tic system check" of the PCM. Refer to SECTION 6E3.
IMPROPER AIR DELIVERY
Figures 11 and 12
System Description
This system is operated completely by vacuum,
except for the electrically powered blower motor assem-
bly (5). Engine vacuum is routed through a vacuum check
valve (38) then to the control assembly vacuum selector
valve (36) and to the vacuum tank (37). The vacuum
check valve (38) is used to prevent vacuum loss due to
heavy acceleration or steep uphill traveling when the
When vacuum is applied to a vacuum actuator
a~sembly, the vacuum actuator assembly will apply suffi-
cient force to overcome any resistance due to air flow
from the blower motor assembly (5) and from the actuator
internal spring, and move the air valve (door) to its correct
position.
Preliminary Inspection
1. Inspect vacuum lines at engine assembly and vac-
uum check valve (38) for proper connection.
2. Disconnect vacuum line leading to engine assembly
at vacuum check valve (38). Start engine assembly
and check for presence Qf .vacuum, if no vacuum is
present, replace vacuum line.
3. Disconnect vacuum line foading to vacuum tank
(37) at vacuum check valve (38). Using hand vac-
uum pump, apply vacuum to vacuum line leading to
vacuum tank (37). If vacuum does not hold, replace
vacuum line and/or vacuum tank (37).
4. Disconnect vacuum line leading to control assembly
(l) at vacuum check valve (38). Apply vacuum to
check valve port. If vacuum does not hold, replace
vacuum check valve (38).
5. Quickly rotate temperature control from "FULL
COLD" to "FULL HOT" several times. Listen for
temperature valve (6) to seat in both positions. If the
sound indicates that the.temperature valve (6) is not
fully seating or opening, check the mechanical
linkage between the control mechanism and the
temperature valve (6).
6. Ma.ke sure all six vacuum line seals are positioned
correctly at vacuum line multi-connector under
right-hand sound insulator panel assembly.
7. Perform diagnosis. Refer to Figure 12.
181 ~12 MANUAL CONTROL AIR CONDITIONING

HEATER AND AIR CONDmONING

SYSTEM RESPONSE
CONTROL ASSEMBLY semNG

TEMPERATURE BLOWER MOTOR BLOWER MOTOR

MODE CONTROL CONTROL LEVER ASSEMBLY ASSEMBLY HEATER A/C DEFROSTER OUTlET
STEP lEVERSmlNG sm1NG SWITCH SPEED OUTLETS OUTLETS OUTLETS COMMENTS TEMPERATURE

OFF COLD LOW OFF NOAIR FLOW NOAIR FLOW NOAIR FLOW AMBIENT
'
2 MAXA/C COLD LOW LOW· NOAIR FLOW AIRFLOW NO AIRFLOW A,E AT LEAST ll'C (2D'A COOLER THAN
AMBIENT

3 MAXA/C COLD LOW TD HIGH LOW TO HIGH NO AIRFLOW AIRFLOW NO AIRFLOW B,E AT LEAST ll'C (2D'FI COOLER THAN
AMBIENT

4. NORMALA/C MID-RANGE HIGH HIGH NO AIRFLOW AIRFLOW NO AIR FLOW A SLIGHTLY WARM

5 Bl-LEVEL A/C COLD HIGH HIGH AIRFLOW AIRFLOW MINIMUM AIR A AT LEAST ll'C (2D'Fl COOLER THAN
FLOW AMBIENT

6 VENT COLD HIGH HIGH NOAIR FLOW AIRFLOW NO AIRFLOW A AMBIENT

7 HEATER HOT HIGH HIGH AIRFLOW NO AIRFLOW MINIMUM AIR A,C.D ATLEAST49'C (12D'Fl
FLOW

8 DEFROSTER HOT HIGH HIGH AIR FLOW NO AIR FLOW AIRFLOW A,D AT LEAST 49'C (120'Fl
BLEND

9 DEFROST HOT HIGH HIGH MINIMUM AIR NO AIRFLOW AIRFLOW A. D ATLEAST49'C (12D'A
FLOW

A ENGAGEMENT OF DETENT MUST BE FELT IN EACH MODE CONTROL LEVER SETTING.

B A NOTICEABLE BLOWER MOTOR ASSEMBLY SPEED INCREASE MUST OCCUR FROM LOW, MEDIUM LOW, MEDIUM HIGH AND HIGH.
C TEMPERATURE LEVER MUST TRAVEL FROM FULL COLD TO FULL HOT.
D AIR FLOW MUST ALSO BE PRESENT AT SIDE WINDOW DEFOGGER OUTLETS.
E INSTRUMENT PANEL OUTLETS MUST HOLD THEIR POSITION DURING HIGH BLOWER MOTOR ASSEMBLY SPEED BUT SHOULD BE MOVEABLE BY HAND.
RC0003-1B1·F·RP

Figure 9 - Functional Test

. PERFORM ON BOARD DIAGNOSTIC SYSTEM CHECK. REFER TO

. SECTION 6E3.
ARE ANY PCM DIAGNOSTIC TROUBLE CODES DISPLAYED?

. I .
I NO
I
I I YES
I
I
. OPEN DOORS AND HOOD TO NEUTRALIZE
VEHICLE INTERNAL TEMPERATURE WITH SHOP
REPAIR DIAGNOSTIC TROUBLE
CODES. REFER TO SECTION 6E3.

. TEMPERATURE.
INSTALL J 39183-C (R-134a MANIFOLD GAGE SET)
OR J 39500-GM (ACR 4 SYSTEM) ONTO VEHICLE.

. REFER TO SECTION 1B.

IS LOW SIDE STATIC (ENGINE NOT RUNNING)
PRESSURE ABOVE 310 kPa (45 psi)?

. I
I NO
. I I YES I
. LEAK TEST NC SYSTEM USING .
I

PERFORM "AIR CONDITIONING

. J 39400. REFER TO SECTION 1B.
AFTER REPAIRS HAVE BEEN
MADE CHARGE SYSTEM WITH
PERFORMANCE TEST" IN THIS
SECTION.
0.9 kg (2 POUNDS) OF R-134a REFER

. TO SECTION 1B.
PERFORM "AIR CONDITIONING
PERFORMANCE TEST" IN THIS
SECTION.
RC0010-1B1·F-RP

Figure 10 - Insufficient Cooling Check

 MANUAL CONTROL AIR CONDITIONING 181-13

MODE CONTROL VACUUM

VALVE POSITIONS

1 OFF
2 MAX NC
3 NORMAL NC
38
4 Bl-LEVEL NC
5 VENT
6 HEATER
7 HEATER/DEFROST BLEND
8 DEFROSTER

36

_______ J .
1--------1

Y : : 1 ~GREEN

32 ~ 35

I
I

A TO WINDSHIELD DEFROST OUTLETS 33 ACTUATOR ASSEMBLY, Bl-LEVEL VACUUM

B TO SIDE WINDOW DEFROST OUTLETS 34 ACTUATOR ASSEMBLY, UPPER AND LOWER MODE
C TO FLOOR OUTLETS VACUUM
D TO INSTRUMENT PANEL OUTLETS 35 ACTUATOR ASSEMBLY, AIR INLET VACUUM
E FROM PLENUM AREA (OUTSIDE AIR) 36 VALVE, CONTROL ASSEMBLY VACUUM SELECTOR
F FROM INSIDE VEHICLE (RECIRCULATED AIR) 37 TANK, VACUUM
G TO ENGINE ASSEMBLY (VACUUM SOURCE) 38 VALVE, VACUUM CHECK
H PARTIALLY OPEN BY DESIGN
J TEMPERATURE CONTROL
1 CONTROL ASSEMBLY, HEATER AND AIR
CONDITIONING
3 EVAPORATOR, AIR CONDITIONING
4 CORE ASSEMBLY, HEATER
5 MOTOR ASSEMBLY, BLOWER
6 VALVE, TEMPERATURE
32 ACTUATOR ASSEMBLY, HEATER AND DEFROST
VACUUM
PC0006-1B1·F-RP

Figure 11 - Improper Air Delivery Vacuum Schematic

181-14 MANUAL CONTROL AIR CONDITIONING

.. PERFORM PRELIMINARY INSPECTION .

. SET MODE SELECTOR VALVE IN THE "OFF" POSITION .

DISCONNECT VACUUM LINE AT CHECK VALVE .
USING A HAND VACUUM PUMP, APPLY VACUUM
TO VACUUM LINE LEADING TO MODE

. SELECTOR VALVE.
DOES VACUUM HOLD?
I
I I

I NO
I
I I YES
I
I
CHECK BLACK VACUUM
LINE LEADING TO MODE
. APPLY VACUUM TO VACUUM LINE LEADING TO ,
MODE SELECTOR VALVE AND CHECK IN EACH SETTING
SELECTOR VALVE. IF LINE IS
CONNECTED AND WORKING
PROPERLY REPLACE MODE
. ("MAX" A/C TO "DEFROST").
DOES VACUUM HOLD IN EVERY SETTING?

SELECTOR VALVE.
l
I I

I YES
I I NO I
. DISCONNECT VACUUM LINE MULTl-CONNECTOR
I
. I
DISCONNECT VACUUM LINE MULTl-CONNECTOR

. AT MODE SELECTOR VALVE.

TURN IGNITION SWITCH TO "RUN" POSITION
. AT MODE SELECTOR VALVE.
APPLY VACUUM TO EACH LINE AT MULTI-
CONNECTOR CONTROLLED BY THE MODE SELECTOR
.. (ENGINE NOT RUNNING).
SELECT "HIGH" BLOWER MOTOR ASSEMBLY SPEED . VALVE AT A SETTING WHERE VACUUM DID
APPLY VACUUM TO EACH VACUUM LINE INDIVIDUALLY
(EXCEPT BLACK AND ORANGE LINE) AND CHECK
. NOT HOLD.
IS A VACUUM LEAK PRESENT AT ONE OR
FOR AIR FLOW AT THE PROPER OUTLETS. MORE LINES?
I
. REFER TO "DIAGNOSTIC AID CHART" BELOW. I
DOES AIR FLOW AT PROPER OUTLETS?
I YES I I NO
-. I
I
•
YES
I
I

I NO I
IAND /OR VACUUM ACTUATOR.
I

REPAIR OR REPLACE VACUUM LINEI I REPLACE MODE SELECTOR

VALVE.
I I

. APPLY VACUUM TO
REPAIR OR REPLACE ACTUATOR
LINKAGE AND/OR AIR VALVE (DOOR).
ORANGE VACUUM

. LINE.
DOES BLOWER MOTOR
ASSEMBLY AIR FLOW NOISE
INCREASE?
I
I l DIAGNOSTIC AID CHART

I YES NO
l APPLY VACUUM TO: AIR FLOW SHOULD BE DIVERTED TO:
I I RED VACUUM LINE INSTRUMENT PANEL OUTLETS ONLY
SIDE WINDOW DEFOGGER AND FLOOR

I
SYSTEM REPAIR OR REPLACE AIR YELLOW VACUUM LINE
OK. INLET VACUUM ACTUATOR OUTLETS
LINKAGE AND/OR AIR PURPLE VACUUM LINE SIDE WINDOW DEFOGGER, FLOOR AND
INLET VALVE. INSTRUMENT PANEL OUTLETS
GREEN VACUUM LINE WINDSHIELD AND SIDE WINDOW
DEFOGGER OUTLETS
ORANGE VACUUM LINE BLOWER MOTOR ASSEMBLY AIR NOISE
INCREASE
NO VACUUM LINES (ALL ALL OUTLETS EXCEPT INSTRUMENT PANEL
LINES VENTED TO
ATMOSPHERE)

PC0007·1B1·F·RP

Figure 12 - Improper Air Delivery Diagnostic Chart


AIR CONDITIONING PERFORMANCE TEST
Figures 13, 14 and 15
Tools Required:
J 39500 ACR4 System or
J 39183-C R-134a Manifold Gauge Set
J 6742-03 Precision Thermometer (or Equiva-
lent)
Before performing the air conditioning performance
test, a functional test should be made to assure that the air
distribution system valves are functioning properly to
route all the air passing through the evaporator to the out-
lets. Refer to "Functional Test" in this section.
Performance testing provides a measure of air
conditioning system operating efficiency by measuring
and comparing pressures at the high-pressure and low-
pressure sides of the refrigeration system, the temperature
of the air being discharged into the passenger compart-
ment, and the evaporator temperature.
Start with the air conditioning performance test in
Figure 13, and compare vehicle air conditioning system
performance with the chart in Figure 14. If system per-
formance is not within specifications, proceed to the
refrigeration system diagnostic chart in · Figure 15 to
pinpoint the problem.
ON-VEHICLE SERVICE
BLOWER MOTOR ASSEMBLY RELAY
The blower motor assembly relay is located in the
underhood electrical center. Refer to the label located
under the underhood electrical center cover for relay iden-
tification.
AIR CONDITIONING COMPRESSOR RELAY
The air conditioning compressor relay is located in
the underhood electrical center. Refer to the label located
under the underhood electrical center cover for relay iden-
tification.
AIR CONDITIONING EVAPORATOR
TEMPERATURE SENSOR ASSEMBLY
Figures 16 and 17
!++I Remove or Disconnect
1. Heater core assembly. Refer to SECTION lA.
2. Evaporator temperature sensor assembly electrical
connector.
3. Evaporator temperature sensor assembly probe from
evaporator.
• Use needle-nose pliers to pull probe straight
out.
4. Evaporator temperature sensor assembly (25) from
heater and air conditioning evaporator module
assembly (11 ).
• Remove grommet with evaporator temperature
sensor assembly (25).
MANUAL CONTROL AIR CONDITIONING 181·15
!++I Install or Connect
1. Evaporator temperature sensor assembly (25) to
heater and air conditioning evaporator module
assembly (11 ).
• Seat grommet in heater and air conditioning
module assembly (11 ).
[I] Important
• Do not insert probe into existing hole. Use
alternate location near the existing hole shown
in the condensate screen and insert probe
straight into evaporator. If probe is not inserted
straight into evaporator, incorrect evaporator
temperature reading may result, causing evap-
orator freeze-up.
2. Evaporator temperature sensor assembly probe
straight into evaporator in new location near pre-
vious location.
3. Evaporator temperature sensor assembly electrical
connector.
4. Heater core assembly. Refer to SECTION IA.
AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR ASSEMBLY
Figure 18
!++I Remove or Disconnect
1. Electrical connector at sensor assembly (26).
2. Sensor assembly (26) and seal (39).
• Sensor assembly (26) is mounted on a
Schrader® type valve so it is not necessary to
discharge the refrigeration system.
• Discard seal (39).
!++I Install or Connect
1. New seal (39) to sensor assembly fitting.
• Coat seal (39) with mineral base 525 viscosity
refrigerant oil.
2. Sensor assembly (26).
l~I Tighten
• Sensor assembly (26) to 6 N•m (53 lb. in.).
3. Electrical connector to sensor assembly (26).
AIR CONDITIONING EVAPORATOR
Figures 16, 17 and 19
!++I Remove or Disconnect
1. Discharge refrigerant into a recovery station. Refer
to SECTION 1B.
2. Right-hand instrument panel sound insulator panel
assembly. Refer to SECTION 8C.
3. Heater hoses at heater core assembly. Refer to
SECTION lA.
181-16 MANUAL CONTROL AIR CONDITIONING

. QUICKLY ROTATE TEMPERATURE KNOB FROM "FULL

COLD" TO "FULL HOT" AND BACK TO "FULL COLD".
LISTEN FOR TEMPERATURE VALVE TO SEAT IN BOTH
"FULL HOT" AND "FULL COLD" POSITION (A "THUD"
. NOISE SHOULD BE HEARD).
DOES TEMPERATURE VALVE SEAT IN BOTH POSITIONS?
I
I I

I YES
T
I I NO
I
l
..
. DISCONNECT TEMPERATURE CABLE AT HEATER
CLOSE DOORS AND WINDOWS .
SELECT "FULL COLD, MAX NC" MODE AND "HIGH" . AND EVAPORATOR MODULE ASSEMBLY.
ROTATE TEMPERATURE LEVER FROM "FULL HOT" TO

. BLOWER MOTOR SPEED.

PLACE VEHICLE IN PARK (AUTOMATIC TRANSMISSION . "FULL COLD" WHILE WATCHING CABLE END.
DOES CABLE END ROTATE WHEN TEMPERATURE LEVER
ASSEMBLY) AND SET PARKING BRAKE (MANUAL IS ROTATED?

..
OR AUTOMATIC TRANSMISSION ASSEMBLY).
START ENGINE ASSEMBLY. I
DOES COMPRESSOR ENGAGE? I I

I NO
I
I I YES
I
I
I I REPAIR OR REPLACE • MANUALLY ROTATE TEMPERATURE
TEMPERATURE CABLE
I YES
I NO
I
I AS NECESSARY.
VALVE BY HAND.
• DOES TEMPERATURE VALVE SEAT IN BOTH
"FULL HOT" AND "FULL COLD"
. I
INSTALL TECH 1 WITH 93 REFER TO SECTION 6E3
POSITION WITH APPROXIMATELY 50 DEGREES
OF TRAVEL?
.. POWERTRAIN CARTRIDGE.
SELECT "FIELD SERVICE" MODE .
FOR NC COMPRESSOR CIRCUIT
DIAGNOSIS
I
ENERGIZE COOLING FANS USING•
.
.. TECH 1.
CHECK COOLING FAN OPERATION:
V-6 COOLING FAN OPERATING .
I YES I I
~

NO I
I I
I I

• V-8 BOTH COOLING FANS

REPLACE TEMPERATURE
. OPERATING.
ARE COOLING FAN(Sl OPERATING?
CABLE.
REPAIR OR REPLACE
HEATER AND EVAPORATOR
MODULE ASSEMBLY.
I
I I

I NO
I
I YES
I

• REPAIR COOLING FAN

CIRCUIT. REFER TO
SECTION 6E3-C12.
. INSTALLJ 39183-C (R-134a MANIFOLD GAGE SET) OR
. J 39500-GM (ACR4 SYSTEM) ONTO VEHICLE. REFER TO SECTION 1B.
INSTALL J 6742-03 (PRECISION THERMOMETER) OR EQUIVALENT
INTO CENTER INSTRUMENT PANEL OUTLET.
• WITH VEHICLE RUNNING IN "MAX NC" MOOE, "FULL CODE"
AND "HIGH" BLOWER MOTOR SPEED FOR 2 MINUTES AT
ENGINE IDLE, RECORD THE FOLLOWING INFORMATION:
- NC SYSTEM HIGH AND LOW SIDE PRESSURE
- EVAPORATOR TEMPERATURE USING TECH 1
.. - AMBIENT TEMPERATURE AND HUMIDITY
COMPARE WITH AIR CONDITIONING PERFORMANCE CHART (FIGURE 14) .
IS VEHICLE NC PERFORMANCE WITHIN SPECIFICATIONS?

. I
I

NO
I
l I YES
I
I
REFER TO
"REFRIGERANT SYSTEM
I SYSTEM OK. I
DIAGNOSIS CHART"
IN THIS SECTION (FIGURE 15).

RC0004-1B1·F-RP

Figure 13 - Air Conditioning Performance Test

 MANUAL CONTROL AIR CONDITIONING 181-17

EVAPASSEMBLY
GAGE PRESSURES CENTER TEMP DISPLAYED
TEMPERATURE HUMIDITY LOW HIGH OUTLET TEMP ONTECH1

110 • 165 kPa 793-1310 kPa 3' • 9'C 1° • 6'C

21°. 27°C LESS THAN 50% (16 • 24 psi) (115·190psi) (38' • 48'F) (33' • 43'F)
145 • 200 kPa 793 • 1379 kPa 4' • 13'C 2°. 10·c
110· - 80°FI HIGHER THAN 50% (21 • 29 psi) (115 • 200 psi) (40° • 55°F) (35' - 50°F)

131 - 207 kPa 965 - 1482 kPa 3° - 13'C 1° -lO°C

27' - 33'C LESS THAN 50% (19 - 30 psi) (140 - 215 psi) (38' • 55°F) (33° - 50°F)
165 • 269 kPa 1034 • 1620 kPa 7° -18'C 4' - 16°C
(80' - 90'F) HIGHER THAN 50% (24 • 39 psi) (150 • 235 psi) (45' - 65°F) (40°. 60°FI

172 • 290 kPa 1138 - 1793 kPa 7° -17'C 4° - 14°C

33' - 38'C LESS THAN 40% (25 - 42 psi) (165 - 260 psi) (45° • 63°F) (40' • 58°F)
234 • 296 kPa 1276 - 1862 kPa 13° • 2o·c l0°- l8°C
1so· - 100°FI HIGHER THAN 40% (34 • 43 psi) (185 - 270 psi) (55° - 68°F) (50' - 65°F)

255- 296 kPa 1448 • 2000 kPa 12· • 18°C s· - 16°C

38°. 44·c LESS THAN 20% (37 • 43 psi) (210 - 290 psi) (53° • 64°F) (48° - 61°F)
262- 352 kPa 1517 • 2137 kPa 14· - 21·c 13·. 18°C
(100° - 110°F) HIGHER THAN 20% (38 - 51 psi) (220 • 310 psi) (58° - 70°F) (55° • 65°F)
PC0010-1B1·F·RP

Figure 14 - Air Conditioning Performance Chart

4. Instrument panel compartment. Refer to SECTION

8C.
5. Heater core assembly. Refer to SECTION lA.
6. Air conditioning evaporator temperature sensor
assembly. Refer to "Air Conditioning Evaporator
Temperature Sensor Assembly" in this section.
7. Temperature control cable assembly at temperature
valve case assembly. Refer to SECTION lA.
8. Bolts/screws (48) located in engine compartment
from temperature valve case assembly (42).
9. Temperature valve case assembly (42).
• Slide case assembly (42) downward to disen-
!++I Install or Connect
gage upper case clip.
• Remove from under the instrument panel
assembly.
10. Thermostatic expansion valve assembly. Refer to
SECTION lB.
rn Important
• This piece of material is required to keep con-
densate from draining inside vehicle.
12. Bolts/screws (41) retaining air conditioning evapo-
rator (3).
13. Air conditioning evaporator (3) from heater and air
conditioning module assembly (11).
• Slide evaporator (3) to the left, then pull out
through the opening enlarged in step 11.
1. Air conditioning evaporator (3) to heater and air
conditioning module assembly ( 11 ).
• If replacing old evaporator (3), transfer con-
densate screen to new evaporator (3).
• If replacing old evaporator (3), install new
evaporator core gasket in same position as

rn Important
• Remove perforated section of heater and air
conditioning evaporator module assembly as
one piece (it will be reused).
• Water can leak onto carpeting when doing this
procedure. It is recommended that a mat be
placed on passenger side floor.
11. Uslng a small hand saw, remove perforated section
of heater and air conditioning evaporator module
assembly (Figure 16).
original with appropriate adhesive.
• Insert evaporator (3) into module assembly
(11) through the opening enlarged during
removal, slide to the right until fully seated.
2. Bolts/screws (41) to air conditioning evaporator (3).
3. Refrigerant oil into evaporator (3), if necessary.
• If installing new evaporator (3), add 89 ml
(3 fluid ounces) of polyalkylene glycol (PAG)
synthetic refrigerant oil, GM P/N 12345923.
4. Thermostatic expansion valve assembly. Refer to
SECTION lB.
181·18 MANUAL CONTROL AIR CONDITIONING

PERFORM AIR CONDITIONING PERFORMANCE TEST BEFORE REFRIGERATION SYSTEM DIAGNOSIS

CONDITIONS

CENTER TECH1
OUTLET LOW SIDE HIGH SIDE EVAPORATOR POSSIBLE
TEMP PRESSURE PRESSURE TEMPERATURE FAULT CORRECTIVE ACTION

OK OR HIGH OK OR LOW OK ORLOW HIGHER LOW REFRIGERANT RECOVER, MEASURE AND RECHARGE A/C
CHARGE SYSTEM. REFER TO SECTION 1B.
RECEIVER AND CHECK FOR PRESSURE DIFFERANCE
DEHYDRATOR GREATER THAN 138 kPa (20 PSI) BETWEEN
ASSEMBLY TECH 1AND HIGH GAUGE, REPLACE
PLUGGED RECEIVER AND DEHYDRATOR ASSEMBLY.

DEBRIS PLUGGING CLEAN THERMOSTATIC EXPANSION

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

HIGHER HIGHER HIGHER HIGHER CONDENSQR AIR . CLEAN, REMOVE RESTRICTION.

RESTRICTION
CONDENSOR AIR INSTALL OR REPOSITION AIR CONTROL
RECIRCULATION BAFFLES.
HIGH REFRIGER- RECOVER, MEASURE AND RECHARGE A/C
ANT CHARGE SYSTEM. REFER TO SECTION 18.
TOO MUCH FLUSH A/C SYSTEM. REFER TO SECTION 18.
REFRIGERANT OIL
OK OK HIGH OK FAN PROBLEMS CHECK FLOW DIRECTION, RELAY, ETC.

OK OK ORLOW OK LOW CIRCUIT FAULT PERFORM A/C ELECTRICAL CIRCUIT TEST.

RC0005·1B1·f·RP

Figure 15 - Refrigeration System Diagnostic Chart

 MANUAL CONTROL AIR CONDITIONING 181·19

3 35
A B

~--- \ I I I I 'II I
~

-1 I I I ")..
I I I I I I I 'I
/ __ rs
I I
I
" 171

...... "~
' :: :: ~ 'I:
~ J
,-.........

,...
'- ......
7

)
l
\
......_ ...
i-- ...... ... ... '
......
I .........
I'"" I
L'-'-
'-'- I I 1
\
l
I
' I I/..... ,/.:.....II
I I\
v
... c..
,l I ...... t7v
...
'- '- '- j J
I /
, I / \ ......' 1::1.
1'
~

1~7 ~~""1 ~,,

\~*
\ I I I I v

11 D B
25
c

A SERVICE PROBE LOCATION

B AIR CONDITIONING EVAPORATOR TUBE PLATE
A PROBE C CONDENSATE SCREEN
B GROMMET D BARBS
C PERFORATION FOR AIR CONDITIONING EVAPORATOR RC0007-1B1·F-RP
REMOVAL
D SERVICE PROBE LOCATION Figure 17 - Air Conditioning Evaporator Temperature
3 EVAPORATOR, AIR CONDITIONING Sensor Assembly Installation
11 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING
EVAPORATOR
25 SENSOR ASSEMBLY, AIR CONDITIONING EVAPORATOR
TEMPERATURE
35 ACTUATOR ASSEMBLY, AIR INLET VACUUM
41 BOLT/SCREW, AIR CONDITIONING EVAPORATOR
26

RC000&-181-F-RP

Figure 16 -Air Conditioning Evaporator Temperature Sensor

Assembly
39
~
~
5. Apply sealer GM P/N 3012078 (do not use epoxy
glue) between evaporator (3) and evaporator upper
and lower case (44 and 45) just behind thermostatic
expansion valve assembly to prevent air entry from
the engine compartment into the passenger compart-
ment.
6. Position perforated section of heater and air condi- 63
tioning evaporator module assembly and use epoxy
glue to adhere it to module assembly. After epoxy
dries, use thumb to grade sealant on inside and out-
side to ensure water-tight seal. 26 SENSOR ASSEMBLY, AIR CONDITIONING REFRIGERANT
7. Temperature valve case assembly (42). PRESSURE
39 SEAL, AIR CONDITIONING REFRIGERANT PRESSURE
• Install from under instrument panel assembly. SENSOR
63 HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR AND
• Slide case assembly (42) upward into position CONDENSER
until upper clip engages. 64 TUBE, AIR CONDITIONING EVAPORATOR
8. Bolts/screws (48) to temperature valve case assem- RC0008·181-F-RP
bly (42). Figure 18 - Air Conditioning Refrigerant Sensor and
• Tighten bolts/screws (48) evenly to compress Cutoff Switch
flange seal.
181·20 MANUAL CONTROL AIR CONDITIONING

44

3 EVAPORATOR, AIR CONDITIONING

4 CORE ASSEMBLY, HEATER
25 SENSOR ASSEMBLY, AIR CONDITIONING EVAPORATOR
TEMPERATURE
41 BOLT/SCREW, AIR CONDITIONING EVAPORATOR
42 CASE ASSEMBLY, TEMPERATURE VALVE
43 CLAMP. HEA,TER CORE TUBE
44 CASE, AIR CONDITIONING EVAPORATOR UPPER
45 CASE, AIR CONDITIONING EVAPORATOR LOWER
46 CASE, AIR DISTRIBUTOR UPPER
47 COVER, HEATER AND AIR CONDITIONING EVAPORATOR
CASE
48 BOLT/SCREW, TEMPERATURE VALVE CASE ASSEMBLY
49 BOLT/SCREW, HEATER AND AIR CONDITIONING
EVAPORATOR CASE OVER
59 BOLT/SCREW, HEATER CORE TUBE CLAMP
65 CLAMP, AIR CONDITIONING EVAPORATOR
66 SEAL, HEATER PIPE
67 BRACKET, HEATER CORE ASSEMBLY
68 BOLT/SCREW, HEATER CORE ASSEMBLY

RC0009·1B1·f·RP

Figure 19 - Air Conditioning Evaporator and Components

 MANUAL CONTROL AIR CONDITIONING 181·21

9. Temperature control cable assembly at temperature 13. Heater hoses to heater core assembly. Refer to
valve case assembly. Refer to SECTION IA. SECTION IA.
10. Air conditioning evaporator temperature sensor 14. Right-hand instrument panel sound insulator panel
assembly. Refer to "Air Conditioning Evaporator assembly. Refer to SECTION 8C. _
Temperature Sensor Assembly" in this section.
11. Heater core assembly. Refer to SECTION IA. 15. Fill radiator and bleed cooling system. Refer to
SECTION6B.
12. Instrument panel compartment. Refer to SECTION
8C. 16. Refrigerant.

SPECIFICATIONS
GENERAL SPECIFICATIONS
A/C System 0-ring and Fitting Lubricant ............ Mineral Base 525 Viscosity Refrigerant Oil,
GM P/N 12301108 or equivalent
A/C System Internal Lubricant
(Including Compressor) ................. Polyalkylene Glycol (PAG) Synthetic Refrigerant Oil,
GM P/N 12345923 or equivalent
A/C System R-134a Capacity ........................................... 0.91 kg (2.0 lbs.)

COMPONENT TIGHTENING SPECIFICATIONS

Air Conditioning Compressor Low Pressure Cutout Switch Assembly ........... 6 N•m (53 lb. in.)
Air Conditioning Refrigerant Pressure Sensor Assembly ..................... 6 N•m (53 lb. in.)

SPECIAL TOOLS

2.

4.
J 39183-C

1. R-12 AND R-134a HALOGEN LEAK DETECTOR

2. AIR CONDITIONING REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING SYSTEM (ACR4 )
3. PRECISION THERMOMETER
4. R-134a MANIFOLD GAUGE SET PC0014-1B1-F-RP
 HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-1

SECTION 102

HD6/HR6-HE
AIR CONDITIONING COMPRESSOR
SERVICE OR UNIT REPAIR R-134a
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repairs.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.

CONTENTS
General Description ........................... 102-1 Major Compressor
Metric Thread Size Information ............... 1D2-3 Repair Procedures .......................... 1D2-8
Unit Repair .................................. 1D2-3 Compressor Shaft Seal Replacement ......... 1D2-8
Minor Compressor Seal Leak Detection ...................... I D2-8
Repair Procedures .......................... 1D2-3 Compressor Pressure Relief Valve .......... 102-10
Compressor Clutch Plate and Control Switches ........................ 102-11
Hub Assembly .......................... 1D2-3 Compressor Leak Testing . . . . . . . . . . . . . . . . . 102-11
Compressor Clutch Rotor and/or Bearing ...... 1D2-4 Bench-Check Procedures ............... 102-11
Compressor Clutch Coil . . . . . . . . . . . . . . . . . . . 1D2-7 Special Tools ........................... 102-12

GENERAL DESCRIPTION
The HD6/HR6-HE Automotive Conditioning Service compressors are supplied with either the control
Compressor and Clutch Assembly is a lightweight, six cylinder switches assembled in the rear head or a plug may be found
axial design consisting of three double ended pistons and where a control switch is required. If the service compressor
weighs 5.8 kg (12.7 lbs.) requires control switches, the plug may be removed from the
appropriate rear head switch cavity of the replaced compressor
CD and assembled as prescribed in this manual.

When servicing the compressor, keep dirt or foreign

[ ) WITHOUT TORQUE
CUSHION
ll) TORQUE
CUSHION
; Kerosene or equivalent and dried with dry air. When necessary
Fig. 1 Clutch Driver Designs
Although this compressor is the same for all vehicle
applications, there are differences in installations, mounting
brackets, pulleys, torque cushions and switches, none of which
will affect the following overhaul procedures.
There are two clutch driver designs for these
compressors. The clutch driver without a torque cushion and
the clutch driver having a thin torque cushion (Fig. I).
material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important for
proper service. The compressor connections and the outside of
the compressor should be cleaned before any "on vehicle"
repairs, or before removal of the compressor. The parts must be
kept clean at all times and any parts to be reassembled should
be cleaned with trichloroethane, naphtha, stoddard solvent,
to use a cloth on any part, it should oe of a non-lint producing
type.
The operations described below are based on bench
overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When a compressor is
removed from the vehicle for servicing, the amount of PAG
lubricant remaining in the compressor should be drained.
102-2 HD6/HR6-HE AIR CONDITIONING COMPRESSOR

0
1- CLUTCH DRIVER
/
2- ROTOR BEARING
RETAINER
3- PULLEY BEARING
4 - PULLEY
5- CLUTCH COIL
ASSEMBLY
6- SHAFT SEAL PARTS
7- PUMP ASSEMBLY
8- SWITCH 0-RING
9- SYSTEM CONTROL
SWITCH
{) o-
.. -0
!
10- HIGH PRESSURE

11 -
RELIEF VALVE
RETAINER RING SWITCH @J-A-4 (!]
12 - SUCTION/DISCHARGE
PORT SEALING
I.. . 'U ._..--@:]
WASHERS 0 } 0 0 ...,__,[ill

~ m_ _ _ _
13 - SPECIAL 134a SUCTION
PORT
----1
14 - SPECIAL 134a
DISCHARGE PORT
I

Compressor - Rear Head

As Viewed in Direction of Arrow "P:'

Fig. 2 Compressor Components - Disassembly

 HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-3
measured and recorded. This PAG lubricant should then be METRIC THREAD SIZE INFORMATION
discarded and an equal amount of new PAG lubricant added to 1. Compressor to mounting bracket bolts.
the compressor. Front M 10 x 1.5 - 6H
The service compressor is shipped with 240 ml (8 oz.) of Rear M8 x l.25-6H
PAG lubricant. This lubricant should be drained and retained
2. Suction-discharge port screw.
for use as replacement lubricant when service procedures
MlOx l.5-6H
require addition of new lubricant to compressor. NOTE:
Replace only with GM approved PAG oil P/N 12345923. 3. Compressor shaft.
M9 x L25-6H
Most minor repair procedures may be done on the
vehicle without discharging the system. Major repair 4. Internal hub-clutch drive assembly.
procedures require that the system be discharged of refrigerant. M22x 1.5-6H

UNIT REPAIR
MINOR COMPRESSOR REPAIR
PROCEDURES
THE FOLLOWING OPERATIONS TO THE
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR
AND BEARING, AND COIL ARE COVERED AS
"MINOR" BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST RECOVERING REFRIGERANT
FROM THE SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE.
The Compressor Shaft Seal assembly, control switches,
and Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE compressor from the vehicle but these
operations are covered later in this section as MAJOR REPAIR
PROCEDURES because the system must be reclaimed,
evacuated and recharged to complete service.
Illustrations used in describing these operations show the
compressor removed from the vehicle only to more clearly
illustrate the various operations.
When servicing the compressor, remove only the parts
that preliminary diagnosis shows are in need of service. Refer
to Figures 2 and 5 for information relative to part names and
location.
Removal and installation of external compressor parts,
and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
center screw into the remover body to remove the clutch
plate and hub assembly (Fig. 3).
NOTICE: Do not drive or pound on the clutch hub or
shaft. Internal damage to compressor may result. The
forcing tip on J 33013-B remover-installer center screw
must be flat or the end of the shaft/axial plate assembly
will be damaged.
3. Remove the shaft key and retain for reassembly.
E3 Install or Connect
1. Install the shaft key into the hub key groove (Fig. 4 ).
Allow the key to project approximately 3.2mm (1/8")
out of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.
2. Be sure the frictional surface of the clutch plate and the
clutch rotor are clean before installing the clutch plate
and hub assembly.
3. Align the shaft key with the shaft keyway and place the
clutch plate and the hub assembly onto the compressor
shaft.

COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
E3 Remove or Disconnect
DJ J 33013-B HUB AND (]] J 33026 HOLDING
1. Clamp the holding fixture J 33026 in a vise and attach CLUTCH DRIVE PLATE FIXTURE
compressor to holding fixture with thumb screws ASM. REMOVER
(TI CLUTCH PLATE
2.
J 33026-1 (Fig. 3).
With center screw forcing tip in place to thrust against
m J 33026·1 THUMB
SCREW
AND HUB ASM.
the end of the shaft, thread the Clutch Plate and Hub
G60070-102-C-R1
Assembly Installer-Remover J 33013-B into the hub.
Hold the body of the remover with a wrench and turn the Fig. 3 Clutch Plate and Hub Assembly Removal
102-4 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
NOTICE: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of the
installer is held and the center screw is rotated, the key
will wedge and will break the clutch hub.

(]] CLUTCH PLATE AND HUB ASSY.

m CLUTCH PULLEY ROTOR

(I] SHAFT KEYWAY

[I) SHAFT KEY
G60080-102-EK
[I) J 33013-B DRIVE
PLATE INSTALLER
m AIR GAP (0.20"-
0.30") 0.5o--0.76mm
Fig. 4 Shaft Key, Clutch Plate/Hub Installation
(I] DRIVE PLATE [I) CLUTCH PLATE
INSTALLER BEARING AND HUBASM.

4. Remove the forcing tip on J 33013-B clutch plate and G60090-1D2-C-R1

hub assembly installer-remover center screw and
Fig. 5 Installing Clutch Plate & Hub Assembly
reverse the body direction on the center screw, as shown
in Figure 5. 7. Remove installer J 33013-B, check for proper
positioning of the shaft key (even or slightly above the
5. Install the clutch plate and hub installer-remover
clutch hub).
J 33013-B with bearing as shown in Figure 8.
8. Spin the pulley rotor by hand to see that the rotor is not
The body of the J 33013-B installer-remover should be rubbing the clutch drive plate.
backed off sufficiently to allow the center screw to be
threaded onto the end of the compressor shaft.
COMPRESSOR CLUTCH ROTOR AND/OR
6. Hold the center screw with a wrench. Tighten the hex
portion of the installer-remover J 33013-B body to press
BEARING
the hub onto the shaft. Tighten the body several turns,
remove the installer and check to see that the shaft I+ +! Remove or Disconnect
key is still in place in the keyway before
installing the clutch plate and hub assembly to l. Remove the clutch plate and hub assembly as described
its final position. The air gap between frictional previously.
surfaces of the clutch plate and clutch rotor should be 2. Remove rotor and bearing assembly retaining ring, using
0.50-0.76mm (.020-.030 11 ). snap ring pliers J 6083 (Fig. 6).
 HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-5

Li] J 33020 PU.LLEY ROTOR

ANO BEARING PULLER
G60120-1D2-EK-R1

Fig. 8 Removing Pulley Rotor and Bearing Assembly

[DJ 6083
PLIERS
[!) PULLEY
ROTOR
[!)RETAINING
RING
G60060,-1D2-C-R1

Fig. 6 Installing-Removing Pulley Rotor & Bearing Assembly

Retaining Ring

(i] J 33020 (LESS (!] PULLEY ROTOR

FORCING SCREW) •FACE DOWN•
INVERTED AND
USED TO SUPPORT (!] J 9398-A BEARING
HUB OF ROTOR REMOVER
(I] J 33023-A PULLEY [!)J 33020 PULLER FOR BEARING
I!) J 29886 DRIVER
ROTOR AND ENGAGES IN INNER REMOVAL. PULLER
TANGS ENGAGED HANDLE .
BEARING PULLER CIRCLE OF SLOTS
GUIDE IN ROTOR IN ROTOR SLOTS.
G60130-1D2-C-R1
G60110-102-C-R1

Fig. 7 Installing Pulley Rotor/Bearing Puller Guide Fig. 9 Pulley Rotor Bearing Removal

Remove the forcing screw from J 33020 puller and, with

3. Install pulley rotor and bearing puller guide J 33023-A
to the front head (Fig. 7) and install J 33020 pulley rotor,
and bearing puller down into the inner circle of slots in
the rotor. Tum the J 33020 puller clockwise in the slots in
6.
the rotor (Fig. 8).
4. Hold the J 33020 puller in place and tighten the puller
screw against the puller guide to remove the pulley rotor
and bearing assembly.
5. To prevent damage to the pulley rotor during bearing
removal the rotor hub must be properly supported.
the puller tangs still ehgaged in the rotor slots, invert the
assembly onto a solid flat surface or blocks as shown in
Figure 9.
Drive the bearing out of the rotor hub with rotor bearing
remover J 9398-A and J 29886 universal handle (Fig. 9).
NOTICE: It is not necessary to remove the staking in
front of the bearing to remove the bearing, however, it
will be necessary to file away the old stake metal for
proper clearance for the new bearing to be installed into
the rotor bore or the bearing may be damaged.
102-6 HD6/HR6-HE AIR CONDITIONING COMPRESSOR

IT] J 33019-1 BEARING STAKING GUIDE

m RUBBER BAND
IT] J 33019-2 BEARING STAKING PIN
G60150-1 D2-EK-R1

Fig. 11 Staking Bearing In Rotor Hub Bore

(TI J 29886 DRIVER (!] PULLEY

HANDLE ROTOR
rn J 21352-A
SUPPORT BLOCK
[!) J 9481-A BEARING
INSTALLER

G60140-1D2-C-R1

Fig. 1O Installing Pulley Rotor Bearing

I+ +I Install or Connect
1. Place the pulley rotor on the J 21352-A support block to
fully support the rotor hub during bearing installation
(Fig. 10).
NOTICE: DO NOT support the rotor by resting the
pulley rim on a flat surface during the bearing
installation or the rotor face will be bent.
2. Align the new bearing squarely with the hub bore and
using puller and bearing installer J 9481-A with
universal handle J 29886, drive the bearing fully into the
hub (Fig. 10). The installer will apply force to the outer
race of the bearing, if used as shown.
3. Place bearing staking guide J 33019-1 and bearing
staking pin J 33019-2 in the hub bore as shown in
Figure 11. Shift the rotor and bearing assembly on the
J 21352-A support block to give full support of the hub
under the staking pin location. A heavy-duty rubber
band may be used to hold the stake pin in the guide (Fig.
11), and the stake pin should be properly positioned in
the guide after each impact on the pin.
4. Using care to prevent personal injury, strike the staking
pin with a hammer until a metal stake, similar to the
original, is formed down to but not touching the
bearing.
Noisy bearing operation and reduced bearing life may
result if outer bearing race is deformed while staking,
The stake metal should not contact the outer race of the
bearing. Stake three places 120 degrees apart as shown in
Figure 12.
520016-102
Fig. 12 Bearing Staked.in Place
5. With the compressor mounted to the J 33026 holding
fixture, position the rotor and bearing assembly on the
front head (Fig. 13).
6. Position the J 33017 pulley, rotor and bearing installer
and J 33023-A puller pilot directly over the inner race of
the bearing (Fig. 13).
7. Position puller crossbar J 8433-1 on the puller pilot
J 33023-A and assemble the two J 33026-2 through bolts
and washers through the puller bar slots and thread them
into the J 33026 holding fixture (Fig. 13). The thread of
the through bolts should engage the full thickness of the
holding fixture.
8. Tighten the center screw in the J 8433,..:.1 puller crossbar
to force the pulley rotor and bearing assembly onto the
compressor front head (Fig. 13). Should the
J 33017 pulley rotor and bearing installer slip off direct
in-line contact with the inner race of the bearing, loosen
the J 8433-1 center forcing screw and realign the
installer and pilot so that the J 33017 installer will
properly clear the front head.
9. Install rotor and bearing assembly retainer ring, using
snap ring pliers J 6083 (Fig. 6).
10. Reinstall clutch plate and hub assembly as described
previously.
 HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-7

(TI J 8433·3 SCREW

[!) J 33023-A PULLER PILOT
(i] J 33026-2 THROUGH BOLTS
1-J 8433-3 SCREW 3-J 33024 CLUTCH
(!] PULLEY ROTOR COIL INSTALLER
[!) J 33017 PULLEY ROTOR AND BEAR· 2-CLUTCH COi L
ASSEMBLY 4-J 8433·1 PULLER
ING INSTALLER
CROSS BAR
(!] J 8433-1 CROSS BAR
G60170-102-C-R1 520019-102-R1

Fig. 13 Installing Pulley Rotor and Bearing Assembly Fig. 15 Installing Clutch Coil Assembly

COMPRESSOR CLUTCH COIL

E3 Remove or Disconnect

1. Perform Steps 1 through 4 of "Clutch Rotor and/or

Bearings" removal procedure. Mark clutch coil
terminal location on compressor front head.
2. Install J 33023-A puller pilot on front head of
compressor (Fig. 14). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 14.
3. Tighten J 8433-3 forcing screw against the puller pilot to
remove the clutch coil.

E3 Install or Connect

1. Place the clutch coil assembly on the front head with the
terminals positioned at the "marked" location.
2. Place the J 33024 clutch coil installer over the internal
OJ J 8433-3 SCREW [I) J 8433-1 PULLER opening of the clutch coil housing and align installer
with the compressor front head.
[I) MARK COIL TERMINAL CROSS BAR
3. Center the J 843'3-l puller crossbar in the counter- sunk
LOCATION ON HEAD (!] J 33023-A center hole of the J 33024 clutch coil installer. Install the
[I) CLUTCH COIL PULLER PILOT J 33026-2 through bolts and washers through the
ASSEMBLY crossbar slots and thread them into the holding fixture
(I] J 33025 PULLER J 33026 to full fixture thickness (Fig. 15).
LEG G60180-102-C-R1 4. Turn the center forcing screw of the J 8433-1 puller
Fig. 14 Clutch Coil Assembly Removal crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay "in-line''
during installation.
102-8 HD6/HR6-HE AIR CONDITIONING COMPRESSOR

1 - FRONT HEAD SURFACE 3-CLUTCH

1-CLUTCH COIL 3-STAKE IN FRONT COIL
HEAD (3 PLACES) 2 - STAKE FRONT HEAD 0.28-0.35MM
HOUSING
2-DRIFT PUNCH DEEP (0.10- 015")
52002CHD2 520021-102

Fig. 16 Staking Clutch Coil to Front Head Fig. 17 Details of Stakes in Front Head for Clutch Coil

5. When coil is fully seated on the front head, use a 1/8"

diameter drift punch and stake the front head at three
places 120 degrees apart (Fig. 16), to ensure clutch coil
remains in position.
• Stake size should be only one-half the area of the
punch tip and be only approximately
0.28-0.35mm (.010-.015") deep (Fig. 17).
6. Install rotor and bearing assembly and the clutch plate 1-STEEL SHELL
and hub assembly as described previously. 2-LIP SEAL
520033--101

Fig. 18 Compressor Shaft Seal

MAJOR COMPRESSOR REPAIR [I) SUCTION PORT [I)cONTROL

PROCEDURES [TI DISCHARGE PORT SWITCHES

[I) MOUNTING BOSS (3) W PRESSURE

RELIEF VALVE
When replacing the shaft seal assembly (Fig. 18),
pressure relief valve or control switches (Fig. 19), it will be
necessary to recover the refrigerant. Other than clutch repair
procedures, the same holds true for any disassembly of the
compressor.
A clean workbench covered with a sheet of clean paper,
and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of proper clean service tools.
NOTICE: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation.
520020-1D2-R1
All parts required for servicing the internal compressor
are protected by a preservative process and packaged in a Fig. 19 Compressor ....:.... Rear Head
manner which will eliminate the necessity of cleaning,
washing or flushing of the parts. The parts can be used in the COMPRESSOR SHAFT SEAL
internal assembly just as they are removed from the service REPLACEMENT
package. Seals and protective packaging should be left Seal Leak Detection
intact until just prior to installation.
A shaft seal should not be changed because of small
If the compressor rear head, front head or cylinder and amounts of oil found on an adjacent surface but only after
shaft assembly is to be serviced or replaced, the oil in the actual refrigerant leakage is found using an approved leak
compressor must be drained, measured, recorded and replaced. detector, J 39400 or equivalent.
 HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-9

I+ +I Remove or Disconnect
1. Recover the refrigerant using J 39500-GM.
2. Loosen and reposition compressor in mounting brackets,
if necessary.
3. Remove clutch plate and hub assembly from compressor
as described in minor repairs.
4. Remove the shaft seal retainer ring, using snap ring
pliers J 5403 (Fig. 21).
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the seal, the
retainer ring groove and the shaft itself. Any dirt or
foreign material getting into compressor may cause
damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J 23128-A into the recessed portion of the Seal
by turning the handle clockwise. Remove the Seal from
the compressor with a rotary-pulling motion (Fig. 22).
Discard the seal. The handle must be hand- tightened
securely. Do not use a wrench or pliers.
7. Remove and discard the seal seat 0-ring from the
compressor neck using 0-ring remover J 9553-01,
Figure 20.
8. Recheck the shaft and inside of the compressor neck for
dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.

Iii Clean

• Thoroughly clean 0-ring seal groove in front head.

NOTICE: Seals should not be re-used. Always use a
new specification service seal on rebuild (Fig. 18). Be
sure that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat and seal
are free of lint and dirt that could damage the seal surface
or prevent sealing.

I+ +I Install or Connect
1. Dip the new seal seat 0-ring in clean 525 viscosity
refrigerant oil and assemble onto 0-ring installer
J 33011, Figure 20.
2. Insert the 0-ring installer J 33011 into the compressor
neck until the installer "bottoms". Lower the moveable
slide of the 0-ring installer to release the 0-ring into the
seal 0-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the 0-ring and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil and

[Il SEAL rn J 9553-01 [!) J 33011

assemble seal to Seal Installer J 23128-A, by turning
handle clockwise. The stamped steel case side of the
[!) J 23128-A [!) 0-RING [!) J 34614 lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and
installed towards the compressor. Install seal protector
Fig. 20 Removing and Installing Shaft Seal and 0-Ring J 34614, in the seal lip and place over the compressor
shaft, Figure 22, and push the seal in place with a
rotary motion or place the seal protector J 34014 over
end of compressor shaft, Figure 22, and slide the new
102-10 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
4. Install the new seal retainer ring with its flat side against
the Seal, using Snap-Ring Pliers J 5403. See Figure 21.
Use the sleeve from 0-ring installer J 33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J 39893 on rear head of compressor and connect gage
charging lines and J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor
with R-134a Refrigerant. Temporarily install (M9 x 1.25
thread on shaft) nut and, with the compressor in
horizontal position, rotate the compressor shaft in
normal direction of rotation several turns by hand. Leak
test the seal area and correct and leak found. Recover the
refrigerant. Remove shaft nut.
6. Remove any excess oil resulting from installing the new
seal parts from the shaft and inside the compressor neck.
7. Install the clutch plate and hub assembly as described in
minor repair procedures.
8. Reinstall compressor belt and tighten bracket.
IT) J 5403
9. Evacuate and charge the refrigerant system.
SNAP RING
PLIERS

[!) SEAL SEAT COMPRESSOR PRESSURE RELIEF VALVE

RETAINER
RING
I+ +! Remove or Disconnect
G60060-102-C-R1
1. Recover the refrigerant using J 39500-GM.
Fig. 21 Removing or Installing Shaft Seal
Retaining Ring 2. Remove old pressure relief valve (Fig. 19).

seal onto the shaft with a rotary motion until it stops.

I• +! Install or Connect

Take care not to dislodge the 0-ring. Be sure the seal l. Clean valve seat area on rear head.
makes good contact with the 0-ring. Disengage the
2. Lubricate 0-ring of new pressure relief valve and 0-ring
installer from the seal and remove the installer
assembly with new 525 viscosity refrigerant oil. Install
J 23128-A and the seal protector J 34614.
new valve and torque in place, 9.0 N•m (6.1 lbs.-ft.)
NOTICE: Handling and care of seal protector is
3. Evacuate and recharge the system.
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation. 4. Leak test system.

(!] ONE-PIECE SEAL (l] J 34614 SHAFT SEAL

ffi J 23128-A PROTECTOR

G60250-1 D2-C-R1

Fig. 22 Removing or Installing Shaft Seal

 HD6/HR&-HE AIR CONDITIONING COMPRESSOR 102-11
CONTROL SWITCHES
Figure 20
I• •I Remove or Disconnect
1. Recover the refrigerant.
2. Disconnect the electrical connector from the switch in
the rear head of compressor.
3. Remove the switch retaining ring using J 5403 internal
snap ring pliers.
4. Remove the switch from the compressor.
5. Remove old 0-ring seal from the switch cavity using
J 9553-01 0-ring removal tool.
If existing control switch is reinstalled in the compressor,
a new 0-ring seal must be used and preferably a new retainer
ring should also be used. A new switch kit has the 0-ring and
retainer ring included.
E3 Install or Connect
1. Check switch cavity and 0-ring groove in the rear head
for dirt or foreign material and clean as necessary. Install
a new 0-ring coated with clean refrigerant oil into
groove in switch cavity.
2. Lubricate the control switch housing with clean
refrigerant oil and carefully insert switch into switch
cavity until switch bottoms in cavity.
3. Using J 9533-1 snap ring pliers install switch retaining
ring with high point of curved sides adjacent to switch
housing. Be sure retaining ring is properly seated in
switch cavity retaining groove. Leak test according to
bench test procedure.
COMPRESSOR LEAK TESTING
(EXTERNAL AND INTERNAL)
Bench-Check Procedure
1. Install test plate J 39893 on rear head of compressor.
2. Using J 39500-GM Refrigerant Recovery System, attach
center hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
3. Connect charging station high and low pressure lines to
corresponding fittings on test plate J 39893. Suction port
(low-side) of compressor has large internal opening.
Discharge port (high-side) has smaller internal opening
into compressor and deeper recess.
4. Open low pressure control, high pressure control and
refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5. Using a leak detector, check for leaks at pressure relief
valve, rear head switch location, compressor front and
rear head seals, center cylinder seal, through bolt head
gaskets and compressor shaft seal. After checking, shut
off low pressure control and high-pressure control on
charging station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been corrected.
7.
8.
Recover the refrigerant.
Disconnect both hoses from the test plate J 39893.
9. Add 90 ml (3 oz.) new J>AG lubricantto the compressor
assembly. Rotate the complete compressor assembly
(not the crankshaft or drive plate hub) slowly several
turns to distribute oil to all cylinder and piston areas.
10. Install a M9 x 1.25 threaded nut on the compressor
crankshaft if the drive plate and clutch assembly are not
installed.
11. Using a box-end wrench or socket and handle, rotate the
compressor crankshaft or clutch drive plate on the
crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
12. Using J 39500-GM Refrigerant Recovery System,
connect J 9893 the charging station high-pressure line to
13.
the test plate high-side connector.
Using J 39500-GM Refrigerant Recovery System,
connect the charging station low-pressure line to the low
pressure port of the test plate J 39893. Oil will drain out
of the compressor suction port if the compressor is
positioned with the suction port downward.
14. Attach the compressor to the J 33026 holding fixture and
mount the compressor jn a vise so that the compressor
will be in a horizontal position and the shaft can be
turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft or
drive plate hub ten complete revolutions at a speed of
approximately one-revolution per second. Turning the
compressor at less than one-revolution per second can
result in a lower pump-up pressure and disqualify a good
pumping compressor.
16. Observe the reading on high-pressure gage at the
completion of the tenth revolution of the compressor.
The pressure reading for a good pumping compressor
should be 690 kPa ( 100 psi) or above. A pressure reading
of less than 620 kPa (90 psi) would indicate one or more
suction and/or discharge valves leaking an internal leak,
or an inoperative valve, and the refrigerant must be
recovered and the compressor disassembled and
checked for cause of leak. Repair as needed, reassemble
and repeat the pump-up test. Externally leak test.
17. When the pressure pump-up test is completed, recover
the refrigerant from the high-side and remove the test
plate J 39893.
18. Tilt the compressor so that the compressor suction and
discharge ports are down. Drain the PAG lubricant from
the compressor.
19. Allow the compressor to drain for 10 minutes, then refill
with the proper amount of PAG lubricant, per oil balance
procedure in section 1B of the service manual. The PAG
lubricant may be poured into the suction port. If further
assembly or processing is required, a shipping plate or
test plate J 39893 should be installed to keep out air, dirt
and moisture until the compressor is installed.
102-12 HD6/HA6-HE AIR CONDITIONING COMPRESSOR

OJ

1-J5403 SNAP RING PLIERS 13- J 33013 HUB & DRIVE PLATE REMOVER
&INSTALLER
2-J6083 SNAP RING PLIERS
14 - J 39500-GM R134a A/C REFRIGERANT RECOVERY,
DRIVER HANDLE RECYCLING AND RECHARGING
3 - J29886
SYSTEM {ACR4)
4 - J 8433-1 PULLER BAR 15- J 33017 PULLEY & BEARING ASSEMBLY
INSTALLER
5 - J 8433-3 FORCING SCREW
16- J 33019 BEARING STAKING TOOL .
6 - J 9396-A BEARING REMOVER
17- J 33020 PULLEY PULLER
7 - J 9481-A BEARING INSTALLER
18- J 34614 SHAFT SEAL PROTECTOR
8 - J 9553-01 "O" RING REMOVER 19- J 33023 PULLER PILOT

9 - J 39893 PRESSURE TESTING CONNECTOR • ,-20- J 33024 CLUTCH COIL INSTALLER ADAPTER

10- J 23126-A SEAL SEAT REMOVER & 21 - J 33025 CLUTCH COIL PULLER LEGS
INSTALLER
22- J 34992 COMPRESSOR HOLDING FIXTURE
11 - J 21352-A SUPPORT BLOCK 23- J 39400 LEAK DETECTOR

12- J 33011 "O" RING INSTALLER 24- J 39037 HIGH-SIDE CHARGE VALVE SOCKET

Fig. 23 Compressor Overhaul - Special Tools

 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-1

STEERING, SUSPENSION, TIRES

AND WHEELS
CONTENTS
Steering, Suspension, Tires and Wheels Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3A
Power Steering Gear and Pump On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B
Power Steering Gear Unit Repair ........................................... Section 3BIA
Power Steering Pump Unit Repair .......................................... Section 3B1B
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3C
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 30
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3E
Steering Wheel and Column On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3F
Supplemental Inflatable Restraint (SIR) Tilt Steering Column Unit Repair .......... Section 3F5B

SECTION 3
STEERING, SUSPENSION, TIRES
AND WHEELS DIAGNOSIS
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description .......................... 3-2
General Diagnosis ........................... 3-2
Power Steering Gear Assembly Diagnosis ........ 3-5
Steering Linkage Diagnosis .................... 3-6
Power Steering Pump Assembly Diagnosis ........ 3-6
Steering Column Assembly Diagnosis ........... 3-7
Lock System ............................. 3-7
Steering Column Assembly .................. 3-8
Turn Signal Switch Assembly ................ 3-9
Ignition Switch ........................... 3-11
Key Reminder ........................... 3-12
Column-Mounted Dimmer Switch ........... 3-14
Pivot and Switch Assembly ................. 3-15
Power Steering Gear and Pump
Assemblies Leak ......................... 3-15
General Procedure ........................ 3-15
External Leakage Check ................... 3-15
Seal Replacement Recommendations ........... 3-15
Power Steering System Test Procedure .......... 3-15
Shock Absorber Assemblies .................. 3-17
Tires ..................................... 3-18
Irregular or Premature Wear ................ 3-18
Tread Wear Indicators ..................... 3-19
Tire Waddle Complaint .................... 3-19
Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . . . . 3-19
Vibration ................................. 3-19
Road Test ............................... 3-22
Tire and Wheel Assembly Balance ........... 3-22
Runout Check ........................... 3-22
Tire Force Variation Check ................. 3-23
Substitution Method ....................... 3-23
Tapered Roller Bearing Diagnosis .............. 3-23
Trim Height ............................... 3-24
Specifications .............................. 3-27
Fastener Tightening Specifications ........... 3-27
Special Tools .............................. 3-27
3-2 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

GENERAL DESCRIPTION
Since the problems in steering, suspension, tire and
wheel assemblies involve several systems, they must all
be considered when diagnosing a complaint. To .avoid
using the wrong symptom, always road test the vehicle
first. Proceed with the following preliminary checks and
correct any substandard conditions which are found.
ll'l'I Inspect
• Wrong pressure and uneven wear on tires.
• Loose connections or wear on joints from the steer-
ing column assembly to the steering gear assembly.
• Loose or damaged parts on the front and rear suspen-
sion or steering gear assembly.
• Out-of-round or out-of-balance tires, bent wheel
assemblies and loose and/or rough wheel bearing
assemblies.
• Leaks in power steering system. Also check the
power steering fluid level and the accessory drive
belt condition and tension. Refer to "Power Steering
Pump Assembly Diagnosis" in this section.
The following symptom diagnosis tables may help
you find the cause of a problem. The tables list a number
of symptoms, along with associated possible causes. More
information on any particular listing can be found in the
sections referenced in the "Refer To" column.

GENERAL DIAGNOSIS
SYMPTOM POSSIBLE CAUSE REFER TO (SECTION)
BODY/CHASSIS - GENERAL

Vehicle Pulls or Leads • Misaligned front tire and wheel 3A

assembly.
• Mismatched or uneven tires. 3E
• Broken or sagging spring. 3C,3D
• Radial tire lead/pull. 3E
• Unbalanced steering gear valve spool. 3B, 3B1A
• Dragging front brake assembly. 5
Shimmy, Shake or Vibratic,m • Bent tire and wheel assembly rim. 3E
• Excessive tire and wheel assembly 3E
run out.
• Out-of-balance tire or wheel assembly. 3E
• Excessive wheel bolt runout. 3E
• Excessive brake drum assembly or brake 5
rotor assembly imbalance.
• Worn steering linkage components. 3B1A
• Worn lower control arm ball stud 3C
assembly.
• Excessive loaded radial runout of tire. 3E
• Worn suspension bushings. 3C, 30
• Blister or bump on tire.
• Out-of-balance propeller shaft assembly. 4A
• Foreign material lodged in wheel rim.
Abnormal Noise at Front End • Damaged suspension components. 3C, 3D
• Worn control arm bushings or steering 3BlA, 3C, 30
linkage.
• Loose stabilizer shaft assembly or 3C, 3D
broken stabilizer shaft links.
• Loose wheel nuts. 3E
• Loose suspension bolts/screws. 3C, 3D
• Misadjusted steering gear assembly. 3B, 3B1A
• Worn shock absorber assemblies or 3C, 3D
mountings.
• Improperly positioned spring. 3C, 3D
• Scuffed tires.

SYMPTOM
Low or Uneven Trim Height
Body Leans or Sways in Comers
Suspension Bottoms
"Dog" Tracking
TIRES/WHEELS - GENERAL
Abnormal or Excessive Tire Wear
Wheel Assembly Tramp
Cupped Tires
STEERING/STEERING WHEEL
ASSEMBLY - GENERAL
Poor Returnability
STEERING, SUSPENSJON, TIRES AND WHEELS DIAGNOSIS 3-3
POSSIBLE CAUSE REFER TO (SECTION)
• Broken, incorrect, or sagging spring. 3C, 3D
• Overloaded vehicle.
• Loose stabilizer shaft assembly or 3C, 30
broken stabilizer shaft links.
• Worn shock absorber assemblies or 3C, 3D
mountings.
• Broken or sagging spring. 3C, 3D
• Overloaded vehicle.
• Overloaded vehicle.
• Worn shock absorber assemblies. 3C,3D
• Incorrect, broken or sagging spring. 3C, 3D
• Damaged rear control arm or worn 3D
control arm bushing assembly.
• Bent rear axle assembly. 4B
• Misaligned tire and wheel assembly. 3A, 3E
• Excessive toe. 3A
• Sagging or broken spring. 3C,3D
• Out-of-balance tire or wheel assembly. 3E
• Worn shock absorber assemblies. 3C, 3D
• Hard driving.
• Overloaded vehicle.
• Tires not rotated. 3E
• Low or excessive inflation pressure. 3E
• Bent suspension components. 3C,3D
• Out-of-balance tire or wheel assembly. 3E
• Improper shock absorber assembly 3C,3D
action.
• Blister or bump on tires.
• Misaligned tire and wheel assembly. 3A
• Weak shock absorber assemblies. 3C, 3D
• Worn wheel bearing assembly. 3C
• Excessive tire or wheel assembly runout. 3E
• Worn control arm ball stud assembly. 3C
• Loose steering gear assembly 3B, 3B1A
adjustment.
• Incorrect caster setting. 3A
• Lack of lubrication at control arm ball OB
stud assembly or tie rod ends.
• Bind in control arm ball stud assembly. 3C
• Bind in steering column assembly. 3F,3F5B
• MisadjuSted steering gear assembly. 3B, 3B1A
• Incorrect steering gear valve spool. 3B,3B1A
• Intermediate steering shaft joints 3B
bindin .
3·4 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

SYMPTOM POSSIBLE CAUSE REFER TO {SECTION)

Hard Steering
Too Much Play in Steering
Wander or Poor Steering Stability
Erratic Steering When Braking
Steering Wheel Assembly
Kickback
Steering Wheel Assembly Surges
or Jerks
RIDE
• Hydraulic system - Perform test as
outlined in "Power Steering System Test
Procedure" in this section.
• Misadjusted steering gear assembly. 3B, 3B1A
• Bind or catch in steering gear assembly. 3B, 3B1A
• Loose steering gear assembly mounting. 3B, 3B1A
• Faulty pipe fitting seat. 3B, 3B1A
• Loose steering gear assembly mounting. 3B, 3BlA
• Loose or worn joints from steering 3B, 3B1A, 3F
column assembly to steering gear
assembly.
• Misadjusted steering gear assembly. 3B,3B1A
• Mismatched or uneven tires.
• Worn shock absorber assemblies. 3C, 3D
• Loose stabilizer shaft assembly. 3C, 3D
• Broken or sagging spring assembly. 3C, 3D
• Misadjusted steering gear assembly. 3B, 3B1A
• Misaligned tire and wheel assembly. 3A, 3E
• Worn wheel bearing assembly. 3C
• Broken or sagging spring assembly. 3C,3D
• Warped brake rotor assembly. 5
• Sticking brake caliper piston. 5
• Leaking wheel cylinder or brake caliper 5
assembly.
• Incorrect or uneven caster. 3A
• Air in power steering system. 3B
• Loose steering gear assembly mounting. 3B, 3B1A
• Loose or worn joints from steering 3B, 3B1A, 3F
column assembly to steering gear
assembly.
• Loose tie rod ends. 3B1A
• Worn or missing pipe fitting seat. 3B, 3B1A
• Worn wheel bearing assembly. 3C
• See "Too Much Play in Steering" for
other possible causes.
• Bad or defective tire.
• Sluggish steering gear valve spool. 3B, 3B1A
• Loose or oil soaked accessory drive belt. 3B,3B1B
• Air in power steering system. 3B

Too Soft • Incorrect shock absorber assemblies. 3C, 3D

(Vehicles with FEl suspension are • Incorrect or sagging spring assembly. 3C, 3D
designed for soft ride.)
Too Harsh • Incorrect shock absorber assemblies. 3C, 3D
• Incorrect spring assembly. 3C, 3D
• Incorrect tires or tire pressure. 3E

POWER STEERING GEAR ASSEMBLY DIAGNOSIS
SYMPTOM
Hissing Noise
Rattle or Chucking Noise
If a rattle occurs when driving over bumps, check front brake linings for loose fit and missing antirattle clips.
Poor Return of Steering Wheel
Assembly to Center
Momentary Increase in Effort When
Turning Steering Wheel Assembly
Fast to Right or Left
Steering Wheel Assembly Surges or • Insufficient pump assembly pressure.
Jerks When Turning with Engine
Running, Especially During Parking
Excessive Steering Wheel Assembly • Air in power steering system.
Kickback or Loose Steering
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-5
POSSIBLE CAUSE REFER TO (SECTION)
• This is commonly heard when steering 3B, 3B1A
wheel assembly is turned and vehicle
is not moving, and especially so if
brakes are applied. If noise is very
objectionable, replace the gear with
a partial service gear assembly.
(A replacement gear will also have a
slight noise, and is not always a cure
for the condition.)
• Loose intermediate steering shaft 3B
universal joints.
• Outlet (pressure) hose assembly contact- 3B,3BlA
ing frame.
• Loose tie rod ends. 3B1A
• Loose steering gear assembly attach- 3B, 3B1A
ment.
• Loose pinion shaft assembly. 3B, 3B1A
• Misaligned front tire and wheel 3A
assembly.
• Worn wheel bearing assembly. 3C
• Binding tie rod ends. 3B1A
• Binding control arm ball stud assembly. 3C
• Steering wheel assembly rubbing against 3F
tum signal switch housing.
• Misadjusted steering gear assembly. 3B, 3B1A
• Tight or frozen steering gear coupling 3F
shaft assembly.
• Sticky or plugged steering gear valve 3B, 3B1A
spool.
• High internal leakage. 3B, 3B1A, 3B1B
• Sticking or damaged steering gear valve 3B, 3B1A
spool.
• Insufficient pump assembly pressure. 3B, 3B1B
• Low fluid level. 3B, 3B1B
3B, 3B1B
• Sticky flow control valve. 3B, 3B1B
3B
• Loose steering gear assembly adjust- 3B,3B1A
ment.
• Loose tie rod ends. 3B1A
• Worn wheel bearing assembly. 3C
• Coupling assembly loose on stabilizer 3B, 3C
shaft assembly.
• Loose thrust bearing preload adjustment. 3B,3B1A
• Worn pipe fitting seat. 3B, 3B1A
3-6 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
SYMPTOM
Hard Steering or Lack of Assist,
Especially During Parking
STEERING LINKAGE DIAGNOSIS
SYMPTOM
Excessive Play or Looseness in
Power Steering System
Excessive Looseness in Tie Rod
Assemblies
Hard Steering
POWER STEERING PUMP ASSEMBLY DIAGNOSIS
SYMPTOM
Foamy, Milky Fluid, Low Fluid
Level, Low Pressure
Low Pressure Due to Pump
Assembly
Low Pressure Due to Steering Gear
Assembly
POSSIBLE CAUSE REFER TO (SECTION)
• Brake assemblies applied while turning
steering wheel assembly.
• Damaged or worn steering gear coupling 3F
shaft assembly.
• Sticky flow control valve. 3B, 3B1B
• Insufficient pump assembly pressure. 3B, 3B1B
• Excessive internal pump assembly 3B, 3B1B
leakage.
• Excessive internal steering gear 3B,3B1A
assembly leakage.
POSSIBLE CAUSE REFER TO (SECTION)
• Worn control arm ball stud assembly. 3C
• Worn tie rod sockets. 3B1A
• Damaged and leaking seal resulting in 3B1A
loss of lubricant, corrosion and excessive
wear.
• Tight or frozen tie rod assemblies 3B1A
• Steering gear assembly adjusted too 3B, 3B1A
tight.
POSSIBLE CAUSE REFER TO SECTION 38, 381 B
• Air in fluid.
• Internal pump assembly leakage.
• Extremely cold temperatures will cause
air bubbles if fluid level is low.
• If fluid level is correct and pump assem-
bly still foams, remove pump assembly;
then remove reservoir assembly from
pump assembly on 3.4L L32 engine.
On 5. 7L LTl engine, remove pump
assembly and remote reservoir assembly.
Check soft plug and housing for cracks.
If cracked, replace housing on 3.4L L32
engine or remote reservoir assembly on
5.7L LTl engine.
• Stuck or inoperative flow control valve.
• Pressure plate not flat against ring.
• Extremely worn ring.
• Scored pressure plate, thrust plate or
rotor.
• Vanes sticking in rotor slots.
• Cracked or broken thrust plate or
pressure plate.
• High internal leakage.
• Scored housing bore.
• Leakage at valve rings or seals.

SYMPTOM
Growling Noise in Pump Assembly
Groaning Noise in Pump Assembly
Rattling Noise in Pump Assembly
Swishing Noise in Pump Assembly
Whining Noise in Pump Assembly
STEERING COLUMN ASSEMBLY DIAGNOSIS
SYMPTOM
LOCK SYSTEM
Will Not Unlock
Will Not Lock
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3.7
POSSIBLE CAUSE REFER TO SECTION 38, 3818
• Restricted hoses or steering gear assem-
bly causing excessive back pressure.
• Scored pressure plates, thrust plate or
rotor.
• Wornring.
• Air in fluid.
• Low fluid level.
• Loose pump assembly mounting.
• Vanes sticking in rotor slots.
• Improperly installed vane.
• Damaged pump bearings.
• Damaged flow control valve.
• Scored pump shaft bushing.
• Scored pressure plates and vanes.
POSSIBLE CAUSE REFER TO SECTION 3F, 3F58
(except where noted)
• Collapsed shear flange on sector shaft.
• Damaged lock bolt.
• Damaged lock cylinder.
• Damaged housing.
• Damaged sector.
• Damaged rack.
• Damaged or incorrectly cut key.
• Broken or worn lock bolt spring.
• Damaged sector.
• Damaged lock cylinder.
• Burr on lock bolt.
• Damaged housing.
• Damaged rack.
• Interference between bowl and rack
coupling.
• Stuck ignition switch.
• Restricted actuator rod.
• Incorrectly installed sector.
3-8 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
SYMPTOM
High Lock Effort
Will Stick in "START"
Key Cannot Be Removed in
"OFF-LOCK"
Lock Cylinder Can Be Removed
High Effort in Lock Cylinder
Between "OFF" and "OFF-LOCK"
Lock Bolt Hits Shaft Lock in "OFF" • Incorrectly set ignition switch.
and "PARK"
STEERING COLUMN ASSEMBLY
Noise in Steering Column Assembly
High Steering Shaft Assembly
Effort
POSSIBLE CAUSE REFER TO SECTION 3F1 3F5B
(except where noted)
• Damaged lock cylinder.
• Damaged ignition switch.
• Broken or deformed rack preload spring.
• Burrs on sector, rack, housing, support or
actuator rod coupling.
• Bent sector shaft.
• Damaged rack.
• Park lock cable damaged or misadjusted.
• Extreme misalignment of housing to
cover.
• Distorted coupling slot in rack.
• Bent actuator rod.
• Bent ignition switch mounting bracket.
• Restricted actuator rod.
• Worn or damaged key.
• Deformed actuator rod.
• Check items under "High Lock Effort."
• Incorrectly set ignition switch.
• Damaged lock cylinder.
• Missing lock cylinder retaining screw.
• Distorted rack.
• Loose joints from steering column 3B, 3B1A
assembly to steering gear assembly.
• Incorrectly aligned steering column
assembly.
• Unlubricated horn contact ring. OB
• Lack of grease on bearings. OB
• Loose sight shields.
• Worn or broken upper or lower steering
shaft bearing assembly.
• Unseated lock plate retainer ring.
• Unlubricated spherical joint. OB
• Misaligned steering column assembly.
• Improperly installed or deformed dust
seal.
• Damaged upper or lower steering shaft
bearing assembly.
• Flash on inside diameter of shift tube.
• Tight universal joint. 4A

SYMPTOM
Lash in Steering Column Assembly
Housing Scraping Bowl
Loose Steering Wheel Assembly
Loose Steering Wheel Assembly
(Every Other Tilt Position)
Steering Column Assembly Not
Locking in Any Tilt Position
Steering Wheel Assembly Fails to
Return to Top Tilt Position
Noise When Tilting Steering
Column Assembly
rn
TURN SIGNAL SWITCH ASSEMBLY
Important
• This diagnosis covers mechanical problems only.
Refer to SECTION 8A for tum signal switch
electrical diagnosis.
Tum Signal Will Not Stay in Tum
Position
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3.9
POSSIBLE CAUSE REFER TO SECTION 3F, 3F5B
{except where noted)
• Loose IP-to-steering column assembly
upper and lower bracket mounting
bolts/screws.
• Broken weld nuts on jacket.
• Sheared IP upper bracket capsule.
• Loose shoes in housing.
• Loose pivot pins.
• Loose lock pin in housing support.
• Loose housing support bolts/screws.
• Loose steering column assembly upper
and lower bracket-to-jacket bolts/screws.
• Loose lower bracket-to-adapter and
bearing assembly mounting bolts/screws.
• Bent bowl or bowl not concentric with
hub.
• Improperly installed cover and housing
end cap.
• Excessive clearance between holes in
housing support or housing and pivot pin
diameters.
• Damaged or missing anti-lash spring in
spheres.
• Steering shaft upper bearing assembly
not seated in housing.
• Missing steering shaft upper bearing
inner race.
• Loose housing support bolts/screws.
• Missing or broken bearing preload
spring.
• Loose fit between shoe and pivot pins.
• Shoe not free in slot.
• Shoe seized on pivot pin.
• Burrs or dirt on shoe grooves.
• Weak or broken shoe lock spring.
• Bound up pivot pins.
• Broken or weak wheel tilt spring.
• Tight tum signal switch assembly wires.
• Worn upper tilt bumpers.
• Shoe lock spring rubbing in housing.
• Foreign material or loose parts impeding
movement of yoke.
• Broken or missing detent or canceling
spring.
• None of the above; replace switch.
3-10 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
SYMPTOM
Tum Signal Will Not Cancel
Tum Signal Difficult to Operate
Tum Signal Will Not Indicate Lane
Change
Hazard Switch Cannot Be Turned
"OFF"
Hazard Switch Will Not Stay "ON"
or Difficult to Tum "OFF"
No Turn Signal Lamps
Tum Indicator Lamps "ON," But
Not Flashing
POSSIBLE CAUSE REFER TO SECTION 3F, 3F5B
(except where noted)
• Loose switch mounting screws.
• Broken switch or anchor bosses.
• Broken, missing or out-of-position
detent, return or canceling spring.
• Worn canceling cam.
• Loose tum signal switch arm.
• Broken or distorted yoke; replace switch.
• Loose or misplaced springs.
• Foreign parts and/or material.
• Loose turn signal switch mounting
screws.
• Broken lane change pressure pad or
spring hanger.
• Broken, missing or misplaced lane
change spring.
• Jammed base or wires.
• Foreign material between hazard support
canceling leg and yoke.
• If no foreign material is found, replace
turn signal switch.
• Loose turn signal switch.
• Interference with other components.
• Foreign material interference.
• None of the above; replace turn signal
switch.
• Electrical failure in chassis harness.
• Inoperative turn signal flasher.
• Loose chassis-to-column connector. Dis-
connect chassis-to-column connector and
connect new turn signal switch to chassis
and operate switch by hand.
- If vehicle lamps now operate
normally, tum signal switch is
inoperative.
- If vehicle lamps do not operate,
refer to SECTION 8A.
• Inoperative turn signal flasher.
• Loose chassis-to-column connection.
• Inoperative turn signal switch.
• To determine if tum signal switch is
inoperative, substitute new turn signal
switch into circuit and operate switch by
hand. If vehicle lamps operate normally,
tum signal switch is inoperative.

SYMPTOM
Front or Rear Turn Signal Lamps
Not Flashing
No Tum Indicator Panel Lamps
Stoplamp Not "ON" When Turn
Indicated
Tum Signal Lamps Flash Very
Slowly
Hazard Signal Lamps Will Not
Flash - l;'urn Signal Functions
Normally
IGNITION SWITCH
Electrical System Will Not Function
Switch Will Not Turn
Switch Cannot Be Set Correctly
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3·11
POSSIBLE CAUSE REFER TO SECTION 3F, 3F5B
{except where noted)
• Burned-out or damaged turn signal bulb.
• High resistance connection to ground at
bulb socket.
• Loose chassis-to-column connector.
Disconnect chassis-to-column connector
and connect new turn signal switch into
system and operate switch by hand.
- If tum signal lamps are now "ON"
and flashing, turn signal switch is
inoperative.
- If vehicle lamps do not operate, refer
to SECTION 8A.
• Burned out bulbs or opens, grounds in
wiring harness from front turn signal
bulb socket to indicator lights. Refer to
SECTION 8A.
• Loose chassis-to-column. connection.
• Disconnect chassis-to-column connector
and connect new turn signal switch into
system and operate switch by hand.
- If brake lamps work when switch is
in turn position, turn signal switch is
inoperative.
• Loose chassis-to-column connection.
• Disconnect chassis-to-column connector
and connect new turn signal switch into
system and operate switch by hand.
- If lamps flash at a normal rate, turn
signal switch is inoperative.
- If lamps still flash very slowly, refer
to SECTION 8A.
• Blown fuse.
• Inoperative hazard warning flasher.
• Loose chassis-to-column connection.
• Disconnect column-to-chassis connector
and connect new turn signal switch into
system, then press in hazard warning
button and watch hazard warning lights.
-If lamps now work normally, turn
signal switch is inoperative.
- If lamps do not flash, check wiring
harness. Refer to SECTION 8A.
• Damaged ignition switch.
• Improperly adjusted ignition switch.
• Loose connector at ignition switch.
• Damaged ignition switch.
• Damaged lock cylinder.
• Deformed switch actuator rod.
• Sector to rack engaged in wrong tooth.
3·12 STEERlNG, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

KEV REMINDER
Figures 1 through 10

Reminder Continues to Operate with Key Out,

but Stops When Driver's Door is Closed

ll•l 1nspect
• Chips, foreign material in lock cylinder bore.
• Sticky lock cylinder actuator tip.
• Damaged or broken reminder switch (3).

Reminder Does Not Sound with Key Fully A TESTLEADS

2 CONNECTOR, COLUMN
Inserted in Lock Cylinder and the Driver's Door
Open

ll•l
PC6002·3·D-RP

1nspect Figure 2 - Checking Reminder at Column Connector

NOTICE: If you are using a multimeter to check
continuity with voltage present in circuits, be sure to
use a voltage setting. A multimeter set on a resis- B
tance scale will be damaged by the voltage from live
circuits.
1. Reminder to see if power is available. Refer to
SECTION 8A.
2. Chassis wiring for open circuit.
A. Separate chassis connector ( 1) from column
connector (2).
B. Connect female contacts of terminals "E" and
"F" on chassis connector (1). A bent paper
clip will work as a jumper.
• If reminder sounds, repair chassis wiring.
• If reminder does not sound, go to step 3.

A TEST LEADS
B PADS, REMINDER SWITCH
PC6003-3-D-RP

Figure 3 - Checking Reminder Switch Pads

3. Continuity between male "E" and "F" column

connector contacts with a multimeter (or test light).
• Push key all the way into lock cylinder (4).
- If there is continuity when key is in, and
off when key is out, function is normal.
- If there is no continuity, fault is in col-
umn. Go to step 4.
4. Probes of reminder switch (3) to ensure good contact
with pads on signal switch.
A. Disassemble upper end of column assembly
until turn signal switch mounting bolts/screws
have been removed.
A BENT PAPER CLIP
B CONTACTS
B. Lift turn signal switch to gain access to probes.
1 CONNECTOR, CHASSIS C. Bend probes, if needed, then replace turn
PC0003-3-F-RP
signal switch and tighten three bolts/screws.
Figure 1 - Checking Reminder at Chassis Connector
D. Check function as in step 3.
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-13

4
A

A ACTUATOR TIP EXTENDED

4. CYLINDER, LOCK
PC6006-3-D-RP

Figure 6 - Lock Cylinder Actuator - Key in Place

A TESTLEADS
3 SWITCH, REMINDER
PC6004-3-D-RP

Figure 4 - Checking Reminder Switch

A TESTLEADS
B SCREWDRIVER
. C PAD, ACTUATOR
3 SWITCH, REMINDER 3
PC6007-3-D-RP

Figure 7 - Checking Key Reminder Switch Continuity

A ACTUATOR TIP RETRACTED

4 CYLINDER, LOCK PC6005-3-D-RP

Figure 5 - Lock Cylinder Actuator - Key Removed

5. Tum signal switch wiring for short or fault.

A. Connect male contacts of terminals "E" and
"F" of column connector (2) with a jumper.
B. Check key reminder switch pads on turn signal
switch with multimeter.
• If there is continuity, function is normal.
• If there is no continuity, replace turn
signal switch.
6. Continuity of check key reminder switch probes, if
problem has not been found.
A. Connect a multimeter to probes on reminder
switch (3).
B. Fully insert and remove key from lock cylinder
(4).
• If there is continuity when key is in lock
cylinder (4) and no continuity when key
is out, function is normal. Retrace diag-
nostic steps starting at step 3.
• If there is no continuity, fault is in lock
cylinder (4) or reminder switch (3).
A TEST LEADS
B STRAIGHT EDGE
C GAGE, PLUG
3 SWITCH, REMINDER
· PC6008-3-D-RP
Figure 8 - Checking Contact Gap
7. Lock cylinder (4) for chips, burrs, or foreign
material that may prevent actuator tip function.
A. Key must be removed, or lock cylinder (4)
must be in "RUN" position, before lock cylin-
der can be removed.
B. Remove chips, burrs or foreign material.
C. Reassemble and recheck (step 6).
3-14 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

8. Lock cylinder for damage. • If reminder stops when key is in "RUN"

position or when it is turned past "RUN"
• With lock cylinder removed, push key all the toward "START," problem is a sticky
way in, tum to "RUN" position and then
lock cylinder actuator.
remove it.
For further diagnosis of key reminder, refer to
A. The lock cylinder actuator tip should SECTION 8A. .
extend and retract smoothly. Total exten-
sion of tip should be 1.27 mm (0.050
inch). COLUMN-MOUNTED DIMMER SWITCH
B. If not, replee lock cylinder (4 ). Reas- No "LOW" or "HIGH'i Beam
semble and recheck per step 4.
9. Reminder switch (3) if it appears good but will not
operate.
ll•l 1nspect
1. Loose connector at dimmer switch.
A. Connect multimeter leads to reminder switch 2. Improper adjustment.
probes on reminder switch (3).
3. Internally damaged or worn switch. Refer to SEC-
B. Press on actuator pad until switch points touch. TION 8A.
C. If there is no continuity, replace reminder • Check continuity on switch at light green and
switch (3). tan switch terminals by pushing in plunger all
the way. A click should be heard.
10. Reminder switch contact gap.
- If there is no continuity, replace dimmer
A. Connect multimeter leads to reminder switch switch.
probes on reinirtder switch (3).
- If there is continuity, refer to SECTION
B. Press a 0.76 tnm (0.030-inch) wire type plug 8A.
gage with a flat piece of stock onto actuator
pad.
• If contact is not made (no continuity),
decrease switch contact gap until positive
contact is made.
11. Reminder switch contact gap, with positive contact
gap set at 0.76 mm (0.030 inch) as outlined above.
A. Use a 0.63 mm (0.025-inch) plug gap wire
beneath flat stock.
• If contact is made (continuity), increase
switch contact gap. A SCREWDRIVER
3 SWITCH, REMINDER 3
B. Reminder switch (3) is set properly when PC6009-3-D-RP

switch contact will touch 0.76 mm (0.030-inch) Figure 9 - Decreasing Switch Contact Gap
wire but not 0.63 mm (0.025-inch) wire.

Reminder Keeps Operating with Key in Lock

Cylinder, Driver's Door Open or Closed; Ceases
When Key is Removed

IL•l 1nspect
• Misadjusted or inoperative door jamb switch on
driver's side.
• Shorted wire from signal switch to door jamb
switch.
A. This condition indicates lock cylinder (4) or
reminder switch (3) is at fault. To verify, check
for continuity at "E" and "F" male column A
connector contacts, with key removed from
lock cylinder (4). A SCREWDRIVER
3 SWITCH, REMINDER
• If continuity exists, fault is in column. PC6010-3-D-RP

B. Insert key into lock, then tum lock toward Figure 10 - Increasing Switch Contact Gap
"START" position.
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3·15
PIVOT AND SWITCH ASSEMBLY
Switch Inoperative: No "LOW," "HIGH" and/or
"WASH"
ll•l 1nspect
1. Loose body-to-switch connector.
2. Broken or damaged switch.
3. Internally damaged or worn switch.
• Connect a new switch without removing old
one.
- If system functions, replace switch.
- If system doesn't function, refer to
SECTION 8A.
POWER STEERING GEAR AND PUMP
ASSEMBLIES LEAK
GENERAL PROCEDURE
ll•l 1nspect
• For these common complaints about the power
steering system:
- Fluid leakage on garage floor.
- Fluid leaks visible on steering gear assembly
or pump assembly.
- Growling noise, especially when parking or
when engine is cold.
- Loss of power steering when parking.
- Excessive steering effort required.
• For an overfilled reservoir assembly.
• For fluid aeration and overflow.
• Hose connections.
• Identify exact point of leakage. Refer to "External
Leakage Check" in this section.
- Point from which fluid is dripping is not
necessarily point where system is leaking. It is
important to identify exact point of leakage.
EXTERNAL LEAKAGE CHECK
Figure 11
This procedure will help identify exact location of
leak. Some leaks can easily be located but seepage type
leaks may be more difficult. To locate seepage leaks, use
the following method:
1. With engine off, wipe dry complete power steering
system.
2. Check fluid level. Adjust fluid level as necessary.
3. Start engine, then turn steering wheel assembly from
stop to stop several times.
• Do not hold it at a stop for any length of time as
this can damage pump assembly (5).
• It is easier for someone else to operate steering
wheel assembly while you search for seepage.
4. Find exact location of leak and repair.
SEAL REPLACEMENT
RECOMMENDATIONS
lip Seals
Lip seals, which seal rotating shafts, require special
treatment. This type of seal is used on the hydraulic pump
shaft and the pinion shaft of the steering gear assembly.·
When leakage occurs in this area, always replace the seal
or seals, after inspecting and throroughly cleaning the
sealing surfaces. Replace the shaft if pitting is found. If
corrosion in the lip seal contact zone is slight, clean
the surface of the shaft with crocus cloth. Replace the
hydraulic pump shaft or complete gear assembly only if
the leakage cannot be stopped by smoothing with crocus
cloth first.
0-Ring Seals
Whenever a part which forms a sealing surface for
an 0-ring is removed, the 0-ring seal should also be
removed and replaced with a new 0-ring seal. Lubricate
all new 0-ring seals with power steering fluid to ease
assembly.
POWER STEERING SYSTEM TEST
PROCEDURE
Tools Required:
J 5176-D Power Steering Pressure Tester
0-2000 PSI and
J 5176-92 18 mm Power Steering Gauge
Adapter
J 25323-A Power Steering System Analyzer
J 29525-92 Power Steering Analyzer 18 mm
Adapter
If a hydraulic or mechanical malfunction of the
pump assembly or power steering gear assembly is sus-
pected, perform the following procedure to determine the
cause.
NOTICE: See "Notice" on page 3-1 of this section.
1. Disconnect outlet hose assembly at pump assembly
on 3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
2. Place drain pan under pump assembly on 3.4L L32
engine or remote reservoir assembly on 5.7L LTl
engine.
3. Connect spare pressure hose to pump assembly on
3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
rn Important
• The power steering system may be tested
using J 5176-D or J 25323-A. Testing with
J 25323-A will measure flow rate as well as
pressure.
4. Connect J 5176-D and J 5176-92 or J 25323-A
and J 29525-92 to outlet hose assembly and spare
pressure hose.
5. Open valve on J 5176-D or J 25323-A.
6. Start engine and allow engine to reach normal
operating temperature.
3·16 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
A 3.4L L32 ENGINE
B 5.7L LT1 ENGINE
C REPLACE DRIVESHAFT SEAL. MAKE CERTAIN THAT
DRIVESHAFT IS CLEAN AND FREE OF PITIING
IN AREA.
D REPLACE HYDRAULIC PUMP FLOW CONTROL VALVE
SEAL (0-RING).
E TORQUE HYDRAULIC PUMP HOSE FITIING NUT TO
28 N•m (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
HYDRAULIC PUMP SEAL (0-RING).
F TORQUE HYDRAULIC PUMP FITIING TO 75 N•m
(55 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
HYDRAULIC PUMP SEAL (0-RING).
G CHECK FLUID LEVEL. IF LEAKAGE PERSISTS WITH THE
LEVEL CORRECT AND HYDRAULIC PUMP RESERVOIR
CAP TIGHT, REPLACE HYDRAULIC PUMP RESERVOIR
CAP.
H IF A CRACKED OR BENT HYDRAULIC PUMP FLUID
RESERVOIR IS DETECTED, REPLACE HYDRAULIC
PUMP FLUID RESERVOIR.
TORQUE STEERING GEAR PIPE FITIING SEAT TO
28 N•m (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
STEERING GEAR PIPE SEAL (0-RING).
Figure 11 - Power Steering Gear and Pump Assemblies Leak Diagnosis
B
c
J REPLACE GEAR WITH PARTIAL STEERING GEAR
ASSEMBLY.
K IF LEAKAGE IS OBSERVED BETWEEN TORSION BAR
AND STEERING GEAR PINION SHAFT ASSEMBLY,
REPLACE WITH PARTIAL STEERING GEAR ASSEMBLY.
L IF LEAKAGE IS OBSERVED AT DRIVER SIDE AND IS
NOT AFFECTED BY DIRECTION OF TURN, REPLACE
WITH PARTIAL STEERING GEAR ASSEMBLY.
M IF LEAKAGE IS OBSERVED AT STEERING GEAR
HOUSING END AND SPURTS WHEN BOTIOMED IN
LEFT TURN, REPLACE WITH PARTIAL STEERING
GEAR ASSEMBLY.
N IF LEAKAGE IS OBSERVED AT THESE POINTS,
REPLACE WITH PARTIAL STEERING GEAR ASSEMBLY.
P TORQUE HYDRAULIC PUMP FITIING TO 75 N•m
(55 LB. FT.) AND HYDRAULIC PUMP HOSE FITIING NUT
TO 28 N•m (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
HYDRAULIC PUMP SEAL (0-RING).
5 PUMP ASSEMBLY, POWER STEERING
6 RESERVOIR ASSEMBLY, POWER STEERING FLUID
7 HOSE ASSEMBLY, POWER STEERING FLUID OUTLET
8 GEAR ASSEMBLY, POWER STEERING
PC0001·3·F-RP
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3·17
7. With engine at idle and valve open on J 5176-D
or J 25323-A, pressure should be no more than
1 050 kPa (150 psi).
[I] Important
• If pressure is more than 1 050 kPa (150 psi),
check the hoses for restrictions and poppet
valve on steering gear assembly for proper
assembly.
NOTICE: Do not leave the valve fully closed for
more than 5 seconds as the pump assembly could be
damaged.
8. Fully close valve on J 5176-D or J 25323-A three
times and record pressure reading each time. Each
reading should show at least 6 895 kPa (1,000 psi).
The three readings should be within 345 kPa (50 psi)
of each other.
• If pressure readings are high enough and are
within 345 kPa (50 psi) of each other, pump
assembly is functioning properly.
• If pressure readings are high enough but are
not within 345 kPa (50 psi) of each other,
control valve in pump assembly is sticking.
A. Remove valve, clean it and remove any
burrs using crocus cloth or fine hone.
B. If system contains some contamination,
flush it.
• If pressure readings are less than 6 895 kPa
(1,000 psi), replace flow control valve and
recheck.
- If pressures are still low, replace rotor and
vanes.
9. If pump assembly checks to specification, leave
valve open and turn steering wheel assembly (or
have someone else turn it) to both stops.
• Record highest pressures and compare with
highest pump assembly pressure recorded
earlier.
- If pressure at both stops is not same as
maximum pressure, steering gear assem-
bly is leaking internally and must be
repaired.
10. Tum off engine.
11. Remove J 5176-D and J 5176-92 or J 25323-A
and J 29525-92
12. Connect outlet hose assembly to pump assembly on
3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
l~I Tighten
• Hydraulic pump hose fitting nut to 28 N•m
(21 lb. ft.).
13. Bleed power steering system. Refer to SECTION
3B.
SHOCK ABSORBER ASSEMBLIES
The following procedure includes both on-vehicle
and bench checks to be done when evaluating perfor-
mance of shock absorber assemblies.
[I] Important
• The single-tubed shock absorber assemblies are
highly gas pressurized and require a force of 445 N
(100 pounds) to initiate shock absorber rod move-
ment. Be careful not to dent or puncture the shock
absorber assemblies, or they must be replaced.
Weak
1. Check and adjust tire pressures to pressures shown
on tire placard.
2. Note load conditions under which vehicle is nor-
mally driven.
3. If practical, ride with owner to be sure you under-
stand complaint before proceeding to next step.
4. Test each shock absorber assembly in tum by
quickly pushing down, then lifting up, comer of the
bumper nearest the shock absorber assembly being
checked.
A. Use same amount of effort on each test and
note resistance on compression and rebound.
B. Compare this with a similar vehicle having
acceptable ride quality.
• Shock absorber assemblies on both
vehicles should provide the same feeling
of resistance. If there is much difference
between the two vehicles, go to next step.
5. Support vehicle to expose shock mounts.
6. Remove shock absorber assemblies. Refer to SEC-
TION 3C.
CAUTION: The shock absorber assem-
blies are highly pressurized. Be sure
to properly disassemble module or
personal injury could result.
7. Disassemble plastic dust tube.
8. Remove shock absorber rod washer.
rn Important
• Do not fully compress shock absorber assem-
bly. Shock absorber assemblies are highly gas
charged and will extend when released.
9. Turn shock absorber assembly so lower mount is up
and upper mount is down.
• Compress shock absorber assembly against
ground at various rates of speed through
approximately one-half the length of the
exposed chromed shock absorber rod (75 mm
(3 inches)-rear; 50 mm (2 inches)-front).
10. Compare right and left shock absorber assemblies
for compression resistance and rebound speed.
• Right and left shock absorber assemblies should
feel comparable.
3-18 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

HU
• Differences between front and rear shock
absorber assemblies are normal.
• If in doubt about condition, compare with a
shock absorber assembly known to be good.

Noisy

iii\\~~
A
1. Check all mountings for proper tightening.
• A loose mounting will cause a noise.
2. If all mountings are intact, jounce vehicle as in step 4
in "Weak" above to isolate suspected unit.
3. If practical, ride with owner to be sure you under-
stand complaint, before proceeding to next step.
4. Remove suspected shock absorber assembly. Refer
to SECTION 3C.
5. Shake shock absorber assembly and listen for loose A WEAR INDICATORS
KC0013-3-B-RP
metallic parts inside shock absorber body.
Figure 12 - Tread Wear Indicators
• If suspicious noise is heard, replace shock
absorber assembly.
6. Tum shock absorber assembly so lower mount is up
and upper mount and rod is down.
• Slowly compress shock absorber assembly. Do
not allow chromed portion of shock absorber
rod to pass below black seal cover.
7. Replace shock absorber assembly if seize is encoun-
tered with more than 25 mm ( 1 inch) of chromed
portion of shock absorber rod exposed above seal
cover.

Leaks
1. Fully extend shock absorber assemblies (tire and
wheel assemblies unsupported) to expose seal cover A c
area for inspection.
2. Look for signs of leaks at top of shock absorber
assembly.
• A small amount of fluid is not cause for
replacement. The seal permits some seepage to
lubricate the shock absorber rod.
• A leaking shock absorber assembly can easily
be found because there will be an excessive
amount of fluid on shock absorber assembly.
3. A leaking shock absorber assembly must be
replaced. B

TIRES
A HARD CORNERING, UNDER INFLATION OR LACK OF
IRREGULAR OR PREMATURE WEAR ROTATION
B EXCESSIVE TOE ON THE NON-DRIVE AXLE ASSEMBLY
Figures 12 and 13 OR LACK OF ROTATION
C HEAVY ACCELERATION ON DRIVE AXLE ASSEMBLY,
Irregular or premature tire wear has many causes. EXCESSIVE TOE ON DRIVE AXLE ASSEMBLY OR LACK
Some of them are: incorrect inflation pressures, lack of OF ROTATION
regular rotation, driving habits, or improper tire and wheel
assembly alignment. If tire and wheel assembly alignment PC8013-3-D-RP
is reset due to a tire wear condition, always reset toe as Figure 13 - Tire Wear Diagnosis
close to zero degrees as the specification allows.
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-19
Rotate tires if following conditions are noted:
• Front and rear tire wear is unequal.
• Uneven wear exists across tread of any tire.
• Left and right front tire wear is unequal.
• Left and right rear tire wear is unequal.
Check tire and wheel assembly alignment if follow-
ing conditions are noted:
• Left and right front tire wear is unequal.
• Wear is uneven across tread of any front tire.
• Front tire treads have a scuffed appearance with
"feather" edges on one side of tread ribs or blocks.
TREAD WEAR INDICATORS
Figure 12
The original equipment tires have built-in tread wear
indicators to show when the tires should be replaced.
These indicators will appear as 12.7 mm (1/2-inch) wide
bands when the tire tread depth becomes 1.6 mm (1/16
inch). When the indicators appear in 2 or more grooves at
3 locations, replace the tire.
TIRE WADDLE COMPLAINT
Figure 14
Tire waddle is side-to-side movement at the front
and/or rear of the vehicle. It can be caused by the steel belt
not being straight within the tire; or by excessive lateral
runout of the tire or wheel assembly. It is most noticeable
at low speed, about 8 to 48 km/h (5 to 30 mph). It may
also appear as a ride roughness at 80 to 113 km/h (50 to
70 mph).
The vehicle can be road tested to see which end of
the vehicle has the faulty tire. If the tire causing the tire
waddle is on the rear, the rear end of the vehicle will
"waddle." From the driver's seat, it feels as if someone is
pushing on the side of the vehicle.
If the faulty tire is on the front, the tire waddle is
more easily seen. The front sheet metal appears to be
moving back and forth. It feels as if the driver's seat is the
pivot point in the vehicle.
PC1003-3-F-RP
Figure 14 - Tire Waddle
A more time-consuming method of determining the
faulty tire is substituting tire and wheel assemblies that are
known to be good. Follow these steps:
1. Drive vehicle to determine if tire waddle is coming
from front or rear.
2. Install tire and wheel assemblies known to be good
from a similar vehicle in place of those on end of
vehicle which is vibrating.
• If tire waddle cannot be isolated to front or
rear, start with rear tires.
3. Road test again.
• If improvement is noted, install original tire
and wheel assemblies one at a time until faulty
tire is found.
• If no improvement is noted, install tires known
to be good in place of all four. Then, install
originals one at a time until faulty tire is found.
RADIAL TIRE LEAD/PULL
Figure 15
Lead/pull is the deviation of the vehicle from a
straight path on a level road with no pressure on the
steering wheel assembly.
Lead is usually caused by:
• Poor tire construction.
• Uneven brake assembly adjustment.
• Improper tire and wheel assembly alignment.
The way in which a tire is built can produce lead in a
vehicle. An example of this is placement of the belt. Off-
center belts on radial tires can cause the tire to develop a
side force while rolling straight down the road and the tire
will tend to roll like a cone.
The lead/pull correction chart should be used to
make sure that the front tire and wheel assembly align-
ment is not mistaken for tire lead (Figure 15). Refer to
SECTION 3A.
Rear tires will not cause lead.
VIBRATION
Figures 16 and 17
IL•l 1nspect
• Improper tire inflation pressure.
• Bent rims from chuckhole or curb impact.
• Faulty tires, such as tread distortions, separations, or
bulges.
- Slight sidewall indentations are normal and
will not affect ride.
- Sidewall bulges are not normal and indicate
impact damage.
• Mud or tar build-up on tire or wheel assembly.
• Replacement tire and wheel assembly does not
conform to original part, or is of lesser quality or
substitute design.
• Loose or missing balance weights or wheel nuts.
• Irregular or excessive tire wear.
• Bent or faulty drive axle assembly.
3-20 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

RADIAL TIRE LEAD/PULL CORRECTION CHART

Adjust the pressure to

specifications (on Tire Placard). Road Test OK

Check for proper trim heights.

Vehicle Lead/Pulls
Check brake assemblies for drag.
Cross switch front tire and wheel
assemblies.

OK

Vehicle leads/pulls same Vehicle leads/pulls opposite

direction. direction.

Probable cause is front tire and Probable cause is tires.

wheel assembly alignment. Check
caster-camber-toe.
Swap left front tire and wheel
assembly with left rear tire and
wheel assembly.

Road Test OK

Alignment not within specifications. Vehicle Still Leads Replace left rear tire.

Swap right front tire and wheel

Adjust front tire and wheel assembly assembly with right rear tire
alignment to specifications. and wheel assembly.

Road Test

Alignment Within Specifications

Vehicle still leads. Replace right rear tire.
Change caster setting.

Leads Left Leads Right

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

Road Test

Still Leads Left Still Leads Right

Continue decreasing right caster Continue decreasing left caster

until pull is eliminated. until pull is eliminated.

DO NOT exceed 2' cross caster.

PC6014-3-D·RP

Figure 15 - Radial Tire Lead/Pull Diagnosis

 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-21

VIBRATION COMPLAINT DIAGNOSIS

Visual inspection

Road test to verify

complaint.

Low speed below 64 High speed above 64

km/h (40 mph) km/h (40 mph)

OK On-vehicle Off-vehicle dynamic

runout check balance

Not OK Not OK

Off-vehicle On-vehicle dynamic

runout check balance

Not OK
Not OK OK

OK Match mount tire Index assemblies on

on wheel assembly wheel studs.

Not OK OK
Not OK

Replace Measure and

tire. replace wheel assembly. Measure axle assembly or
brake rotor runout.

OK OK
Not OK

Replace brake rotor or

axle shaft.

OK

Off-vehicle dynamic
balance

Not OK

On-vehicle finish
balance

Not OK

Check for engine drive

line imbalance.

PC6015-3-D-RP

Figure 16 - Wheel and Tire Vibration

3·22 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
A TIRE OUT OF ROUND
B TIRE STIFFNESS VARIATION
Figure 17 - Causes of Vibration/Runout
ROAD TEST
Before performing any work or testing, always road
test the vehicle. Warming up the tires is necessary to
eliminate any flat spotting. For vibrations that appear to
be engine related, refer to SECTION 6. A road test is also
necessary to determine the speed at which the vibration
occurs. Low-speed vibration at speeds less than 64 km/h
(40 mph) is usually related to runout. High-speed vibra-
tion at speeds greater than 64 km/h (40 mph) is usually the
result of imbalance, but may be a product of both runout
and imbalance.
TIRE AND WHEEL ASSEMBLY BALANCE
Before removing the tire and wheel assembly from
the vehicle, mark the wheel bolt nearest the valve stem
for future reference. Also mark the vehicle position
(left front, etc.) on each tire.
Balance is the easiest procedure to perform and
should be done first if the vibration occurs at highway
speeds. An off-vehicle, two-plane dynamic balance
should be performed first. This will correct any imbalance
in the tire and wheel assembly. An on-vehicle finish
balance may also be required. This may offset brake
drum, rotor, drive axle, or wheel cover imbalance.
If balance does not correct the highway speed vibra-
tion, or if the vibration occurs at low speeds, runout may
be the probable cause. Runout is the term used when com-
ponents are checked for symmetry. Runout can be caused
by the drive axle assembly, tire, the wheel assembly, the
bearing assembly, or the way the wheel assembly attaches
to the vehicle.
RUNOUT CHECK
This procedure may be stopped at whatever point the
acceptable level of runout is reached.
1. Measure free runout of tire and wheel assembly on
vehicle using a dial indicator with a roller wheel.
• Lateral runout (side to side) should be
measured on tire's sidewall as close to tread
shoulder as possible.
• Radial runout (up and down) should be
measured on center tread rib.
C RIM BENT OR OUT OF ROUND
KC0017-3-B-RP
- Some tread designs may require wrap-
ping a piece of tape tightly around center
tread circumference for better dial indi-
cator contact.
2. Disregard any instantaneous indicator needle jumps
due to sidewall depressions, tread blocks, etc.
3. Record total indicator reading, and location of high
point of runout.
4. If radial or lateral runout exceeds 1.52 mm (0.060
inch), mount tire and wheel assembly on a dynamic
balance machine and remeasure runout.
• Make sure wheel is centered on machine by
wheel center pilot hole.
5. Record total indicator reading, and location of the
high point of runout.
6. If radial or lateral runout exceeds 1.27 mm (0.050
inch), break down assembly and rotate tire on rim
180 degrees.
• In many cases, rotating tire on wheel assembly
will bring runout to an acceptable range.
• Whenever a tire is rotated on the wheel
assembly, in this way, the assembly must be
rebalanced.
7. Reinflate, mount on dynamic balance machine and
remeasure runout.
8. Record total indicator reading and location of high
point of runout.
9. If radial or lateral runout still exceeds 1.27 mm
(0.050 inch) and high point has moved approxi-
mately 180 degrees, following tire around rim, tire is
faulty and should be replaced.
10. If second high point still exceeds 1.27 mm (0.050
inch) and is close to original high point, relative to
the rim, wheel is faulty and should be replaced.
A. Before replacing tire and wheel assembly,
break down assembly and measure wheel sep-
arately.
B. Replace wheel if radial runout exceeds 1.02
mm (0.040 inch), or lateral runout exceeds
1.14 mm (0.045 inch).
11. If runout of tire and wheel assembly is within limits
when measured off the vehicle, yet exceeds the
limits when measured on the vehicle, the attachment
of tire and wheel assembly to hub is probable cause.
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3·23

12. Rotate assembly two wheel bolts and recheck
run out.
• Several positions may have to be tried to find
best location.
13. If runout can not be reduced to an acceptable level,
remove tire and wheel assembly and measure hub
stud runout.
14. If runout exceeds 0.76 mm (0.030 inch), replace hub
or drive axle shaft.
TIRE FORCE VARIATION CHECK
Tire stiffness variation, or loaded radial runout can
also cause a vibration. However, this is difficult to
measure without a tire problem detector or a loaded radial
runout buffer.
The tire problem detector is simply a roller drum
that slowly rotates the tire, while under load, (mounted on
the vehicle) measuring spindle movement.
The loaded radial runout buffer is a more automated
machine that slowly rotates the tire under load with a
roller drum off the vehicle and measures the tire's
stiffness. It will then "match" the tire to the wheel by
buffing off small amounts of rubber from the outer tread
rows at the stiff spot. This procedure is usually effective,
especially when used as a measuring device and for fine
buffing only. This equipment requires careful use. Do not
remove too much rubber.
Because this equipment is not always available, the
most basic procedure of measuring free runout with a dial
indicator, as previously detailed, is usually more practical.
The free runout of the tire will usually correspond with the
tire's stiff spot.
SUBSTITUTION METHOD
Install a known good set of tire and wheel assem-
blies. If these correct the vibration, the original tire and
wheel assemblies should be reinstalled one at a time until
the vibration returns.
TAPERED ROLLER BEARING
DIAGNOSIS
Figure 18
When diagnosing a bearing condition:
1. Consider general condition of all parts during dis-
assembly and inspection.
2. Identify bearing problem (Figure 18).
3. After identifying bearing problem, refer to diag-
nostic chart to identify cause and appropriate repair
procedures.

TAPERED ROLLER BEARING DIAGNOSIS

CONDITION CAUSE REPAIR PROCEDURE
Bent Cage Damage due to improper handling or Replace bearing.
tool usage.
Galling Metal smears on roller ends due to Replace bearing. Check inner bearing
overheating. Lubricant failure or seals and for proper lubrication.
overload.
Abrasive Step Wear Pattern on roller ends caused by fine Clean all parts and housing. Check inner
abrasives. bearing seals and bearings. Replace if
leaking, rough, or noisy.
Etching Bearing surfaces appear gray or grayish Replace bearings. Check inner bearing
black iri color with related etching away seals for proper lubrication.
of material usually at roller spacing.
Misalignment Outer race misalignment due to a Clean related parts and replace bearing.
foreign object. Make sure races are properly seated.
Indentations Surface depressions on race and rollers Clean all parts and housings. Check
caused by hard particles of foreign inner bearing seals and replace bearings
material. if rough or noisy.
Fatigue Spalling Flaking of surface metal resulting from Replace bearing. Clean all related parts.
fatigue.
Brinelling Surface indentations in raceway caused Replace bearing if rough or noisy.
by rollers either under impact loading
or vibration while bearing is not
rotating.
Cage Wear Wear around outside diameter of cage Replace bearings. Check inner bearing
and roller pockets caused by abrasive seals and for proper lubrication.
material and insufficient lubrication.
Abrasive Roller Wear Pattern on races and rollers caused by Clean all parts and housings. Check
fine abrasives. inner bearing seals and bearings.
Replace if leaking, rough, or noisy.
3-24 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

CONDITION CAUSE REPAIR PROCEDURE

Cracked Inner Race
Smears
Frettage
Heat Discoloration
Stain Discoloration
Race cracked due to improper fit, Replace inner race.
cocking, or poor bearing seats.
Smearing of metal due to slippage. Replace bearings. Clean related parts
Slippage can be caused by poor fits, and check for proper fit and lubrication.
poor lubrication, overheating, over- Replace shaft if damaged.
loads, or handling damage.
Corrosion set up by small relative Replace bearing. Clean related parts.
movement of parts with no lubrication. Check inner bearing seals and for proper
lubrication.
Discoloration can range from faint Replace bearings if overheating damage
yellow to dark blue and can result from is indicated. Check inner bearing seals
overload or incorrect lubricant, and and for proper lubrication.
overheating.
Excessive heat can cause softening of
the races on rollers.
To check for heat tempering on races or
rollers a file test can be done. A file
drawn over a tempered part will grab
and cut metal.
A file drawn over a hard part will glide
easily without cutting the metal.
Discoloration can range from light Reuse bearings if stains can be removed
brown to black and can be caused by by light polishing and if there is no
incorrect lubricant or moisture. evidence of overheating. Check inner
bearing seals and related parts for
damage. Check for proper lubrication.

TRIM HEIGHT Measuring "Z," "J" and "A" Dimensions

Figure 19
Incorrect trim heights can produce symptoms simi-
lar to those produced when there is a problem with the
tire and wheel assembly alignment. Trim heights should
be checked when diagnosing steering and vibration
complaints (Figure 19).
In order to measure trim height accurately, make
sure:
• Tires are at correct pressure as shown on tire placard
"up to vehicle capacity."
• Fuel tank assembly is full.
• Vehicle has no additional weight or passengers.
• Seat assemblies are in full back position.
• Rear compartment is empty except for spare tire and
jack assembly and simulated fuel load if required.
1. Lift front bumper of vehicle up approximately
38 mm (1 1/2 inches). Gently remove hands and let
vehicle settle.
A. Repeat operation for a total of 2 times.
B. After second time, measure "Z," "J" and "A"
dimensions.
2. Push front bumper down approximately 38 mm
(1 1/2 inches). Gently remove hands and let vehicle
rise on its own.
A. Repeat operation for a total of 2 times.
B. Measure "Z," "J" and "A" dimensions.
3. Calculate trim heights.
• Trim heights are average of high and low
measurements.
4. Verify trim heights with Figure 19.

• Vehicle is on a known level floor. 5. Correct trim heights as necessary.

• All door assemblies, hood assembly and rear

compartment lid assembly are closed. Measuring "D," "K" and "B" Dimensions
All dimensions shown on Figure 19 are measured Repeat procedure as described for "Measuring "Z,"
vertical to the ground. Trim heights should be within "J" and "A" Dimensions" using the rear bumper and
± 10 mm (0.4 inch) to be considered correct. measuring "D," "K" and "B" at the appropriate times.
 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-25

fll '\] fll ·~

.
A B c D

fl) 11 ~';f ·~
E F
l~IDrn® fQll Jrn~1
G H

~~~ ~l ~
IJd]rnB mg ~mffil
J K L

~r :· ·'1
M N 0 p

tmrn1 a
A GOOD BEARING F ETCHING K CAGE WEAR P HEAT DISCOLORATION

B BENTCAGE G MISALIGNMENT L ABRASIVE ROLLER WEAR O STAIN DISCOLORATION

C BENT CAGE H INDENTATIONS M CRACKED INNER RACE

D GALLING I FATIGUE SPALLING N SMEARS

E ABRASIVE STEPWEAR J BRINELLING O FRETTAGE

KC0018·3-B·RP

Figure 18 - Tapered Roller Bearing Diagnosis

3·26 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS

CENTERLINE CENTERLINE

828mm 438mm
(32.59") (17.24")
FRONT AXLE REAR AXLE
ASSEMBLY ASSEMBLY

ROCKER
OUTER
PANEL

REAR BUMPER
ROCKER
BRACKET BOLT/SCREW 1
---- INNER
PANEL

LOWEST DISTANCE
POINT OF TO
ROCKER PANEL GROUND
TOP OF REAR AXLE
(J &Kl
ASSEMBLY BRACKET
LGROUND

SECTION A-A
REAR AXLE
ASSEMBLY
CENTER OF FRONT LOWER
!VIEWA I CONTROL ARM - FRONT
LOWER CONTROL ARM
BUSHING BOLT/SCREW HEAD

LOWEST POINT ON
FRONT LOWER CONTROL
ARM BALL STUD
!VIEWB I ASSEMBLY (EXCLUDING
GREASE FITIING)
(LEFT-HAND SHOWN)

SUSPENSION TIRE A B z D J K
mm inch mm inch mm inch mm inch mm inch mm inch
F41 215-60 420 16.5 367 14.4 32 1.3 121 4.8 204 8.0 208 8.2
235-55 420 16.5 367 14.4 30 1.2 118 4.6 204 8.0 208 8.4
FE2 235-55 420 16.5 367 14.4 31 1.2 118 4.6 204 8.0 208 8.4
245-50 420 16.5 367 14.4 37 1.5 125 4.9 204 8.0 208 8.4

NOTE: Trim heights should be within ±10 mm (0.4 inch).

PC1004-3·F·RP

Figure 19 - Trim Height Diagnosis

 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-27

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Hydraulic Pump Fitting ............................................... 75 N•m (55 lb. ft.)
Hydraulic Pump Hose Fitting Nut ...................................... 28 N•m (21 lb. ft.)
Power Steering Gear Pipe Fitting Seat ................................... 28 N•m (21 lb. ft.)

SPECIAL TOOLS

1. ~J5176·D
3. r~J5176-92
2.

J 29525-92
1. POWER STEERING PRESSURE TESTER O- 2000 PSI 4.
2. POWER STEERING SYSTEM ANALYZER
3. POWER STEERING PRESSURE TESTER ADAPTER
4. POWER STEERING ANALYZER 18 mm ADAPTER

NC4005-3-B-RP

SECTION 3A
WHEEL ALIGNMENT
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Camber ................................ 3A-1
Toe ................................... 3A-1
Thrust Angle , . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Preliminary Inspections ................... 3A-2
Diagnosis ...................... Refer to Section 3
On-Vehicle Service ........................ 3A-3
Measuring Front Alignment Angles ......... 3A-3
GENERAL DESCRIPTION
Tire and wheel assembly alignment refers to the
angular relationship between the tire and wheel assem-
blies, the suspension attaching parts and the ground.
CASTER
Figures 1 and 2
Caster is the tilting of the front steering axis (at the
top) either forward or backward from the vertical. A back-
ward tilt is positive (+) and a forward tilt is negative (-).
Caster influences directional control of the steering but
does not affect tire wear and is adjustable only at the front
tire and wheel assemblies.
Caster is affected by vehicle height; therefore, it is
important to keep the body at its designated trim height.
Overloading the vehicle or a weak or sagging rear spring
will affect caster. When the rear of the vehicle is lower
than its designated trim height, the front suspension
moves to a more positive caster. If the rear of the vehicle is
higher than its designated trim height, the front suspen-
sion moves to a less positive caster. For trim height
information, refer to SECTION 3.
CAMBER
Figures 1 and 3
Camber is the tilting of the front tire and wheel
assemblies from the vertical when viewed from the front
of the vehicle. When the tire and wheel assemblies tilt
outward at the top, the camber is positive (+). When the
tire and wheel assemblies tilt inward at the top, the camber
is negative (-). The amount of tilt is measured in degrees
from the vertical and is called the camber angle. Camber
setting influences directional control and tire wear.
WHEEL ALIGNMENT 3A·1
Front Caster and Camber Adjustment . . . . . . . . 3A-4
Front Toe Adjustment .................... 3A-4
Measuring Rear Alignment Angles .......... 3A-5
Rear Thrust Angle Adjustment . . . . . . . . . . . . . 3A-6
Specifications ............................. 3A-6
Tire and Wheel Assembly
Alignment Specifications ................ 3A-6
Fastener Tightening Specifications .......... 3A-6
Special Tools ............................. 3A-6
When tire and wheel assemblies are set to a positive
camber angle, they will tend to roll in a path away from
the vehicle's true path. The effect of each tire and wheel
assembly tends to cancel the other. The suspension geom-
etry and camber setting are designed to keep the tire tread
flat on the road through bumps or dips.
TOE
Figures 1 and 4
Toe is a measurement of how much the front tire and
wheel assemblies are turned in or out from a straight-
ahead position. When the tire and wheel assemblies are
turned in, toe is positive (+). When the tire and wheel
assemblies are turned out, toe is negative (-). The actual
amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the tire and wheel assem-
blies roll parallel.
Toe also serves to offset the small deflections of the
tire and wheel assembly support system which occur
when the vehicle is rolling forward. In other words, even
when the tire and wheel assemblies are set to toe in or out
slightly when the vehicle is standing still, they tend to roll
parallel on the road when the vehicle is moving. Toe
affects tire wear.
THRUST ANGLE
Figures
The front tire and wheel assemblies aim or steer the
vehicle, but the rear tire and wheel assemblies control
tracking. This tracking action is relative to thrust angle.
Thrust angle is defined as the path that the rear tire and
wheel assemblies will take. Ideally, the thrust angle is
geometrically aligned with the body centerline.
3A-2 WHEEL ALIGNMENT

2
tp

A B c

A CASTER K CENTERLINE OF VEHICLE

B CAMBER L CENTERLINE OF BOLT/SCREW HEAD
C TOE M TRIM HEIGHT
D VERTICAL N CENTERLINE OF FRONT TIRE AND WHEEL ASSEMBLIES
E NEGATIVE CASTER ANGLE P POSITIVE WHEEL TOE-IN ANGLE (ONE TIRE AND
F POSITIVE CASTER ANGLE WHEEL ASSEMBLY)
G CENTERLINE OF TIRE AND WHEEL ASSEMBLY Q NEGATIVE CAMBER ANGLE
H LOWER INBOARD CORNER OF LOWER CONTROL ARM 1 FRAME ASSEMBLY
BALL STUD ASSEMBLY 2 CROSSMEMBER ASSEMBLY, FRONT
J POSITIVE CAMBER ANGLE 3 ARM ASSEMBLY, FRONT LOWER CONTROL

PC0001-3A-F-RP

Figure 1 - Caster, Camber and Toe

I \

D
A B
A CASTER IS POSITIVE WHEN LOWER CONTROL BALL C SPINDLE
STUD ASSEMBLY IS AHEAD OR PULLING THE SPINDLE D VERTICAL
B CASTER IS NEGATIVE WHEN THE LOWER CONTROL 4 STUD ASSEMBLY, FRONT LOWER CONTROL ARM BALL
BALL STUD ASSEMBLY IS BEHIND OR PUSHING THE
SPINDLE
PC0002-3A·F-RP

Figure 2 - Caster

PRELIMINARY INSPECTIONS
Steering and vibration complaints are not always the
result of improper alignment. Another possibility is tire
"lead" due to worn or improperly manufactured tires.
"Lead" is the vehicle deviation from a straight path on a
level road without pressure on the steering wheel assem-
bly. To determine if the vehicle has a tire lead problem,
refer to SECTION 3.
Before making any adjustment affecting tire and
wheel assembly alignment, make the following inspec-
 WHEEL ALIGNMENT 3A-3

E
c
A

A B
--- ----
~~~
m
B I
I

A THRUST ANGLE
B THRUST LINE - OFF CENTER
C GEOMETRIC CENTERLINE D
D REAR TOE-OUT CONDITION
E REAR TOE-IN CONDITION
PC0004-3A-F-RP
Figure 5 - Thrust Angle
c • Tie rod ends. If they are loose, correct them before
adjusting tire and wheel assembly alignment. Refer
A A CYLINDER WILL ROLL STRAIGHT AHEAD to SECTION 3B.
B A CONE WILL ROLL IN A CIRCLE TOWARD THE SMALL
END • Runout of tire and wheel assemblies. Refer to SEC-
C TIRE CONTACTS THE ROAD SURFACE TION 3.
D POSITIVE CAMBER ANGLE
E VERTICAL • Vehicle trim height. If out of limits and a correction
is to be made, do so before adjusting alignment.
PC0003-3A-F-RP
Refer to SECTION 3 for trim height chart.
Figure 3 - Camber • Steering gear assembly for looseness at frame
assembly.
• Control arm assemblies for loose bushing assem-
blies.
• Stabilizer shaft for loose or missing parts.
-------''A''-------.

....
FRT
• Improperly operating shock absorber and spring
assemblies. ·
• Suspension and steering components for damage.
Replace parts as necessary.
• Vehicle for stability. The fuel tank assembly should
be full, or the vehicle should have compensating bal-
last.
• Jounce vehicle lightly three times rear and three
times front.
Consideration must be given to excess loads, such as
- - - - - - - ''B'' -------1 tool boxes, sample cases, etc. If these items are normally
DIMENSION "A" SHOULD BE LESS THAN "B"
carried in the vehicle, they should remain in the vehicle
during alignment adjustments.
KCOOCM-3A·F·RP
Consideration should also be given to the condition
of the equipment being used to adjust alignment. Be sure
Figure 4 - Toe to follow the equipment manufacturer's instructions.
Regardless of the equipment used to adjust alignment, the
vehicle must be on a level surface, both front-to-rear and
tions to ensure correct alignment readings and alignment side-to-side.
adjustments.

IL•l 1nspect ON-VEHICLE SERVICE

• All tires for proper inflation pressures. Also check
that all tires have about the same tread wear.
• Control arm ball stud assemblies. If they are loose,
correct them before adjusting tire and wheel assem-
bly alignment. Refer to SECTION 3C.
MEASURING FRONT ALIGNMENT ANGLES
Satisfactory vehicle operation may occur over a
wide range of alignment settings. However, should the
settings vary beyond the specifications shown at the end
of this section, the alignment angles should be corrected.
3A·4 WHEEL ALIGNMENT

l@I Measure
• Front alignment angles.
A. Install alignment equipment according to the
manufacturer's instructions.
B. Jounce the front and rear bumper assemblies
lightly three times to normalize suspension
prior to measuring angles.
C. Measure alignment angles and record the read-
ings. If adjustments are required, make them in
the following order: caster, camber and toe.

FRONT CASTER AND CAMBER

ADJUSTMENT 2 CROSSMEMBER ASSEMBLY, FRONT
Figures 6 and 7 3 ARM ASSEMBLY, FRONT LOWER CONTROL

Tool Required: PC0005-3A-F-RP

J 38658 Camber/Caster Adjuster Figure 6 - Front Caster Adjustment

1£1 Adjust
1. Jounce front bumper assembly three times to allow
vehicle to return to normal height before making any
adjustments in caster.
2. Raise and suitably support vehicle. Refer to SEC-
TION QA.
3. Loosen front lower control arm nuts. Refer to SEC-
TION 3C.
4. Install J 38658 to slot holes in lower control arm
assembly (3) and front crossmember assembly (2) 2
(Figure 6).
5. Caster by rotating turnbuckle on J 38658.
• Rotating turnbuckle clockwise will increase
caster.
2 CROSSMEMBER ASSEMBLY, FRONT
• Rotating turnbuckle counterclockwise will 3 ARM ASSEMBLY, FRONT LOWER CONTROL
decrease caster.
6. Install J 38658 to slot holes in lower control arm Figure 7 - Front Camber Adjustment
assembly (3) and front crossmember assembly (2)
(Figure 7).
7. Camber by rotating turnbuckle on J 38658.
• Rotating turnbuckle clockwise will increase 5
camber.
• Rotating turnbuckle counterclockwise will
decrease camber.
8. Remove J 38658 from slot holes.
9. Tighten front lower control arm nuts. Refer to SEC-
TION 3C.
10. Lower vehicle.

FRONT TOE ADJUSTMENT. 1 KNUCKLE ASSEMBLY, STEERING

Figures 2 ROD, STEERING LINKAGE OUTER TIE
3 ROD, STEERING LINKAGE INNER TIE
[el Adjust 4 NUT, STEERING LINKAGE TIE ROD ADJUST,
47 N•m (35 LB. FT.)
5 BOOT, STEERING GEAR
NOTICE: See "Notice" on page 3A-1 of this sec- PC0007-3A·f·RP
tion. Figure 8 - Front Toe Adjustment
• Toe
 WHEEL ALIGNMENT 3A·5

A. Make sure steering wheel assembly is set in a
straight-ahead position within ± 3.5 degrees.
B. Toe adjustments are made separately at each
individual tire and wheel assembly.
C. Loosen nut ( 4) on inner tie rod ( 3).
D. Toe to specification by turning inner tie rod
(3). Refer to "Alignment Specifications" in
this section.
- Left and right toe adjustment should be
equal within ± 0.2 degrees.
E. Check steering gear boot seal is not twisted.
l~I Tighten
• Nut (3) to 47 N•m (35 lb. ft.).
F. Check specifications for adjustment. Readjust
by repeating steps if necessary.
MEASURING REAR ALIGNMENT ANGLES
Figure 9
After front tire and wheel assembly alignment has
been completed, ·the rear alignment angles should be
checked if there is excessive rear tire wear or tire and
wheel assemblies do not track properly. Rear tire and
wheel assemblies ( 14) should be parallel to and the same
distance from the vehicle's centerline ..
If tires do not track correctly after a front tire and
wheel assembly alignment, no amount of adjustment will
correct the problem. Poor tracking or excessive rear tire
wear after a front tire and wheel assembly alignment usu-
ally indicates that the axle housing assembly, frame
assembly or suspension arms have been bent.
Rear alignment angles can be checked as follows:
131 Measure
• Rear alignment angles.
A. Back vehicle squarely onto alignment
machine.

E E 13
E G G
13 13
G

\ F

14 14

A
\ F
B

A RIGHT SIDE OF REAR AXLE ASSEMBLY IS FORWARD

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

Figure 9 - Rear Tire and Wheel Assemblies

3A-6 WHEEL ALIGNMENT

B. Compensate for tire and wheel assembly run-
out the same as for checking front tire and
wheel assembly toe-in.
C. Check camber reading which should be 0.0
degrees ± 0.6 degrees.
D. Check amount of toe which should be 0.0
degrees ± 0.3 degrees.
• When using an alignment machine to
measure toe-out, the measurement will
read as toe-in on the scale.
• When checking toe-in with a tram gage,
the measurement will read correctly as
toe-out. However, when using a tram
gage, it will still be necessary to perform
steps A and B to check camber
REAR THRUST ANGLE ADJUSTMENT
If the thrust angle is not within specifications,
inspect the upper and lower control arm assemblies for
damage. If the control arm assemblies are not damaged,
then check the frame dimensions. Refer to SECTION
10-3.

SPECIFICATIONS

TIRE AND WHEEL ASSEMBLY ALIGNMENT SPECIFICATIONS

SET CHECK
Front
Caster ................................................. 4.4° ± 0.5° 4.4° ± 1.0°
Cross Caster ............................................ 0.0° ± 0.7° 0.0° ± 0.7°
Camber ................................................ 0.4° ± 0.5° 0.4° ± 1.0°
Cross Camber ........................................... 0.0° ± 0.7° 0.0° ± 0.7°
Individual Toe ........................................... 0.0° ± 0.1 ° 0.0° ± 0.1 °
Total Toe ............................................... 0.0° ± 0.2° 0.0° ± 0.2°
Steering Wheel Angle ..................................... 0.0° ± 3.5° 0.0° ± 3.5°

Rear
Camber ................................................ 0.0° ± 0.6° 0.0° ± 0.6°
Cross Camber ........................................... 0.0° ± 0.6° 0.0° ± 0.6°
Total Toe ............................................... 0.0° ± 0.3° 0.0° ± 0.3°
Thrust Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0° ± 0.15° 0.0° ± 0.15°

FASTENER TIGHTENING SPECIFICATIONS

Steering Linkage Tie Rod Adjust Nut .................................... 47 N•m (35 lb. ft.)

SPECIAL TOOLS

1.

J 38658

1. CAMBER/CASTER ADJUSTER
PC0009-3A-F-RP
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38·1

SECTION 38

POWER STEERING GEAR AND PUMP

ON-VEHICLE SERVICE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.

NOTICE: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When discon-
nected, cap or plug all openings of components. Failure to do so could result in contamination or loss of power
steering fluid and damage to the system.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3B-1
Power Steering Gear Assembly . . . . . . . . . . . . . 3B-1
Power Steering Pump Assembly . . . . . . . . . . . . 3B-1
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Diagnosis ...................... Refer to Section 3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Checking and Adding Power Steering Fluid . . . 3B-4
Power Steering Fluid Replacement . . . . . . . . . . 3B-4
Flushing the Power Steering System ....... 3B-4
Bleeding the Power Steering System . . . . . . . 3B-4
Power Steering Pump Belt (Serpentine Belt) .. 3B-5
Power Steering Pump Pulley Assembly ...... 3B-5
Power Steering Gear Assembly . . . . . . . . . . . . . 3B-5
Power Steering Gear Inlet and Outlet
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . 3B-6
Hydraulic Pump Flow Control Valve . . . . . . . . . 3B-8
Power Steering Pump Support . . . . . . . . . . . . . . 3B-9
Power Steering Pump Assembly . . . . . . . . . . . 3B-10
Power Steering Fluid Reservoir Assembly . 3B-12
Power Steering Fluid Reservoir
Hose Assembly .................... 3B-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13
Power Steering Fluid Recommendations ..... 3B-13
Fitting Tightening Specifications . . . . . . . . . . . 3B-13
Fastener Tightening Specifications . . . . . . . . . 3B-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-14

GENERAL DESCRIPTION
POWER STEERING GEAR ASSEMBLY
Figures 1 and 2
The major internal components of the steering gear
assembly (1) are the power steering gear pinion and valve
shaft assembly, steering gear rack and piston assembly
and steering linkage tie rod assemblies (inner and outer tie
rods). The steering gear rack and piston assembly is sup-
ported at its ends in the steering gear housing and sealed to
prevent both external and internal leakage across the
piston. The pinion and valve assembly intersects and
meshes directly with the teeth of the rack and piston
assembly. Manual steering is always available at times
when the engine is not running or in the event of power
steering pump assembly (4 or 32) or serpentine belt
failure. Steering effort is increased under such conditions.
The movement of the steering gear assembly
components, when either parked or moving, is aided by
hydraulic pressure and fluid flow supplied by the power
steering pump assembly (4 or 32). Pressurized fluid is
directed by the steering gear valve during a steer
manuever and travels through external steel cylinder lines
to act on the rack and piston assembly. When the vehicle
is turned right, the steering gear valve is opened and
routes pressurized fluid to the left side of the piston, while
allowing fluid to escape from the right side and return to
the valve area. The pressure of the fluid is converted to a
mechanical force applied to the piston and the difference
in force across the piston causes the rack to move to the
right. The opposite occurs when the gear assembly (1) is
turned to the left. Whenever the pump assembly (4 or 32)
provides pressurized fluid to the gear assembly (1) and the
valve is operating correctly, the effort to steer the vehicle
is created by this pressure difference at the piston. For
information on power steering gear assembly unit repair,
refer to SECTION 3B1A.
POWER STEERING PUMP ASSEMBLY
Figures 1 and 2
A constant displacement vane-type pump assembly
provides hydraulic pressure and flow for the power steer-
ing system. The pump assembly (4 or 32) is located on the
engine and is belt driven by the power steering pulley
assembly (3 or 31 ).
The major components of the pump assembly (4 or
32) are the fluid reservoir, pump shaft, pump housing,
pump fitting, flow control valve and spring, thrust and
pressure plates, pump ring, pump rotor and pump vanes.
The housing and component parts are "submerged"
in the fluid reservoir in the 3.4L L32 engine. The 5. 7L
38-2 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

1 GEAR ASSEMBLY, POWER STEERING

2 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
3 PULLEY ASSEMBLY, POWER STEERING PUMP
4 PUMP ASSEMBLY, POWER STEERING
5 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
28 N•m (21 LB. FT.)
6 BOOT, STEERING GEAR
7 SHAFT ASSEMBLY, STEERING GEAR COUPLING
8 KNUCKLE ASSEMBLY, STEERING
9 CLAMP, STEERING GEAR COUPLING SHIELD
PC0001-38-f.RP

Figure 1 - Power Steering System (3.4L L32 Engine)

LTl engine has a remote reservoir assembly (10). The res-
ervoir cap assembly (24) has a fluid level indicator
attached to show the fluid level in the reservoir.
For the 3.4L L32 engine pump assembly (4), there
are two bore openings at the rear of the housing. The
larger opening contains all of the pump assembly compo-
nents, except the flow control valve, spring and pump fit-
ting, which are in the small bore. The pump fitting,
working with the flow control valve and spring, limits the
maximum flow of the pump assembly (4). The pressure
relief valve, inside the flow control valve, limits the maxi-
mum pump assembly (4) pressure.
For the 5.7L LTl engine pump assembly (32), the
bore at the rear of the housing contains the same set of
components as the 3.4L L32 engine pump assembly (4).
The flow control valve, spring and pump fitting are
located in the top of the pump housing, in the casting boss
that runs across the housing. For information on power
steering pump assembly unit repair, refer to SECTION
3BlB.
SEAL REPLACEMENT
Lip Seals
Lip seals, which seal rotating shafts, require special
treatment. This type of seal is used on the hydraulic pump
shaft of the pump assembly. When leakage occurs in this
area, always replace the seal or seals, after inspecting and
thoroughly cleaning the sealing surfaces. Replace the
shaft if pitting is found. If corrosion in the lip seal contact
zone is slight, clean the surface of the shaft with crocus
cloth. Replace the shaft only if the leakage cannot be
stopped by smoothing with crocus cloth first.
0-Ring Seals
Whenever a part which forms a sealing surface for
an 0-ring is removed, the 0-ring seal should also be
removed and replaced with a new 0-ring seal. Lubricate
all new 0-ring seals with power steering fluid to ease
assembly.
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38·3

1 GEAR ASSEMBLY, POWER STEERING

6 BOOT, STEERING GEAR
7 SHAFT ASSEMBLY, STEERING GEAR COUPLING
8 KNUCKLE ASSEMBLY, STEERING
9 CLAMP, STEERING GEAR COUPLING SHIELD
10 RESERVOIR ASSEMBLY, POWER STEERING FLUID
11 HOSE ASSEMBLY, POWER STEERING FLUID
RESERVIOR
24 CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
30 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
31 PULLEY ASSEMBLY, POWER STEERING PUMP
32 PUMP ASSEMBLY, POWER STEERING
33 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
28 N•m (21 LB. FT.)
PC0002-3B-F·RP

Figure 2 - Power Steering System (5.7L LT1 Engine)

38-4 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
CHECKING AND ADDING POWER
STEERING FLUID
Fluid level is indicated by marks on a fluid level
indicator on the reservoir cap assembly.
NOTICE: When adding fluid or making a complete
fluid change, always use the proper fluid. Failure to
use the proper fluid will cause hose and seal damage
and fluid leaks. Refer to "Power Steering Huid Rec-
ommendations" in this section.
If the fluid is about 77°C (170°F), the fluid level
should be at the "H'' mark.
If the fluid is about 21 °C (70°F), the fluid level
should be at the "C" mark.
POWER STEERING FLUID REPLACEMENT
The fluid replacement procedure is a two-stage pro-
cess: first, flushing the old fluid from the system with new
fluid; and second, bleeding the system to remove trapped
air. The following two sequences outline the steps in each
procedure.
Flushing the Power Steering System
NOTICE: When adding fluid or making a complete
fluid change, always use the proper fluid. Failure to
use the proper fluid will cause hose and seal damage
and fluid leaks. Refer to "Power Steering Fluid Rec-
ommendations" in this section.
1. Raise and suitably support front of vehicle off
ground until tire and wheel assemblies are free to
tum. Refer to SECTION OA.
2. Remove inlet hose assembly on 3.4L L32 engine or
reservoir hose assembly on 5.7L LTl engine at fluid
reservoir inlet connector and plug fluid inlet connec-
tor port on fluid reservoir assembly.
rn Important
• Position inlet or reservoir hose assembly
toward large container to catch draining fluid.
3. While an assistant is filling fluid reservoir assembly
with fluid, start and run engine at idle.
NOTICE: Do not hold the steering wheel assembly
against tire and wheel assembly stops while flushing
system. Holding steering wheel assembly against
stops will cause high power steering system pres-
sure, overheating, and damage to the pump assem-
bly and/or steering gear assembly.
4. Tum steering wheel assembly from stop to stop.
5. Continue draining until all old fluid is cleared from
power steering system. Addition of approximately
0.94 liters (1 quart) of new fluid will be required to
flush system.
ll•l 1nspect
• Draining fluid while refilling fluid reservoir
assembly.
- If necessary, replace all lines and disas-
semble, and clean or replace system com-
ponents.
- Do not reuse any drained fluid.
6. Unplug fluid inlet connector port on fluid reservoir
assembly and reconnect inlet hose assembly on 3.4L
L32 engine and reservoir hose assembly on 5. 7L
LTl engine at fluid reservoir inlet connector.
7. Tum engine off and fill fluid reservoir on 3.4L L32
engine or remote fluid reservoir assembly on 5.7L
LTl engine to "C" mark on fluid level indicator.
Continue with following procedure "Bleeding the
Power Steering System."
Bleeding the Power Steering System
NOTICE: When adding fluid or making a complete
fluid change, always use the proper fluid. Failure to
use the proper fluid will cause hose and seal damage
and fluid leaks. Refer to "Power Steering Fluid Rec-
ommendations" in this section.
NOTICE: If the system has been serviced, an accu-
rate fluid level reading cannot be obtained unless air
is bled from the system. The air in the fluid may
cause pump assembly cavitation noise and may
cause pump assembly damage over a period of time.
After replacing the fluid or servicing the system, you
must bleed air from the system. Air in the system prevents
an accurate. fluid level reading, causes pump assembly
cavitation noise and over time could damage the pump
assembly. To bleed the system proceed as follows:
1. Begin with engine off, front tire and wheel assem-
blies off ground and turned all the way to left. Refer
to SECTION OA.
2. Add either standard fluid or optional cold climate
fluid to "C" mark on fluid level indicator.
3. Bleed system by turning tire and wheel assemblies
from side to side without hitting stops.
rn Important
• It may be necessary to tum tire and wheel
assemblies from side to side several times.
Keep fluid level at "C" mark on fluid level
indicator. Fluid with air in it has light tan
appearance. This air must be eliminated from
fluid before normal steering action can be
obtained.
4. Start engine. With engine idling, recheck fluid level.
If necessary, add fluid to bring level to "C" mark on
fluid level indicator.
5. Return tire and wheel assemblies to center position.
Lower front tire and wheel assemblies to ground.
Continue running engine for two or three minutes.
6. Test vehicle to be sure steering functions normally
and is free from noise.
ll•l 1nspect
• For fluid leakage at connection points along
system.
7. Recheck fluid level as described in steps 3 and 4
except fluid level should now be up to "H" mark on
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38·5
fluid level indicator after system has stabilized at its
normal operating temperature.
. POWER STEERING PUMP BELT
(SERPENTINE BELT)
The pump assembly is driven by a serpentine belt.
No adjustment of the serpentine belt is required.
To remove or install the serpentine belt, refer to
SECTION 6A2A or 6A3A.
POWER STEERING PUMP PULLEY
ASSEMBLY
Figure3
Tools Required:
J 25034-B Pump Pulley Remover
J 25033-B Pump Pulley Installer
l++I Remove or Disconnect
1. Raise and suitably support vehicle on 5.7L LTl
engine only. Refer to SECTION OA.
2. Drain engine coolant on 5. 7L LTl engine only. Refer
to SECTION 6B.
3. Serpentine belt. Refer to SECTION 6A2A or 6A3A.
4. Lower vehicle on 5.7L LTl engine only.
5. Front air intake duct. Refer to SECTION lA.
6. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
7. Radiator outlet hose assembly from engine assembly
on 5.7L LTl engine only. Refer to SECTION 6B.
8. Heater inlet and outlet hose assemblies from water
pump assembly on 5.7L LTl engine only. Refer to
SECTION lA.
9. Throttle body heater return hose from heater outlet
hose assembly on 5.7L LTl engine only. Refer to
SECTION lA.
10. Power steering pump bolts/screws on 5.7L LTl
engine only. Refer to "Power Steering Pump
Assembly" in this section.
11. Inlet and reservoir hose assemblies from pump
assembly on 5.7L LTl engine only. Refer to "Power
Steering Gear Inlet and Outlet Hose Assemblies"
and "Power Steering Fluid Reservoir Assembly" in
this section.
12. Pulley assembly (3 or 31) from pump assembly (4 or
32) using J 25034-B.
l++I Install or Connect
1. Pulley assembly (3 or 31) to pump assembly (4 or
32) using J 25033-B.
rn Important
• Face of pulley assembly hub must be flush
with end of pump shaft before applying load to
pulley assembly hub.
• Load required to press pulley assembly hub
onto pump shaft must be greater than 6 672 N
(1,500 lbs.) but less than 31 136 N (7,000 lbs.) .
2. Inlet and reservoir hose assemblies to pump assem-
bly on 5.7L LTl engine only. Refer to "Power Steer-
ing Gear Inlet and Outlet Hose Assemblies" and
"Power Steering Fluid Reservoir Assembly" in this
section.
3. Power steering pump bolts/screws on 5.7L LTl
engine only. Refer to "Power Steering Pump
Assembly" in this section.
4. Throttle body heater return hose to heater outlet hose
assembly on 5.7L LTl engine only. Refer to SEC-
TION IA.
5. Heater inlet and outlet hose assemblies to water
pump assembly on 5.7L LTl engine only. Refer to
SECTION lA.
6. Radiator outlet hose assembly to engine assembly on
5.7L LTl engine only. Refer to SECTION 6B.
7. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
8. Front air intake duct. Refer to SECTION lA.
9. Raise and suitably support vehicle on 5.7L LTl
engine only. Refer to SECTION OA.
10. Serpentine belt. Refer to SECTION 6A2A or SEC-
TION 6A3A.
11. Lower vehicle on 5. 7L LTl engine only.
12. Refill and bleed engine coolant on 5.7L LTl engine
only. Refer to SECTION 6B.
13. Refill and bleed power steering system on 5.7L LTl
engine only. Refer to "Bleeding the Power Steering
System" in this section.
POWER STEERING GEAR ASSEMBLY
Figure 4
l++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Special security wheel lock nuts, if equipped. Refer
to SECTION 3E.
3. Tire and wheel assemblies. Refer to SECTION 3E.
4. Place drain pan under steering gear assembly (1).
5. Inlet and outlet hose assemblies from steering gear
assembly. Refer to "Power Steering Gear Inlet and
Outlet Hose Assemblies" in this section.
6. Steering linkage outer tie rod assembly from steer-
ing knuckle assembly. Refer to SECTION 3B1A.
7. Steering gear coupling shaft assembly from steering
gear assembly. Refer to SECTION 3F.
8. Nuts (26) and bolts/screws (27).
9. Steering gear assembly (1).
l++I Install or Connect
NOTICE: See "Notice" on page 3B-1 of this sec-
tion.
38·6 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

A
J 25033-B
J 25034-8

32 32

A 3.4L L32 ENGINE

B 5.7L LT1 ENGINE
3 PULLEY ASSEMBLY, POWER STEERING PUMP
4 PUMP ASSEMBLY, POWER STEERING
31 PULLEY ASSEMBLY, POWER STEERING PUMP
32 PUMP ASSEMBLY, POWER STEERING
PC0003-3B·F-RP

Figure 3 - Power Steering Pump Pulley Assembly

1. Position steering gear assembly ( 1) to crossmember 7. Tire and wheel assemblies. Refer to SECTION 3E.
assembly (34). 8. Special security wheel lock nuts, if equipped. Refer

1£1 Adjust to SECTION 3E.

9. Lower vehicle.
• Steering gear assembly ( 1) so it aligns as 10. Refill and bleed power steering system. Refer to
straight as possible with steering gear coupling "Bleeding the Power Steering System" in this
shaft assembly. section.
2. Hand start bolts/screws (27) and nuts (26). POWER STEERING GEAR INLET AND
3. Position back-up wrench to nuts (26). OUTLET HOSE ASSEMBLIES
Figures 5 and 6
l~I Tighten
l++I Remove or Disconnect
• Bolts/screws (27) to 85 N•m (63 lb. ft.).
1. Place drain pan under steering gear assembly ( 1) and
4. Steering gear assembly to steering gear coupling pump assembly (4 or 32).
shaft assembly. Refer to SECTION 3F.
2. Outlet hose assembly (5) from pump assembly (4)
5. Steering linkage outer tie rod assemblies to steering on 3.4L L32 engine only.
knuckle assemblies. Refer to SECTION 3B1A. 3. Raise and suitably support vehicle. Refer to SEC-
6. Inlet and outlet hose assemblies to steering gear TION OA.
assembly. Refer to "Power Steering Gear Inlet and 4. Inlet and outlet hose assemblies (2 and 5 or 30 and
Outlet Hose Assemblies" in this section. 33) from steering gear assembly (1 ).
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38·7
1 GEAR ASSEMBLY, POWER STEERING
8 KNUCKLE ASSEMBLY, STEERING
26 NUT, STEERING GEAR
27 BOU/SCREW, STEERING GEAR, 85 N•m (63 LB. FT.)
34 CROSSMEMBER ASSEMBLY, FRONT
Figure 4 - Power Steering Gear Assembly
5. Inlet hose assembly (2) from pump assembly (4) on
3.4L L32 engine only.
6. Drain engine coolant on 5.7L LTl engine only. Refer
to SECTION 6B.
7. Serpentine belt on 5.7L LTl engine only. Refer to
SECTION 6A3A.
8. Lower vehicle on 5.7L LTl engine only.
9. Front air intake duct on 5.7L LTl engine only. Refer
to SECTION lA.
10. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
11. Radiator outlet hose assembly from engine assembly
on 5.7L LTl engine only. Refer to SECTION 6B.
12. Heater inlet and outlet hose assemblies from water
pump assembly on 5.7L LTl engine only. Refer to
SECTION lA.
13. Throttle body heater return hose from heater outlet
assembly on 5.7L LTl engine only. Refer to SEC-
TION lA.
14. Power steering pump bolts/screws on 5.7L LTl
· engine only. Refer to "Power Steering Pump
Assembly" in this section.
15. Inlet hose assembly (30) from pump assembly (32)
on 5.7L LTl engine only.
16. Power steering fluid reservoir bolt/screw and power
steering fluid reservoir retainer on 5. 7L LTl engine
only. Refer to "Power Steering Fluid Reservoir
Assembly" in this section.
_ _ _ _ _ _ JI
PC0011-3B-f.RP
17. Outlet hose assembly (33) from reservoir assembly
(10) on 5.7L LTl engine only.
l++I Install or Connect
NOTICE: See "Notice" on page 3B-1 of this
section.
NOTICE: Inlet and outlet hose assemblies must be
installed to clear each other and all surrounding
parts to prevent chafing. Use minimum clearance of
12 mm (0.47 inch). The outlet hose assembly must
not be twisted during installation. Do not bend or
distort inlet and outlet hose assemblies to make
installation easier. Failure to follow these proce-
dures could result in component damage.
1. Outlet hose assembly (33) to reservoir assembly
(10) using clamp on 5.7L LTl engine only. Lubri-
cate as required.
2. Power steering fluid reservoir bolt/screw and power
steering fluid reservoir retainer on 5.7L LTl engine
only. Refer to "Power Steering Fluid Reservoir
Assembly" in this section.
3. Inlet hose assembly (30) to pump assembly (32) on
5.7L LTl engine only.
l~I Tighten
• Inlet hose assembly (30) to 28 N•m (21 lb. ft.).
4. Power steering pump bolts/screws on 5. 7 LTl
engine only. Refer to "Power Steering Pump
Assembly" in this section.
38·8 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

,0 4

\f~1
4

2
5

jVIEWA I

1 GEAR ASSEMBLY, POWER STEERING

2 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
3 PULLEY ASSEMBLY, POWER STEERING PUMP
4 PUMP ASSEMBLY, POWER STEERING
5 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
28 N•m (21 LB. FT.)
34 CROSSMEMBER ASSEMBLY, FRONT
PC0005-3B·F-RP

Figure 5 - Power Steering Gear Inlet and Outlet Hose Assemblies (3.4L L32 Engine)

5. Throttle body heater return hose to heater outlet hose
assembly on 5.7L LTl engine only. Refer to SEC-
TION lA.
6. Heater inlet and outlet hose assemblies to water
pump assembly on 5.7L LTl engine only. Refer to
SECTION lA.
7. Radiator outlet hose assembly to engine assembly on
5. 7L LTl engine only. Refer to SECTION 6B.
8. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
9. Front air intake duct on 5.7L LTl engine only. Refer
to SECTION lA.
10. Raise and suitably support vehicle on 5.7L LTl
engine only. Refer to SECTION OA.
11. Serpentine belt on 5.7LLT1 engine only. Refer to
SECTION 6A3A.
12. Inlet hose assembly (2) to pump assembly (4) on
3.4L L32 engine only.
13. Inlet and outlet hose assemblies (2 and 30 or 5 and
33) to steering gear assembly (1 ).
l~I Tighten
• Inlet hose assembly (2 or 30) to 28 N•m (21 lb.
ft.).
• Outlet hose assembly (5 or 33) to 28 N•m (21
lb. ft.).
14. Outlet hose assembly (5) to pump assembly (4) on
3.4L L32 engine only.
l~I Tighten
• Outlet hose assembly (5) to 28 N•m (21 lb. ft.).
15. Lower vehicle on 5.7L LTl engine only.
16. Refill and bleed engine coolant on 5.7L LTl engine
only. Refer to SECTION 6B.
17. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this sec-

rn Important
• Maintain at least 5 mm (0.20 inch) clearance
tion.

HYDRAULIC PUMP FLOW CONTROL VALVE

between the inlet hose assembly (2) and the Figure 7
power steering pump support on the 3.4L L32
engine only.
l++I Remove or Disconnect
l~I Tighten 1. Place drain pan under pump assembly (4 or 32).
2. Inlet hose assembly (2 or 30) from fitting (15).
• Inlet hose assembly (2) to 28 N•m (21 lb.
ft.). 3. Fitting (15) and 0-ring seal (14).
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE .38-9

32
11

30

,~~~
V-IE_W_A-,
-1

1 GEAR ASSEMBLY, POWER STEERING

10 RESERVOIR ASSEMBLY, POWER STEERING FLUID
11 HOSE ASSEMBLY, POWER STEERING FLUID
RESERVIOR
24 CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
30 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
32 PUMP ASSEMBLY, POWER STEERING
33 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
30 28 N•m (21 LB. FT.)
40 CLIP, POWER STEERING GEAR PIPE \

PC0006-3B-F-RP

Figure 6- Power Steering .Gear Inlet and OuUet Hose Assemblies (5.7L LT1 Engine)

rn Important
• The flow control valve must be installed in the
2. New 0-ring seal (14) to fitting (15).

rn Important
same position it was in wheh removed or flow • Lubricate 0-ring seal (14) with power steering
control and pressure relief will be affected. fluid.
4. Flow control valve (13) and valve spring (12) from 3. Hand start fitting (15) and 0-ring seal (14) to pump
pump assembly (4 or 32) using magnet. assembly (4 or 32).
NOTICE: Do not disassemble ·the flow control
valve. l~I Tighten
• Fitting (15) to 75 N•m (55 lb. ft.).
ll1"1 Inspect 4. Inlet hose assembly (2 or 30) to fitting (15).
• Flow control valve (13) for free movement
within housing bore. l~I Tighten
- If sticking occurs, check ·for burrs and • Inlet hose assembly (2 or 30) to 28 N•m (21 lb.
clean as necessary. ft.).
- If necessary, replace flow control valve 5. Fill reservoir assembly with fluid. Refer to "Check-
(13). ing and Adding Power Steering Fluid" in this sec-
tion.
E3 Install or Connect 6. Bleed system. Refer to "Bleeding the Power Steer-
ing System" in this section.
NOTICE: See "Notice" on page 3B-1 of this sec-
tion.
POWER STEERING PUMP SUPPORT
rn Important
• The flow control valve (13) should be installed
3.4L L32 Engine Only

face out, away from contact with the valve Figures

spring (12).
1. Valve spring (12) and flow control valve (13) to
l++I Remove or Disconnect
pump assembly (4 or 32). 1. Place drain pan under pump assembly (4).
38·10 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE
30
~-
13
14
A B
A 3.4L L32 ENGINE
B 5.7L LT1 ENGINE
2 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
4 PUMP ASSEMBLY, POWER STEERING
11 HOSE ASSEMBLY, POWER STEERING FLUID
RESERVOIR
12 SPRING, HYDRAULIC PUMP FLOW CONTROL VALVE
Figure 7 - Hydraulic Pump Flow Control Valve
2. Outlet hose assembly from pump assembly. Refer to
"Power Steering Gear Inlet and Outlet Hose Assem-
blies" in this section.
3. Bolts/screws (18) and nuts (19).
4. Support ( 17) from pump assembly (4) and brace
assembly (35).
l++I Install or Connect
NOTICE: See "Notice" on page 3B-1 of this sec-
tion.
1. Position support (17) to pump assembly (4) and
brace assembly (35).
2. Hand start nuts (19).
3. Hand start bolts/screws (18).
l~I Tighten
• Nuts (19) to 50 N•m (37 lb. ft.).
• Bolts/screws (18) to 50 N•m (37 lb. ft.).
4. Outlet hose assembly to pump assembly. Refer to
"Power Steering Gear Inlet and Outlet Hose Assem-
blies" in this section.
5. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this sec-
tion.
,.;; 14
11
32
13 VALVE, HYDRAULIC PUMP FLOW CONTROL
14 SEAL, HYDRAULIC PUMP FLOW CONTROL VALVE
(0-RING)
15 FITTING, HYDRAULIC PUMP
30 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 N•m (21 LB. FT.)
32 PUMP ASSEMBLY, POWER STEERING
PC0004-3B·F-RP
POWER STEERING PUMP ASSEMBLY
Figures 8 and 9
l++I Remove or Disconnect
1. Place drain pan under pump assembly (4 or 32).
2. Raise and suitably support vehicle on 5.7L LTl
engine only. Refer to SECTION OA.
3. Drain engine coolant on 5. 7L LTl engine only. Refer
to SECTION 6B.
4. Serpentine belt. Refer to SECTION 6A2A or 6A3A.
5. Lower vehicle on 5.7L LTl engine only.
6. Front air intake duct. Refer to SECTION IA.
7. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
8. Radiator outlet hose assembly from engine assembly
on 5.7L LTl engine only. Refer to SECTION 6B.
9. Heater inlet and outlet hose assemblies from water
pump assembly on 5.7L LTl engine. Refer to SEC-
TION lA.
10. Throttle body heater return hose from heater outlet
hose assembly on 5.7L LTl engine only: Refer to
SECTION lA.
11. Bolts/screws (21) on 5.7L LTl engine only.
12. Inlet and outlet hose assemblies from pump assem-
bly on 3.4L L32 engine only. Refer to "Power Steer-
ing Gear Inlet and Outlet Hose Assemblies" in this
section.
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38-11

19

4 PUMP ASSEMBLY, POWER STEERING

17 SUPPORT, POWER STEERING PUMP ~FRT
18 BOLT/SCREW, POWER STEERING PUMP REAR 17
BRACKET, 50 N•m (37 LB. FT.)
19 NUT, POWER STEERING PUMP SUPPORT, 18
50 N•m (37 LB. FT.) !VIEWA!
20 BOLT/SCREW, POWER STEERING PUMP,
50 N•m (37 LB. FT.)
35 BRACE ASSEMBLY, POWER STEERING PUMP REAR
PC0008-3B·F·RP

Figure 8 - Power Steering Pump Assembly (3.4L L32 Engine)

13. Pulley assembly from pump assembly on 3.4L L32

engine only. Refer to "Power Steering Pump Pulley
Assembly" in this section.
14. Inlet and reservoir hose assemblies from pump
assembly on 5.7L LTl engine only. Refer to "Power
Steering Gear Inlet and Outlet Hose Assemblies"
and "Power Steering Fluid Reservoir Hose Assem-
bly" in this section.
15. Pump support from pump assembly on 3.4L L32
engine only. Refer to "Power Steering Pump Sup-
port" in this section.
16. Bolts/screws (20) on 3.4L L32 engine only.
17. Pump assembly (4 or 32).

l++I Install or Connect

NOTICE: See "Notice" on page 3B-1 of this sec-
tion.
1. Position pump assembly (4) to brace assembly (35)
on 3.4L L32 engine only.
2. Bolts/screws (20) on 3.4L L32 engine only. 4 PUMP ASSEMBLY, POWER STEERING
11 HOSE ASSEMBLY, POWER STEERING FLUID

l~I Tighten
RESERVOIR
21 BOLT/SCREW, POWER STEERING PUMP,
25 N•m (18 LB. FT.)
• Bolts/screws (20) to 50 N•m (37 lb. ft.). 36 BRACKET ASSEMBLY, GENERATOR AND AIR
3. Pump support to pump assembly on 3.4L L32 CONDITIONER COMPRESSOR AND POWER STEERING
engine only. Refer to "Power Steering Pump Sup- PUMP AND DRIVE BELT TENSIONER
f'C0009.3B·F·RP
port" in this section.
Figure 9- Power Steering Pump Assembly (5.7L LT1 Engine)
4. Inlet and reservoir hose assemblies to pump assem-
bly on 5.7L LTl engine only. Refer to "Power Steer-
ing Gear Inlet and Outlet Hose Assemblies" and
38-12 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

"Power Steering Fluid Reservoir Hose Assembly"

in this section.
5. Pulley assembly to pump assembly on 3.4L L32
enigne only. Refer to "Power Steering Pump Pulley
Assembly" in this section.
6. Inlet and outlet hose assemblies to pump assembly 23
on 3.4L L32 engine only. Refer to "Power Steering
Gear Inlet and Outlet Hose Assemblies" in this sec-
tion.
7. Position pump assembly (30) to bracket assembly
(36) on 5.7L LTl engine only.
8. Bolts/screws (21) on 5.7L LTl engine only.

l~I Tighten
• Bolts/screws (21) to 25 N•m (18 lb. ft.).
9. Throttle body heater return hose to heater outlet hose
A CLAMP, POWER STEERING HOSE ASSEMBLY
assembly on 5.7L LTl engine only. Refer to SEC- B CLAMP, POWER STEERING RESERVOIR HOSE
TION lA. ASSEMBLY
10. Heater inlet and outlet hose assemblies to water 5 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
28 N•m 1i1 LB. FT.)
pump assembly on 5.7L LTl .engine only. Refer to 10 RESERVOIR ASSEMBLY, POWER STEERING FLUID
SECTION lA. 11 HOSE ASSEMBLY, POWER STEERING FLUID
11. Radiator outlet hose assembly to engine assembly on RESERVOIR
22 BOLT/SCREW, POWER STEERING FLUID RESERVOIR,
5.7L LTl engine. Refer to SECTION 6B. 10 N•m (89 LB. IN.)
12. Generator assembly on 5.7L LTl engine only. Refer 23 RETAINER, POWER STEERING FLUID RESERVOIR
24 CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
to SECTION 6D3.
PC0010-3B·f·RP
13. Front air intake duct. Refer to SECTION lA.
14. Raise and suitably support vehicle on 5.7L LTl Figure 1O- Power Steering Fluid Reservoir Assembly
(5.7L LT1 Engine)
engine only. Refer to SECTION OA.
15. Serpentine belt. Refer to SECTION 6A2A or 6A3A.
1. Outlet hose assembly and reservoir hose assembly to
16. Lower vehicle on 5.7L LTl engine only. reservoir assembly. Refer to "Power Steering Gear
17. Refill and bleed engine coolant system on 5.7L LTl Inlet and Outlet Hose Assemblies" and "Power
engine only. Refer to SECTION 6B. Steering Fluid Reservoir Hose Assembly" in this
18. Refill and bleed power steering system. Refer to section.
"Bleeding the Power Steering System" in this sec- 2. Position reservoir assembly (10) to right front
tion. wheelhouse assembly.
3. Reta.iner (23) and bolt/screw (22).
Power Steering Fluid Reservoir Assembly
5.7L LT1 Engine Only
l~I Tighten
• Bolt/screw (22) to 10 N•m (89 lb. in.).
Figure 10 4. Cap assembly (24) to reservoir assembly (10).

l++I Remove or Disconnect

5. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this sec-
tion.
1. Place drain pan under reservoir assembly ( 10).
2. Cap assembly (24) from reservoir assembly (10). Power Steering Fluid Reservoir Hose
3. Bolt/screw (22) and retainer (23). Assembly
4. Outlet hose assembly and reservoir hose assembly
from reservoir assembly. Refer to "Power Steering 5.7 LT1 Engine Only
Gear Inlet and Outlet Hose Assemblies" and
"Power Steering Fluid Reservoir Hose Assembly" Figure6
in this section.
5. Reservoir assembly (10). I++! Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
(+3 Install or Connect TION OA.
NOTICE: See "Notice" on page 3B-1 of this sec- 2. Drain engine coolant. Refer to SECTlON 6B.
tion. 3. Serpentine belt. Refer to SECTION 6A3A.
 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38-13

4. Lower vehicle. 2. Power steering fluid reservoir retainer and power

5. Front air intake duct. Refer to SECTION lA.
6. Generator assembly. Refer to SECTION 603.
7. Radiator outlet hose assembly from engine assem-
bly. Refer to SECTION 6B.
8. Heater inlet and outlet hose assemblies from water
pump assembly. Refer to SECTION IA.
9. Throttle body heater return hose from heater outlet
assembly. Refer to SECTION IA.
10. Power steering pump bolts/screws. Refer to "Power
Steering Pump Assembly" in this section.
11. Reservoir hose assembly (11) from pump assembly
(32).
12. Power steering fluid reservoir bolt/screw and power
steering fluid reservoir retainer from reservoir
assembly. Refer to "Power Steering Fluid Reservoir
Assembly" in this section.
13. Reservoir hose assembly (11) from reservoir assem-
bly (10).
l++I Install or Connect
NOTICE: See "Notice" on page 3Bl of this sec-
tion.
1. Reservoir hose assembly (11) to reservoir assembly
( 10) using clamp. Lubricate as required.
steering fluid reservoir bolt/screw. Refer to "Power
Steering Fluid Reservoir Assembly" in this section.
3. Reservoir hose assembly (11) to pump assembly
(32).
4. Power steering pump bolts/screws. Refer to "Power
Steering Pump Assembly" in this section.
5. Throttle body heater return hose to heater outlet hose
assembly. Refer to SECTION IA.
6. Heater inlet and outlet hose assemblies to water
pump assembly. Refer to SECTION IA.
7. Radiator outlet hose assembly from engine assem-
bly. Refer to SECTION 6B.
8. Generator assembly. Refer to SECTION 603.
9. Front air intake duct. Refer to SECTION IA.
10. Raise and suitably support vehicle. Refer to SEC-
TION OA.
11. Serpentine belt. Refer to SECTION 6A3A.
12. Lower vehicle.
13. Refill and bleed engine coolant. Refer to SECTION
6B.
14. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this sec-
tion.

SPECIFICATIONS

POWER STEERING FLUID RECOMMENDATIONS

Temperate Climate
Power Steering Fluid Requirement ................. GM Power Steering Fluid PIN 1050017 or
1052884, or equivalent meeting GM Specification 9985010
Cold Climate
Power Steering Fluid Requirement ................ GM Power Steering Fluid PIN 12345867 or
12345866 (System should be drained and refilled prior to using this fluid.)
FITTING TIGHTENING SPECIFICATIONS
Hydraulic Pump Fitting-to-Power Steering Pump Assembly .................. 75 N•m (55 lb. ft.)
Power Steering Gear Inlet Hose Assembly Fitting-to-Power Steering
Gear Assembly ................................................... 28 N•m (21 lb. ft.)
Power Steering Gear Inlet Hose Assembly Fitting-to-Power Steering
Pump Assembly .................................................. 28 N•m (21 lb. ft.)
Power Steering Gear Outlet Hose Assembly Fitting-to-Power Steering
Gear Assembly ................................................... 28 N•m (21 lb. ft.)
FASTENER TIGHTENING SPECIFICATIONS
Power Steering Fluid Reservoir Bolt/Screw ............................... 10 N•m (89 lb. in.)
Power Steering Pump Bolt/Screw - 3.4L L32 Engine ....................... 50 N•m (37 lb. ft.)
Power Steering Pump Bolt/Screw - 5.7L LTl Engine ....................... 25 N•m (18 lb. ft.)
Power Steering Pump Rear Bracket Bolt/Screw ............................ 50 N•m (37 lb. ft.)
Power Steering Pump Support Nut ...................................... 50 N•m (37 lb. ft.)
Steering Gear Bolt/Screw ............................................. 85 N•m (63 lb. ft.)
38-14 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

SPECIAL TOOLS

1. J 25034-B 2. J 25033-B

1. PUMP PULLEY REMOVER

2. PUMP PULLEY INSTALLER

PC0013-3B-F·RP
 POWER STEERING GEAR UNIT REPAIR 3B1A·1

SECTION 381 A

POWER STEERING GEAR

UNIT REPAIR
NOTICE: When fasteners are removed, always reinsta11 them at the sarrie location from which they were removed. If
a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener
is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those
requiring thread locking compound wi11 be ca11ed out. The correct torque value must be used when insta11ing fasteners
that require it. If the above conditions are not fo11owed, parts or system damage could result.

CONTENTS
Power Rack & Pinion Steering Gear Assembly ... 3B1A-2
Outer Tie Rod .................................................. 3B 1A-3
Rack Bearing Preload .......... ,........................... 3B1A-4
Rack & Pinion Boot ......................................... 3BtA-4
Inner Tie Rod ................................................... 3B t A-4
Cylinder Line Assembly and 0-Ring Seals ....... 3B 1A-5
Pinion Seal, Dust Seal and Bearing
Annulus Assembly ........................................... 3B t A-6
Specifications ........................................................ 3B t A-9
Fluid Capacities ............................................... 3B t A-9
Fastener Tightening Specifications .................. 3B t A-9
Special Tools ........................................................ 3B 1A-9
3B1A-2 POWER STEERING GEAR UNIT REPAIR

-------------1

VIEW A-A

13

~
1~,.
16
23 17~

20
2~

13

({)

2
8 ,, 1
J 7 e-
"'• 5 ~3

~6

Figure 1 Power Rack and Pinion· End Take Off

 POWER STEERING GEAR UNIT REPAIR 3B1A-3

Key No. Part Name Key No. Part Name

1 - NUT, HEXAGON SLOTTED 17- RING, RETAINING
2 - PIN, COTTER 18 - SEAL, STUB SHAFT DUST
3 - SEAL, Tl E ROD 20 - SEAL, STUB SHAFT
5 - ROD ASM, OUTER TIE 21 - BEARING ANNULUS ASM, NEEDLE
6 - FITTING, LUBE (90 DEG ELBOW) 23 - SEAL, 0-RING (4.50 1.D.)
7 - NUT, METRIC HEX (M14 X 1.5) 25 - LINE ASM, CYLINDER (RT)
8- CLAMP, TIE ROD END 26 - LINE ASM, CYLINDER (LT)
10 - BOOT, RACK & PINION 30 - GEAR ASM, RACK & PINION (PARTIAL)
11 - CLAMP, SEAL RETAINING 32 - NUT, HEX LOCK
12- ROD ASM, INNER TIE 33 - COVER, DUST
13- RING, SHOCK DAMPENER 35 - CLIP, PIPE
15- NUT, ADJUSTER PLUG LOCK 36 - BUSHING, STEERING GEAR
16-ADAPTER,SEAL 37 - SLEEVE, STEERING GEAR BUSHING

Figure 2 Power Rack and Pinion - End Take Off- Legend

OUTER TIE ROD

Figures 1 thru 3
(ZJ Adjust

Tool Required: • Toe by turning inner tie rod (12).

J 24319-01 Universal Steering Linkage Puller

I+ +I Remove or Disconnect rn Important

• Be sure rack and pinion boot (10) is not

1. Cotter pin (2) and hex slotted nut ( 1) from outer tie twisted or puckered during toe adjustment.
rod assembly (5).
2. Loosen hex nut (7).
3. Outer tie rod (5) from steering knuckle with ~ Tighten
J 24319-01.
4. Outer tie rod (5) from inner tie rod (12). • Hex nut (7) against outer tie rod (5) to
68 N•m (50 lb. ft.).

l++I Install or Connect

1. Outer tie rod assembly (5) to inner tie rod (12). Do
not tighten hex nut (7).
2. Outer tie rod (5) to steering knuckle, hex slotted
nut (1) to outer tie rod stud.

~ Tighten

• Hex slotted nut (1) to 47 N•m (35 lb. ft.).

• Tighten nut up to 1/6 additional turn, or 70 N•m
(52 lb. ft.) maximum, to align cotter pin slot. 5
Do not back off nut for cotter pin insertion.

3. Cotter pin (2) into hole in tie rod stud (5).

A-STEERING KNUCKLE A , ,.,,,,

1-NUT, HEXAGON SLOTTED
2-PIN, COTTER
5-ROD ASM, OUTER TIE
7-NUT, METRIC HEX (M14 X 1.5)
12-ROD ASM, INNER TIE
""--l\:'rr•';
1 '-lJ-'·~-- ~
~ _ . , . , - """-..... 2
~

Figure 3 Outer Tie Rod Replacement

3B1A-4 POWER STEERING GEAR UNIT REPAIR

RACK BEARING PRELOAD

(on vehicle adjustment} I+ +I Install or Connect
Figure 15
1. New seal retaining c1amp (11) onto rack and pinion
(ZI Adjust 2.
boot (10).
Apply ~rease to in~er tie rod ( 12) and gear assembly
1. Make adjustment with front wheels raised and (30) pnor to boot mstallation (see Figure 5).
steering wheel centered. Be sure to check • Boot (10) onto inner tie rod assembly (12).
retumability of the steering wheel to center after 3. Boot (10) onto gear assembly (30) until seated in
gear assembly groove.
adjustment.
2. Loosen adjuster plug lock nut (15) and tum adjuster
plug clockwise until it bottoms in gear assembly
(30), then back off 50° to 70° (approximately one
rn Important

3.
flat).
Lock nut (15) to adjuster plug.
• Boot ( 10) must not be twisted, puckered or
out of shape in any way. If the boot is not
shaped properly, adjust by hand before
~ Tighten
installing seal retaining clamp (11 ).

• Lock nut (15) to 75 N•m (55 lb. ft.) while 4. Seal retaining clamp (11) on boot (10) with tool
holding adjuster plug stationary. J ~2610 and crimp as shown (see Figure 6). ·
5. Tte rod end clamp (8) with pliers on boot (10).
6. Hex nut (7) to inner tie rod assembly (12).
RACK & PINION BOOT
7. Do all steps of OUTER TIE ROD "Install or
Figures 1 thru 6 Connect."
Tool Required:
J 22610 Service Boot Clamp Installer INNER TIE ROD
Figures 1 thru 9
I+ +I Remove or Disconnect
1. Do all steps of OUTER TIE ROD "Remove or I+ +I Remove or Disconnect
Disconnect."
1. Rack and pinion assembly from vehicle (see
2. Hex nut (7) from inner tie rod assembly (12).
Section 3B).
3. Tie rod end clamp (8).
2. Do alt steps of RACK & PINION BOOT "Remove
4. Seal retaining clamp ( 11) with side cutters and
or Disconnect."
discard.
3. Shock da~pener (13) from inner tie rod assembly
5. Rack and pinion boot (10).
(12) and shde back on rack (see Figure 7).

APPLY GREASE TO
THESE AREAS

30

7-NUT, METRIC HEX (M14 X 1.5)

8-CLAMP, TIE ROD END
10-BOOT, RACK & PINION
10-BOOT, RACK & PINION
11-CLAMP, SEAL RETAINING 12-ROD ASM, INNER TIE
30-GEAR ASM, RACK & PINION (PARTIAL) 30-GEAR ASM, RACK & PINION (PARTIAL)
Figure 4 Rack and Pinion Boot Replacement Figure 5 Boot Seal Grease Application
 P,OWER STEERING GEAR UNrT REPAIR 381A-5

Notice: Steering gear rack must be held stationary during Notice: Steering gear must be held stationary during inner
inner tie rod removal to prevent steering gear damage. Use tie rod installation to prevent steering gear damage.
an appropriate size wrench at the rack teeth to hold the rack
during inner tie rod removal. For right side inner tie rod 4. Install inner tie rod assembly onto steering gear
(see Figure 9).
removal, it will be necessary to remove the left side boot to
access the rack teeth. ~ Tighten
4. Inner tie rod assembly (12) from rack assembly as • Inner tie rod (12) to 100 N•m (74 lb. ft.)
follows: (See Figure 7.)
• Place a wrench on flat of rack assembly. 5. Slide shock dampener up against inner tie rod
• Place another wrench on flats of inner tie rod assembly.
housing. 6. Do all steps of RACK & PINION BOOT "Install
• Rotate inner tie rod housing counterclock- or Connect."
wise until inner tie rod (12) separates from 7. Rack and pinion assembly to vehicle (see
rack. Section 3B).

I+ +I Install or Connect CYLINDER LINE ASSEMBLV

and 0-RING SEALS
1. Remove old Loctite® from threads of rack and inner Figures 1 and 2
tie rod. Tools Required:

rn Important
12mm Flare Nut Wrench
16mm Flare Nut Wrench

• Threads must be clean prior to Loctite appli- I+ +I Remove or Disconnect

cation. Be sure Loctite® container expiration
date has not passed. Do not use too much 1. Loosen cylinder line fittings (25) or(26) on cylinder
Loctite®. Use only enough to evenly coat end of gear assembly (30).
threads. 2. Loosen fittings on cylinder line assemblies (25) or
(26) at valve end of gear assembly (30).
2. Apply Loctite 262® to inner tie rod threads 3. Cylinder line assemblies (25) or (26) from rack and
(see Figure 8). pinion gear assembly (30).
3. If shock damper was removed, slide it onto steering 4. 0-ring seals (23) from valve end oflines (25) or(26)
gear. and discard.

13

A-RACK ASM, PISTON AND STEERING

B-HOUSING, INNER TIE ROD
12-ROD ASM, INNER TIE
10-BOOT, RACK AND PINION 13-RING, SHOCK DAMPENER
11-CLAMP, SEAL RETAINING 30-GEAR ASM, RACK & PINION (PARTIAL)

Figure 6 Boot Clamp Installation Figure 7 Inner Tie Rod Removal

3B1A-6 POWER STEERING GEAR UNIT REPAIR

I+ +I Install or Connect 3.
4.
Adjuster plug from gear assembly (30).
Adjuster spring and rack bearing.
5. Retaining ring (17) from valve bore of gear
ll•I Inspect
6.
assembly (30).
Dust cover (33) from bottom of gear assembly (30)
Lines for: (see Figure 11 ).
• Cracks.
• Dents. Notice: Stub shaft must be held to prevent damage to the
• Damage to threads. pinion teeth.
Replace as needed.
7. Hex lock nut (32) from lower end of pinion and
1. New 0-ring seals (23) to valve end of lines (25) valve assembly, while holding stub shaft with
or (26). 14 mm Crowfoot Wrench (see Figure 11).
2. Cylinder line assemblies (25) or (26) to gear
assembly (30). Notice: DO NOT hammer or pound on pinion and valve
assembly. This will cause damage or loosen the drive pin.
Notice: Carefully align threads on all fittings and finger
tighten to avoid stripping and cross-threading.

~ Tighten
rn•
Important
When performing the following procedure,
do not remove pinion and valve assembly
• Valve end fittings to 16.9 N•m (12.5 lb. ft.). from gear assembly. Press pinion and valve
• Cylinder end fittings to 27 .0 N•m (20 lb. ft.). assembly only far enough to allow removal
ofbearingannulusandseal. Pinion and valve
assembly removal is not required.
PINION SEAL, DUST SEAL
and BEARING ANNULUS ASSEMBLY 8. Use an arbor press (see Figure 12). Press on
Figures 1, 2, 10 Thru 15 threaded end of pinion until it is possible to remove
stub shaft dust seal (18), stub shaft seal (20),
Tools Required: and stub shaft bearing annulus assembly (21) (see
J 29810 Stub Shaft Seal Protector
Figure 13).
14 mm Crowfoot Wrench

I+ +I Remove or Disconnect
1. Rack and pinion steering assembly from vehicle
(see Section 3B).
2. Adjuster plug lock nut (15) from adjuster plug (see
Figure 10).

APPLY
LOCTITE9

A-RACK ASM, PISTON AND STEERING

B-HOUSING, INNER TIE ROD
C-TORQUE WRENCH
12-ROD ASM, INNER TIE 12-ROD ASM, INNER TIE
13-RING, SHOCK DAMPENER 13-RING, SHOCK DAMPENER
30-GEAR ASM, RACK & PINION (PARTIAL) 30-GEAR ASM, RACK & PINION (PARTIAL)

Figure 8 Inner Tie Rod Installation Figure 9 Inner Tie Rod Tightening
 POWER STEERING .GEAR UNIT REPAIR 3B1A-7

9. Lock nut (15) to adjuster plug.

I+ +I Install or Connect
Notice: If the stub shaft is not held, damage to the pinion ~ Tighten
teeth will occur'.
• Lock nut (15) to 75 N•m (55 lb. ft.) while
1. Hex lock nut (32) onto pinion, while holding the holding adjuster plug stationary.
valve stub shaft.

~ Tighten
10. Rack and pinion assembly into vehicle.

• Hex Jock nut (32) to 30 N•m (22 lb. ft.).

[I] Important
2. Dust cover (33) to gear assembly (30). • Flush and bleed power steering system (hoses,
3. Stub shaft bearing annulus assembly (21) onto valve reservoir and cooler Jines) with cold cJimate
stub shaft. power steering fluid - GM Part #12345866
4. Seal protector J 29810 onto valve stub shaft. 16-oz. or 12345867 32-oz. (see flushing and
5. Apply a sma11 quantity of grease between seals (20) bleeding procedures, Section 3B).
and (18).
• Stub shaft seal (20) and stub shaft dust
seal (18) over protector and into gear
assembly (30).
6. Retaining ring (17) into groove in gear
assembly (30).
A
7. Lubricate stub shaft and dust seal area with grease.
8. Coat rack bearing; adjuster spring and adjuster plug
with lithium base grease and insta11 in gear
assembly (30) (see Figure 15).

(ZI Adjust

• With rack centered in the gear assembly (30),

tum adjuster plug clockwise until it bottoms
in the gear assembly, then back off 50° to 70°
(approximately one flat). Check rotational
torque on pinion. Maximum pinion preload
torque is 1.8 N•m (16 lb. in.) (see Figure 15). A-SHAFT, STUB
30-GEAR ASM, RACK & PINION (PARTIAL)
32-NUT, HEX LOCK
33-COVER, DUST

Figure 11 Retaining Ring and Lock Nut Removal

A-ARBOR PRESS
B-THREADED END OF PINION
30-GEAR ASM, RACK & PINION (PARTIAL)

Figure 10 Rack Bearing Removal Figure 12 Pressing Pinion

381A-8 POWER STEERING GEAR UNIT REPAIR

BACK OFF 50 DEGREES

TO 70 DEGREES
(APPROX. ONE FLAn

21-BEARING ANNULUS ASM, NEEDLE

30-GEAR ASM, RACK & PINION (PARTIAL)

Figure 13 Bearing Annulus Installation

A-BEARING, RACK
17-RING, RETAINING B-SPRING, ADJUSTER
18-SEAL, STUB SHAFT DUST C-PLUG, ADJUSTER
20-SEAL, STUB SHAFT 15-NUT, ADJUSTER PLUG LOCK
30-GEAR ASM, RACK & PINION (PARTIAL) 30-GEAR ASM, RACK & PINION (PARTIAL)

Figure 14 Seal Installation Figure 15 Rack Bearing Installation and Adustment

 POWER STEERING GEAR UNIT REPAIR 381A-9

SPECIFICATIONS

FLUID CAPACITIES

Lubricant ...................................................................................... Cold Climate Power Steering Fluid 12345866 (16-oz.)

12345867 (32-oz.)
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)

FASTENER TIGHTENING SPECIFICATIONS

(1) Hexagon Slotted Nut ............................................................................................... 47.0 N•m (35 lb. ft.)
(7) Hex Nut ................................................................................................................... 68.0 N•m (50 lb. ft.)
(12) Inner Tie Rod .......................................................................................................... 100.0 N•m (74 lb. ft.)
(15) Lock Nut .................................................................................................................. 75.0 N•m (55 lb. ft.)
(32) Hex Lock Nut.......................................................................................................... 30.0 N•m (22 lb. ft.)
Pinion Preload ......................................................................................................... 1.8 N•m (16th.in.)
Valve End Fittings................................................................................................... 16.9 N•m (12.5 lb. ft.)
Cylinder End Fittings .............................................................................................. 27.0 N•m (20 lb. ft.)

SPECIAL TOOLS

1. J 22610 2. J 24319-01

3. J 29810

1. SERVICE BOOT CLAMP INSTALLER

2. UNIVERSAL STEERING LINKAGE PULLER
3. STUB SHAFT SEAL PROTECTOR
 POWER STEERING PUMP UNIT REPAIR 381 B-1

SECTION 381 B

POWER STEERING PUMP

UNIT REPAIR

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fa~tener for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused and
those requiring thread locking compound will be called out. The correct torque value must be used when installing
fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CONTENTS
Subsection A: P Series Power Steering Pump
P Series Power Steering Pump Assembly ............. 3B1B-2
P Series Power Steering Pump Service ................. 3B1B-3
Drive Shaft Seal Replacement ......................... 3B1B-3
Pump Reservoir Replacement .......................... 3B1B-3 ·,
End Plate and Rotating Group Replacement .... 3B 1B-4
Subsection B: Reverse Rotation Power Steering Pump
Reverse Rotation Power Steering
Pump Assembly .................................................... 3B 1B-5
Reverse Rotation Power Steering
Pump Service ........................................................ 3B 1B-6
Control Valve Assembly .................................. 3B1B-6
Drive Shaft Seal ............................................... 3B 1B-6
Hydraulic Pump Assembly .............................. 3B1B-7

Specifications ....................................................... 3B 1B-9

Fluid Specifications .......................................... 3B 1B-9
Fastener Tightening Specifications .................. 3B 1B-9
Special Tools ........................................................ 3B1B-9
381 B-2 POWER STEERING PUMP UNIT REPAIR

40

Figure 1 P Series Power Steering Pump

3818-4 POWER STEERING PUM.P UNIT REPAIR.

rn Important
END PLATE AND ROTATING GROUP
REPLACEMENT
Figures 1, 2 and 4
• Use new seals when assembling pump.

l+!+I Assemble
I+ +I Remove or Disconnect

• Power steering pump from vehicle. Refer to

• Lubricate 0-ring seals ( 1, 10, 35 and 40) with power
steering fluid.
1. Flow control spring (6) and control valve assembly
(2) to housing (8). See Figure 1 for proper orienta-
tion.
2. 0-ring seals (1, 10, and 40) to housing (8).
3. Magnet (7) to housing (8).
4. Reservoir (37) to housing (8).
5. 0-ring seal (35) and fitting (33).
Notice: See "Notice" on page 3B 1B-1 of this section.
6. Bolts (36).
"Power Steering Pump Replacement" in section 3B.
l+:+I Disassemble
1. Pump reservoir. Refer to "Pump Reservoir
Replacement" in this section.
2. Retaining ring (25).
3. End plate (23) and spring (22).
Notice: Examine exposed portion of pump drive shaft. If
it is corroded, clean with crocus cloth before removing.
This will prevent damage to the shaft bushing which might
require replacement of the entire housing.

~ Tighten
4. Pressure plate (21) by using a rubber mallet to tap
lightly on the drive shaft (12).
• Bolts (36) to 58 N•m (43 lb. ft.). 5. Pump ring (20).
• Fitting (33) to 75 N•m (55 lb. ft.). 6. Pump vanes (18).
7. Shaft, rotor and thrust plate assembly.
8. Shaft retaining ring (17).
I+ +I Install or Connect 9. Pump rotor (16).
10. Thrust plate (15).
• Power steering pump. Refer to "Power Steering 11. Drive shaft (12).
Pump Replacement" in section 3B. 12. Dowel pins (13).
13. 0-ring seals (3 and 5).

rn Important

• Use new seals and drive shaft retaining ring

when assembling pump.

l+!+I Assemble
• Lubricate 0-ring seals (3 and 5) with power steering
fluid.
1. 0-ring seals (3 and 5) to housing (8).
2. Dowel pins (13) to housing (8).
3. Thrust plate (15) and pump rotor (16) to drive shaft
(12) and secure with retaining ring (17).
4. Shaft, rotor and thrust plate assembly to housing (8).
5. Pump vanes (18) to pump rotor (16).
A-IDENTIFICATION ARROW
6. Pump ring (20) to housing (8) with identification
3-SEAL arrow on top edge of ring (20) facing outward.
5-SEAL 7. Pressure plate (21).
8-HOUSING 8. Spring (22) and end plate (23).
12-SHAFT, DRIVE 9. Retaining ring (25).
13-PINS, DOWEL
15-PLATE, THRUST
1O. Pump reservoir (37). Refer to "Pump Reservoir
16-ROTOR, PUMP Replacement" in this section.
17-RING, SHAFT RETAINING
18-VANES, PUMP
20-RING, PUMP
I+ +I Install or Connect
21-PLATE, PRESSURE
• Power steering pump. Refer to "Power Steering
Figure 4 Rotating Group Pump Replacement" in section 3B.
 POWER STEERING PUMP UNIT REPAIR 381 B-5

10

13

~16

36
37

Figure 1 Power Steering Pump - Reverse Rotation

3818-6 . POWER STEERING PUMP UNIT REPAIR

Key No. Part Name Key No. Part Name

6 - PIN, PUMP RING DOWEL 26 - RING, PUMP
7- SHAFT, DRIVE 27-VANE, PUMP
10- HOUSING ASM, BUSHING & 28 - ROTOR, PUMP
11 - SEAL, DRIVE SHAFT 30- RING, SHAFT RETAINING
12- SPRING, FLOW CONTROL 31-PLATE,PRESSURE
13-VALVE ASM, CONTROL 32 - SEAL, 0-RING
15 - SEAL, 0-RING 33 - SPRING, PRESSURE PLATE
16- FITTING, 0-RING UNION 35 - SEAL, 0-RING
25- PLATE, THRUST 36 - COVER, END
37- RING, RETAINING

Figure 2 Power Steering Pump - Reverse Rotation - Legend

CONTROL VALVE DRIVE SHAFT SEAL

Figure 1 ( without disassembly of pump)
Figures 3 and 4

I+ +I Remove or Disconnect
Tool Required:
J 7728 Shaft Oil Seal Installer
1. Pump assembly from vehicle, if necessary

2.
for access.
0-ring union fitting ( 16) and 0-ring ( 15).
I+ +j Remove or Disconnect
3. Control valve assembly (13). 1. Pump assembly from vehicle, if necessary for ac-
4. Flow control spring ( 12). cess.
I+ +I Install or Connect 2. Protect drive shaft (7) with shim stock (see
Figure 3).
1. Flow control spring ( 12). 3. Seal (11) and discard. (Use small chisel to cut drive
2. Control valve assembly (13). shaft seal.)
3. Lubricate new 0-ring (15) with power steering
fluid.
I+ +I Install or Connect
• 0-ring (15) on fitting (16). 1. New drive shaft seal (11 ), lubricated with power
4. Fitting (16) into hydraulic pump housing steering fluid, using tool J 7728 (see Figure 4).
assembly (10). 2. Pump assembly to vehicle, if removed.
~ Tighten
• Fitting (16) to 75 N•m (55 lb. ft.).
5. Pump assembly to vehicle, if removed.

J 7728

@--11
10

A-CHISEL
B-SHIM STOCK
7-SHAFT, DRIVE
10-HOUSING ASM, HYD PUMP
11-SEAL, DRIVE SHAFT

Figure 3 Shaft Seal Removal Figure 4 Seal Installation

 POWER STEERING PUMP UNIT REPAIR 381 B-7
HYDRAULIC PUMP ASSEMBLY
Figures 1, 4 thru 8 4. Dowe] pins (6).
Too] Required: 5. Drive shaft sea] (11 ).
J 7728 Shaft Oil Sea] Instal1er 6. End cover (36), pressure plate spring (33) and
0-ring (35) from pressure plate (31 ).
l+:+I Disassemble 7. Pump ring (26) and vanes (27) from drive shaft sub-
assembly.
1. Retaining ring (37) using punch in access hole (see 8. Shaft retaining ring (30) from drive shaft (7).
Figure 5). 9. Pump rotor (28) and thrust plate (25) from drive
2. Internal components of pump from pump shaft (7).
housing (10) by gently pushing on drive shaft (7).
Components should include pressure plate
sub-assembly consisting of:
11-ll Clean

• End cover (36). • Al1 parts in power steering fluid.

• 0-ring sea] (35). • Dry parts.
•
•
Pressure plate spring (33).
Pressure plate (31 ).
!L•I Inspect
Drive shaft sub-assembly consisting of: • Pressure plate (31 ).
• Pump rotor (28). • Pump ring (26).
• Thrust plate (25). • Rotor (28).
• Drive shaft (7). • Vanes (27).
• Shaft retaining ring (30). • Thrust plate (25).
Pump ring (26) and vanes (27). • Drive shaft (7).
3. 0-ring (32) from pump housing (10). For scoring, pitting or chatter marks. If noted,
replace appropriate parts.

7-SHAFT, DRIVE
A-ACCESS HOLE 25-PLATE, THRUST
B-PUNCH 28-ROTOR, PUMP
37-RING, RETAINING 30-RING, SHAFT RETAINING

Figure 5 Retaining Ring Removal Figure 6 Retaining Ring Installation (Shaft)

3818-8 POWER STEERING PUMP UNIT REPAIR

l+!+I Assemble 7. Pump ring (26), with holes positioned correctly onto
dowel pins (6), in pump housing (10) (see Figure 7).
8. Lubricate new 0-ring (32) with power steering fluid.
1. Lubricate new drive shaft seal (11) with power • 0-ring (32) into groove in pump housing (10).
steering fluid. 9. Pressure plate (31).
• Drive shaft seal ( 11) into pump housing ( 10) 10. Pressure plate spring (33).
with tool J 7728 (see Figure 4). 11. Lubricate new 0-ring (35) with power steering fluid.
2. Pump ring dowel pins (6) into pump housing (10). • 0-ring (35) into end cover (36).
3. Thrust plate (25) and pump rotor (28) to drive 12. Lubricate outer edge of end cover (36) with power
shaft (7) (see Figure 6). steering fluid.
4. New shaft retaining ring (30) onto drive shaft (7). 13. Press end cover (36) into pump housing (10).
5. Drive shaft sub-assembly into pump housing (10). 14. Retaining ring (37) into groove in pump housing
6. Vanes (27) into pump rotor (28). ( 10), with ring opening near access hole in pump
housing (see Figure 8).

28 THIS SIDE FACING UP

26

B
COUNTERBORE
FACING DRIVE
SHAFT END OF
HOUSING
A-ACCESS HOLE
A-DOWEL PIN HOLE (LARGE) B-PRESS
B-CROSS-OVER SLOT C-RETAINING RING OPENING
26-RING, PUMP 0-BOLT HOLE
28-ROTOR, PUMP 37-RING, RETAINING

Figure 7 Rotor or Pump Ring Installation Figure 8 Retaining Ring Installation (Housing)
 POWER STEERING PUMP UNIT REPAIR 381 B-9

SPECIFICATIONS

FLUID CAPACITIES

Lubricant ...................................................................................................... GM Power Steering Fluid Part No. 1050017

or Equivalent meeting GM Specification 9985010
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)
Pump Only ................................................................................................................................................. 0.5 liter (1 pint)

FASTENER TORQUES

P Series Power Steering Pump

(33) Connector and Fitting Assembly ............................................................................. 75.0 N•m (55 lb. ft.)
(36) Pump Mounting Bolt ............................................................................................... 58.0 N•m (43 lb. ft.)

Reverse Rotation Power Steering Pump

(16) 0-ring Union Fitting ................................................................................................ 75.0 N•m (55 lb. ft.)

SPECIAL TOOLS

1. J 22670
2. J 7728

1. SHAFT OIL SEAL INSTALLER (P SERIES PUMP)

2. SHAFT OIL SEAL INSTALLER (REVERSE ROTATION PUMP)

SECTION 3C
FRONT SUSPENSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
Diagnosis ...................... Refer to Section 3
On-Vehicle Service ........................ 3C-3
Control Arm Ball Stud Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
Lower Control Arm Ball Stud Assembly . . . 3C-3
Upper Control Arm Ball Stud Assembly . . . . 3C-4
Control Arm Ball Stud Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4
Lower Control Arm Ball Stud Assembly .... 3C-4
Upper Control Arm Ball Stud Assembly . . . . 3C-5
Wheel Hub Assembly . . . . . . . . . . . . . . . . . . . . 3C-6
Front Wheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
GENERAL DESCRIPTION
Figures 1 and 2
The short/long arm (SLA) front suspension assem-
bly is designed to allow each wheel assembly to com-
pensate for changes in the road surface level without
appreciably affecting the opposite wheel assembly. Each
wheel assembly is independently connected to the frame
assembly by a steering knuckle assembly (6) and wheel
hub assembly (44), shock absorber assembly (24) and
spring assembly (23), upper and lower ball stud assem-
blies (2 and 10) and upper and lower control arm assem-
blies ( I and 17). The steering knuckle and hub assemblies
(6 and 44) move in a prescribed three-dimensional arc.
The front wheel assemblies are held in proper relationship
to each other by two front tie rod axle assemblies. The
front tie rod axle assemblies are connected to steering
arms on the knuckles and to the steering gear assembly.
Spring assemblies (23) are mounted on the lower
control arm assemblies (17). Ride control is provided by
direct acting shock absorber assemblies (24). The upper
portion of the shock absorber assembly is connected to the
front upper shock absorber mount assembly (45). The
upper mount assembly (45) extends through the upper
control arm support (46) and the center wheelhouse
assembly and attaches with two shock absorber upper
mount bolts/screws (26) and two shock absorber upper
mount nuts (25).
FRONT SUSPENSION 3C·1
Lower Control Arm Assembly ............. 3C-8
Lower Control Arm Bushing Assembly . . . . . . 3C-9
Shock Absorber and Spring Assembly ...... 3C-11
Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 3C- l 5
Stabilizer Shaft Link Assembly ............ 3C-16
Steering Knuckle Assembly ............... 3C-16
Upper Control Arm Assembly ............. 3C-17
Upper Control Arm Bushing Assembly ...... 3C-18
Wheel Bearing Assembly ................ 3C-19
Crossmember Assembly . . . . . . . . . . . . . . . . . 3C-19
Specifications ............................ 3C-21
Fastener Tightening Specifications ......... 3C-21
Special Tools ............................ 3C-22
Side roll of the front suspension assembly is con-
trolled by a stabilizer shaft (11). The stabilizer shaft is
mounted to stabilizer shaft insulators (16) that are held to
frame side rails by stabilizer shaft bracket assemblies. The
.ends of the stabilizer shaft ( 11) are connected to the lower
control arm assemblies (17) by stabilizer shaft link
assemblies (12) and are isolated by complaint bushings.
The inner ends of the lower control arm assembly
(17) have pressed-in bushings. Bolts (passing through the
bushings) attach the lower control arm assembly (17) to
the crossmember assembly (20).
The upper control arm assembly (1) is attached to
the steering knuckle assembly (6) with a nut (4) and cotter
pin (3) and is bolted to the shock absorber assembly (24)
through an upper control arm support (46) which attaches
to the body.
The lower ball stud assembly (10) is a press fit in the
lower control arm assembly (17) and is attached to the
steering knuckle assembly (6) with a nut (8) and cotter pin
(9).
Rubber grease seals are provided at ball socket
assemblies to keep dirt and moisture from entering the
stud assembly and damaging bearing surfaces.
The upper ball stud assembly (2) is riveted to the
upper control arm assembly (1) and is attached to the
steering knuckle assembly (6) with a nut (4) and cotter pin
(3).
3C·2 FRONT SUSPENSION

---- - . e 1 - Front Suspension

- - ~ ~Figure
r . Components
 FRONT SUSPENSION 3C·3

1 ARM ASSEMBLY, FRONT UPPER CONTROL 16 INSULATOR, FRONT STABILIZER SHAFT

2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
3 PIN, FRONT UPPER CONTROL ARM COTTER
4 NUT, FRONT UPPER CONTROL ARM, 53 N•m (39 LB. FT.)
5 NUT, FRONT STABILIZER SHAFT LINK ASSEMBLY,
23 N•m (17 LB. FT.)
6 KNUCKLE AND HUB ASSEMBLY, STEERING
7 SLEEVE, FRONT STABILIZER SHAFT LINK ASSEMBLY
8 NUT, FRONT LOWER CONTROL ARM,
110 N•m (81 LB. FT.)
9 PIN, FRONT LOWER CONTROL ARM COTTER
10 STUD ASSEMBLY, FRONT LOWER CONTROL ARM BALL
11 STABILIZER SHAFT, FRONT
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT,
23 N•m (17 LB. FT.)
13 BOLT/SCREW, FRONT STABILIZER SHAFT INSULATOR
CLAMP, 55 N•m (41 LB. FT.)
14 CLAMP. FRONT STABILIZER SHAFT INSULATOR
15 BOLT/SCREW, FRONT SHOCK ABSORBER,
65 N•m (48 LB. FT.)
17 ARM ASSEMBLY, FRONT LOWER CONTROL
18 NUT, FRONT LOWER CONTROL ARM, 115 N•m
(85 LB. FT.)
19 BOLT/SCREW, FRONT LOWER CONTROL ARM
20 CROSS MEMBER ASSEMBLY, FRONT
21 BOLT/SCREW, FRONT LOWER CONTROL ARM
22 NUT, FRONT SHOCK ABSORBER LOWER BRACKET,
65 N•m (48 LB. FT.)
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
25 NUT, FRONT SHOCK ABSORBER UPPER MOUNT,
43 N•m (32 LB. FT.)
26 BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT, 50 N•m (37 LB. FT.)
27 NUT, FRONT LOWER CONTROL ARM, 95 N•m
(70 LB. FT.)
44 HUB ASSEMBLY, FRONT WHEEL
45 MOUNT ASSEMBLY, FRONT UPPER SHOCK
ABSORBER
46 SUPPORT, FRONT UPPER CONTROL ARM RC0011-3C-F-RP

Figure 2 - Front Suspension Components - Legend

A B

c
A WORN
E
B NEW
C WEAR SURFACES ~
D SINTERED IRON BEARING •
E HOUSING SOCKET H __
F RUBBER PRESSURE RING 1.27 mm (0.050")
G WEAR INDICATOR SHOULDER (OUT WHEN NEW)
H WHEN LOWER CONTROL ARM BALL STUD ASSEMBLY
WEAR CAUSES WEAR INDICATOR SHOULDER TO BE
BELOW SURFACE, REPLACEMENT IS NEEDED
PC0003-3C-F-RP

Figure 3 - Lower Control Arm Ball Stud Assembly Wear Indicator

ON-VEHICLE SERVICE Lower Control Arm Ball Stud Assembly

Figure 3
CONTROL ARM BALL STUD ASSEMBLY
INSPECTION The lower control arm ball stud assembly has a
visual wear indicator. Checking the condition of the lower
control arm ball stud assembly is a simple procedure but
Figures 3 and 4 must be followed accurately to prevent unnecessary
!L•l 1nspect replacement.

• Ball stud assembly seals should be carefully

inspected for cuts and tears. Whenever cuts or tears
!L•l 1nspect
1. Vehicle must be supported by wheel assemblies so
are found, ball stud assembly must be replaced. weight of vehicle will properly load ball stud
• Ball studs for wear. assemblies.
3C-4 FRONT SUSPENSION

2. Ball stud assembly is inspected for wear by visual CONTROL ARM BALL STUD ASSEMBLY
observation alone. Wear is indicated by position of REPLACEMENT
12.7 mm (0.50 inch) diameter nipple into which
front suspension lubricant fitting is threaded. This
round nipple projects 1.27 mm (0.050 inch) beyond Lower Control Arm Ball Stud Assembly
surface of ball stud assembly cover when new.
Normal wear will result in surface of this nipple Figures 5 through 1O
retreating very slowly inward. Tools Required:
3. Wipe front suspension lubricant fitting and nipple J 39549 Ball Joint(fie Rod Separator
free of dirt and grease. Observe or scrape screw- J 9519-7 Ball Joint Remover
driver or fingernail across cover. If round nipple is J 9519-9 Ball Joint Installer
flush or inside cover surface, replace ball stud
assembly. J 9519-18 Ball Joint Pressing Screw
J 9519-23 Ball Joint C-Clamp

Upper Control Arm Ball Stud Assembly I++! Remove or Disconnect

1. Raise and suitably support vehicle with floor stands
Figure 4 under frame assembly. Refer to SECTION OA.
2. Special security wheel lock nut, if equipped. Refer
!l'l'I Inspect to SECTION 3E.
1. Raise vehicle and position floor stands under both 3. Tire and wheel assembly. Refer to SECTION 3E.
lower control arm assemblies as near as possible to 4. Place floor jack under lower control arm assembly
each ball stud assembly. Refer to SECTION OA. (17).

m Important
• Vehicle must be stable and should not rock on
m Important
• Floor jack must remain under shock absorber
floor stands. assembly mounting location on lower control
2. Position dial indicator against wheel rim. arm assembly (17) during removal and instal-
lation to hold spring assembly and lower
3. Grasp wheel assembly and push in on bottom of tire control arm assembly in position.
while pulling out at top. Read gage, then reverse 5. Separate ball stud assembly from steering knuckle
push-pull procedure. Horizontal deflection on dial assembly, using J 39549.
indicator should not exceed 3.18 mm (0.125 inch).
6. Lower control arm cotter pin and loosen lower
• If dial indicator reading exceeds 3.18 mm cont~ol arm nut.
(0.125 inch), replace ball stud assembly. 7. Press ball stud assembly out of lower control
4. Anytime ball stud assembly is disconnected from arm assembly (17), using J 9519-7, J 9519-18 and
steering knuckle assembly, check for looseness or if J 9519-23.
ball stud assembly can be twisted in its socket with
your fingers. If either of these conditions exist,
replace ball stud assembly.
l++I Install or Connect
NOTICE: See "Notice" on page 3C-1 of this
5. Lower vehicle. section.
1. Position ball stud assembly into lower control
arm assembly (17) and press in, using J 9519-9,
J 9519-18 and J 9519-23, until it bottoms on lower
control arm assembly (17). Ball stud assembly must
SUPPORT FRONT LOWER
CONTROL ARM ASSEMBLY AS
firmly press into lower control arm assembly ( 17). If
FAR OUTBOARD AS POSSIBLE it does not, replace lower control arm assembly (17).
2. Ball stud assembly to steering knuckle assembly.
3. Hand start lower control arm nut.
2 POSITION DIAL INDICATOR TO
CHECK MOVEMENT AT THIS
POINT IJJ Important
• Tighten nut enough to align nut slot with stud
hole. Never loosen nut in order to align slot
3 ROCK WHEEL AND TIRE
ASSEMBLY IN AND OUT AT
with hole.
TOP AND BOTTOM PC6004-3C-D-RP

Figure 4 - Checking Upper Control Arm Ball Stud Assembly

l~I Tighten
• Nutto 110 N•m (81 lb. ft.).
 FRONT SUSPENSION 3C·5

A
J 9519-18 B

A REMOVING LOWER BALL STUD ASSEMBLY

B INSTALLING LOWER BALL STUD ASSEMBLY
17 ARM ASSEMBLY, FRONT LOWER CONTROL

Figure 5 - Removing and Installing Lower Control Arm Ball Stud Assembly

4. Lower control arm cotter pin.

5. Remove floor jack from under shock absorber
assembly mounting location on lower control arm
rn Important
• Floor jack must remain under the shock
assembly (17). absorber assembly mounting location on lower
6. Tire and wheel assembly. Refer to SECTION 3E. control arm assembly (17) during removal and
7. Special security wheel lock nut, if eqµipped. Refer installation to hold the spring assembly and
to SECTION 3E. lower control arm assembly in position.
8. Check wheel assembly alignment. Refer to SEC-
TION 3A. 5. Loosen ball stud assembly (2) from steering knuckle
assembly (6).
· 9. Lower vehicle.
6. Cotter pin (3) and nut (4).
Upper Control Arm Ball Stud Assembly
7. Support steering knuckle assembly (6) with floor
Figures 6 through 10 stands.
!++I Remove or Disconnect 8. Separate ball stud assembly (2) from upper control
arm assembly (1), using J 39549.
Tool Required:
J 39549 Ball Joint{fie Rod Separator 9. With upper control arm assembly (1) in raised
1. Raise and suitably support vehicle. Refer to SEC- position, drill out four rivets approximately 6 mm
TION OA. (0.25 inch) deep, using 1/8-inch drill bit. Refer to
2. Special security wheel lock nut, if equipped. Refer Figure 7.
to SECTION 3E.
10. Drill off rivet heads, using 1/2-inch drill bit. Refer to
3. Tire and wheel assembly. Refer to SECTION 3E. Figure 8.
4. Place floor jack under shock absorber assembly
mounting location on lower control arm assembly 11. Punch out rivets, using small punch, and remove ball
(17). stud assembly (2). Refer to Figure 9.
3C-6 FRONT SUSPENSION

KCOl 00-3&-B-RP

Figure 8 - Drilling Upper Control Arm Ball Stud Assembly

1 ARM ASSEMBLY, FRONT UPPER CONTROL Rivet Heads
2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
6 KNUCKLE ASSEMBLY, STEERING
PC0005-3C-F-RP

Figure 6 - Separating Upper Control Arm Ball Stud Assembly

A PUNCH
2 STUD ASSEMBLY, FRONT UPPER
CONTROL ARM BALL
KC0095-3C-B-RP PC6010-3C·D-RP

Figure 7 - Drilling Upper Control Arm Ball Stud Assembly Figure 9 - Removing Upper Control Arm Ball Stud Assembly
Rivet

4. Cotter pin (3).

!-++I Install or Connect 5. Remove floor jack from under spring seat.
NOTICE: See "Notice" on page 3C-1 of this 6. Tire and wheel assembly. Refer to SECTION 3E.
section. 7. Special security wheel lock nut, if equipped. Refer
1. Position new ball stud assembly (2) and install four to SECTION 3E.
service kit bolts/screws (28) and nuts (29). Use 8. Lower vehicle.
specifications in ball stud assembly kit.
2. Remove temporary support from steering knuckle WHEEL HUB ASSEMBLY
assembly (6), then connect ball stud assembly (2) to
steering knuckle assembly (6). Figure 11
3. Hand start nut (4).
!++I Remove or Disconnect
rn Important
• Tighten nut enough to align slot with stud hole.
1. Raise and suitably support vehicle. Refer to SEC-
TION QA.
Never loosen nut in order to align slot with 2. Special security wheel lock nut, if equipped. Refer
hole. to SECTION 3E.
3. Tire and wheel assembly. Refer to SECTION 3E.
l~I Tighten 4. Brake caliper assembly. Refer to SECTION 5Bl.
• Nut (4) to 53 N•m (39 lb. ft.). 5. Brake rotor assembly. Refer to SECTION 5Bl.
 FRONT SUSPENSION 3C·7

29

39

6 KNUCKLE AS.SEMBLY, STEERING

39 ROTOR ASSEMBLY, FRONT BRAKE
40 CALIPER ASSEMBLY, FRONT BRAKE
41 BOLT/SCREW, FRONT BRAKE CALIPER
. 42 BOLT/SCREW, FRONT WHEEL, 86 N•m (63 LB. FT.)
43 BRACKET, WHEEL SPEED SENSOR WIRE
44 HUB ASSEMBLY, FRONT WHEEL

PC0024-3C-F-RP
1 ARM ASSEMBLY, FRONT UPPER CONTROL Figure 11 - Front Wheel Hub Assembly
2 STUD ASSEMBLY, FRONT UPPER CONTROL BALL
3 PIN, FRONT UPPER CONTROL ARM COTTER
4 NUT, FRONT UPPER CONTROL ARM, 53 N•m (39 LB. FT.)
6 KNUCKLE ASSEMBLY, STEERING 3. Wheel speed sensor electrical connector. Refer to
28 BOLT/SCREW, SERVICE KIT SECTION 5El.
29 NUT, SERVICE KIT
4. Brake rotor assembly. Refer to SECTION 5Bl.
5. Brake caliper assembly. Refer to SECTION 5Bl.
6. Tire and wheel assembly. Refer to SECTION 3E.
PC0006-3C-F-RP
7. Special security wheel lock nut, if equipped. Refer
Figure 1 O - Upper Control Arm Ball Stud Assembly to SECTION 3E.
Attachment
8. Lower vehicle.

FRONT WHEEL BOLT

6. Wheel speed sensor electrical connector and move
aside. Refer to SECTION 5El. Wheel Hub Assembly Removed
Tool Required:
7. Bolts/screws (42) from hub assembly (44 ).
J 6627-A Wheel Stud Remover
8. Pull hub assembly (44) from spindle.

l++I Install or Connect l++I Remove or Disconnect

NOTICE: Do not damage wheel assembly mount-
I. Position hub assembly (44) to spindle. ing surface on hub assembly flange. Brake assembly
2. Bolts/screws (42). disc must be supported before pressing wheel
assembly bolt in or out.
l~.J Tighten • Hub assembly or disc bolts, using J 6627-A.
• Bolts/screws (42) to 86 N•m (63 lb. ft.).
!++I Install or Connect
rn Important
• Make sure wheel speed sensor electrical
NOTICE: See "Notice" on page 3C-1 of this
section.
connector is reconnected to wheel speed sensor • New serrated bolt into hole in hub assembly. Tap
wire bracket (43) and wheel speed sensor or lightly with hammer to start bolt serration in hole,
wires could be damaged. making sure that bolt is square with hub flange.
3C-8 FRONT SUSPENSION

LOWER CONTROL ARM ASSEMBLY 1. Position lower control arm assembly ( 17) to cross-
member assembly (20).
Figure 12 2. Hand tighten bolts/screws (19 and 21) and nuts
!+•I Remove or Disconnect (18 and 27).

1. Raise and suitably support vehicle. Refer to SEC-

TION OA.
l~I Tighten
• Nuts (18) to 115 N•m (85 lb. ft.).
2. Special security wheel lock nut, if equipped. Refer
• Nuts (27) to 95 N•m (70 lb. ft.).
to SECTION 3E.
3. Tire and wheel assembly. Refer to SECTION 3E. 3. Position lower control arm assembly ( 17) to steering
knuckle assembly (6).
4. Power steering gear assembly from steering knuckle
4. Hand start nut (8).
assembly. Refer to SECTION 3B.
5. Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
6. Shock absorber and spring assembly from lower
rn Important
• Tighten nut enough to align slot with stud hole.
control arm assembly. Refer to "Shock Absorber Never loosen nut in order to align slot with
and Spring Assembly" in this section. hole.
7. Separate lower control arm ball stud assembly from
steering knuckle assembly. Refer to "Control Arm l~I Tighten
Ball Stud Assembly Replacement" in this section. • Nut (8) to 110 N•m (81 lb. ft.).
8. Lower control arm assembly (17) from steering 5. Cotter pin (9).
knuckle assembly (6).
6. Lower control arm assembly to shock absorber and
9. Bolts/screws (19 and 21) and nuts (27 and 18). spring assembly. Refer to "Shock Absorber and
10. Lower control arm assembly (17). Spring Assembly" in this section.

!•+I Install or Connect 7. Stabilizer shaft link assembly. Refer to "Stabilizer

Shaft Link Assembly" in this section.
NOTICE: See "Notice" on page 3C-1 of this 8. Power steering gear assembly to steering knuckle
section. assembly. Refer to SECTION 3B.

23

5 NUT, FRONT STABILIZER SHAFT LINK ASSEMBLY,

23 N•m (17 LB. FT.)
6 KNUCKLE ASSEMBLY, STEERING
7 SLEEVE, FRONT STABILIZER SHAFT LINK ASSEMBLY
8 NUT, FRONT LOWER CONTROL ARM, 110 N•m
(81 LB. FT.)
9 COTIER PIN, FRONT LOWER CONTROL ARM
10 BALL STUD ASSEMBLY, FRONT LOWER CONTROL
ARM
11 STABILIZER SHAFT, FRONT
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT 20
15 BOLT/SCREW, FRONT SHOCK ABSORBER, 65 N•m
(48 LB. FT.)
17 ARM ASSEMBLY, FRONT LOWER CONTROL
18 NUT, FRONT LOWER CONTROL ARM, 115 N•m
(85 LB. FT.)
19 BOLT/SCREW, FRONT LOWER CONTROL ARM
20 CROSSMEMBER ASSEMBLY, FRONT
21 BOLT/SCREW, FRONT LOWER CONTROL ARM
22 NUT, FRONT SHOCK ABSORBER LOWER BRACKET, 10
65 N•m (48 LB. FT.)
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
27 NUT, FRONT LOWER CONTROL ARM, 95 N•m
(70 LB. FT.)
44 HUB ASSEMBLY, FRONT WHEEL

15
RC0010·3C·F·RP

Figure 12 - Lower Control Arm Assembly


9. Tire and wheel assembly. Refer to SECTION 3E.
10. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
11. Lower vehicle.
12. Align wheel assembly. Refer to SECTION 3A.
LOWER CONTROL ARM BUSHING
ASSEMBLY
The lower control arm bushing assembly can be serv-
iced separately from the lower control arm assembly.
Front Bushing
Figures 12 and 13
Tools Required:
J 21474-3 Lower Control Arm Bushing Screw
Assembly
J 21474-4 Lower Control Arm Bushing Nut
Assembly
J 21474-5 Control Arm Bushing Receiver
J 21474-6 Control Arm Bushing Receiver
J 39875 Half Moon Spacer
J 39876 Lower Control Arm Bushing Receiver
!+!+I Disassemble
1. Lower control arm assembly. Refer to "Lower Con-
trol Arm Assembly" in this section.
2. Remove lower control arm front bushing from lower
control arm assembly (17).
A. Place J 21474-3 through large end of J 21474-6.
B. Thread J 21474-3 through front bushing and
push it through open end of J 39876.
C. Place thrust washer onto J 21474-3 with seam
facing toward front bushing.
D. Install J 39875 around outside of bushing to
avoid rnetal distortion during removal.
E. After making sure all tools are properly lined
up with front bushing and control arm, install
J 21474-4 and tighten uhtil bushing is pushed
all the way out (popping noise may be heard
while removing).
l+:+I Assemble
NOTICE: See "Notice" on page 3C-1 of this sec-
tion.
1. Lower control arm front bushing.
A. Thread J 21474-3 through J 21474-5.
B. Install J 21474-3 through new front bushing
and into lower control arm.
C. Thread J 21474-3 and accessories into lower
control arm - front.
D .. Install J 39876 onto J 21474-3 with operi end
of J 39876 facing toward control arm.
E. Install J 39875 around outside bushing to avoid
metal distortion during installation.
FRONT SUSPENSION 3C·9
F. Place thrust washer onto threaded end of
J 21474-3 with seam facing toward control
arm.
G. After making sure all tools are properly lined
up with control arm and bushing, install
J 21474-4 onto J 21474-3. Tighten J 21474-4
and J 21474-3 until bushing becomes flush
with control arm.
2. Lower control arm assembly. Refer to "Lower Con-
trol Arm Assembly" in this section.
Rear Bus.hing
Figures 12 and 14
Tools Required:
J 21474-3 Lower Control Arm Bushing Screw
Assembly
J 21474-4 Lower Control Arm Bushing Nut
Assembly
J 21474-5 Control Arm Bushing Receiver
J 39874 Lower Control Arm Bushing Receiver
J 39931 Lower Control Arm Bushing Receiver
l+!+I Disassemble
1. Lower control arm assembly. Refer to "Lower Con-
trol Arm Assembly" in this section.
2. Remove lower control arm rear bushing from lower
control arm assembly (17).
A. Install J 39874 onto J 21474-3 with sealed end
of J 39874 facing head of screw.
B. Run J 21474-3 through control arm bushing,
control arm, and into small end of J 39931.
C. Install thrust washer onto J 21474-3 with seam
facing toward control arm.
D. Install J 21474-4 onto J 21474-3, making sure
all parts are lined upwhh control arm bushing.
E. Tighten assembly until control arm bushing is
able to be removed (popping noise may be
heard while removing).
l+!+I Assemble
NOTICE: See "Notice" on page 3C-1 of this sec-
tion.
1. Lower control arm rear bushing.
A. With lower control arm securely tightened in
vise, place J 21474-3 through small end of
J 39931.
B. Install J 21474-3 through new rear bushing and
then through closed end of lower control arm -
rear.
C. Place small end of J 21474-5 onto J 21474-3.
D. Install thrust washer onto J 21474-3 with seam
of washer facing toward control arm.
E. Making sure all tools are lined up with bushing
and control arm and that window is facing
straight up and visible on J 39931, install
J 21474-4 onto J 21474-3 and tighten until rub-
ber protrusion on J 39931 side bottoms out
against J 39931.
3C·10 FRONT SUSPENSION

J 21474-5 c
J 21474-4

17

~ I

A B

A REMOVING FRONT BUSHING

B INSTALLING FRONT BUSHING
C WASHER, THRUST
17 ARM ASSEMBLY, FRONT LOWER CONTROL

RC0001•3C-F-RP

Figure 13 - Removing and Installing Lower Control Arm Front Bushing Assembly

J 39931 J 39874 J 39931

J 21474-4

J 21474-3

J 21474-3

J 21474-4

17

A B

A REMOVING REAR BUSHING

B INSTALLING FRONT BUSHING
C VVASHER,THRUST
17 ARM ASSEMBLY, FRONT LOVVER CONTROL

RC0002-3C-F-RP

Figure 14 - Removing and Installing Lower Control Arm Rear Bushing Assembly
 FRONT SUSPENSION 3C·11

2. Lower control arm assembly. Refer to "Lower Con-

trol Arm Assembly" in this section.

SHOCK ABSORBER AND SPRING

ASSEMBLY 26-=---e.a
25""""'11::~-.. ,
Figures 15 through 23
Tools Required:
J 34013-B Strut Spring Compressor
J 34013-114 Modular Shock Assembly 46
Compressor Adapter
J 34013-88 Strut Compressor Adapter 2
J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 inch)
J 34013-115 Modular Shock Assembly
· Alignment Rod

!++I Remove ~r Disconnect

1. Brake master cylinder nuts (driver-side only). Refer
to SECTION 5A.
2. Move brake master cylinder assembly aside (driver-
side only). Refer to SECTION 5A.
3. Bolts/screws (26) and nuts (25).
4. Raise and suitably support vehicle. Refer to SEC-
TION OA.
5. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
6. Tire and wheel assembly. Refer to SECTION 3E.
7. Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
8. Nuts (22).
9. Bolts/screws (15).
10. Separate lower .ball stud assembly from steering
knuckle assembly. Refer to "Control Arm Ball Stud
Assembly Replacement" in this section.

[]] Important
• Be sure to mark with chalk or paint (do not
scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber assembly or the assembly can-
not be reinstalled.
11. Shock absorber and spring assembly (24 and 23).
!+!+I Disassemble
1. Install J 34013-114 to J 34013-B. Use wing nuts
to secure tool to mounting holes C-H (lower left
corner) and P (upper right corner) for driver-side
shock absorber assembly and to secure tool to
mounting holes A-X-P (upper left corner) and C-H
(lower right corner) for passenger-side shock
absorber assembly.
1 ARM ASSEMBLY, FRONT UPPER CONTROL
2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
3 PIN, FRONT UPPER CONTROL ARM COTTER
4 NUT, FRONT UPPER CONTROL ARM, 53 N•m (39 LB. FT.)
6 KNUCKLE ASSEMBLY, STEERING
8 NUT, FRONT LOWER CONTROL ARM,
110 N•m (81 LB. FT.)
9 PIN, FRONT LOWER CONTROL ARM COTTER
10 STUD ASSEMBLY, FRONT LOWER CONTROL ARM BALL
15 BOLT/SCREW, FRONT SHOCK ABSORBER,
65 N•m (48 LB. FT.)
17 ARM ASSEMBLY, FRONT LOWER CONTROL
22 NUT, FRONT SHOCK ABSORBER LOWER BRACKET,
65 N•m (48 LB. FT.)
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
25 NUT, FRONT SHOCK ABSORBER UPPER MOUNT,
43 N•m (32 LB. FT.)
26 BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT, 50 N•m (37 LB. FT.) .

rn Important
• Be sure J 34013-114 and J 34013-88 are
44 HUB ASSEMBLY, FRONT WHEEL
45 MOUNT ASSEMBLY, FRONT UPPER SHOCK ABSORBER
46 SUPPORT, FRONT UPPER CONTROL ARM
PC0008-3C·f·RP ·

aligned so they can open and close together. Figure 15 - Shock Absorber and Spring Assembly
3C-12 FRONT SUSPENSION

KENT-MOORE
Ktlfl·Moort
A..,,_,,irrOfri.1i""
SPXCorpt>raliolt
197MU,,kM.ri
R..ur11lt.All4*Jl'll\·l19.'I
l-/lflO.. f4.1-22fJ

J 34013-B Strut Spring Compressor J 34013-B

Read Instruction Sheet J 34013-29/29A
Before Using

C-H-E/K

PC0018-3C-F-RP

Figure 18 - Modular Shock Assembly Compressor Adapter -

Passenger-Side Position

J-N-L
J 34013-44C Nova Twin-Cam

PC0016-3C-F-RP

Figure 16 - Modular Shock Assembly Compressor Mounting

Hole Location

RC0007·3C-F-RP

Figure 19 - Installing Strut Compressor Adapter to Strut

Spring Compressor

4. Install shock absorber assembly into J 34013-114

PC0017·3C·F-RP
Figure 17 - Modular Shock Assembly Compressor Adapter -
Driver-Side Position
If the tools are not aligned properly, they
will not open.
2. Install J 34013-114 and J 34013-88.
[I] Important
• Be sure the top of the shock absorber assembly
is flat against J 34013-114. The shock absorber
assembly will not be aligned correctly if it does
not lay flat against the tool.
3. Shock absorber assembly to top of J 34013-114.
and J 34013-88.
5. Close J 34013-114 and J 34013-88 and install
locking pin.
[I] Important
• Be sure the mounting ears of the shock
absorber assembly are facing downward
toward the rear of J 34013-B or the shock
absorber assembly will not align properly.
6. Turn screw on J 34013-B counterclockwise to raise
shock absorber assembly up to J 34013-114. Be
sure studs go through guide holes in J 34013-114
and the top of the shock absorber assembly is flat
against the tool.
 FRONT SUSPENSION 3C·13

J 34013-

J 34013-114

A 24
24
A MATCHING ANGLE BETWEENSHOCK ABSORBER
J 34013-8 ASSEMBLY AND J 34013-114
23 SPRING ASSEMBLY, FRONT
23 SPRING ASSEMBLY, FRONT 24 ABSORBER ASSEMBLY, FRONT SHOCK
24 ABSORBER ASSEMBLY, FRONT SHOCK
RC0008-3C-F-RP PC0022-3C-F-RP

Figure 20 - Installing Shbck Absorber Assembly to Figure 22 - Passenger-Side Shock Absorber Assembly
Strut Spring Compressor Installation

9. Remove shock absorber nut with J 39642-1 while

holding shock absorber assembly rod from rotating
with J 39642-2.
- - - J 34013-8. 10. Discard shock absorber nut.
11. Turn J 34013-B clockwise to fully relieve spring
assembly pressure.
- - J 34013-114
l+!+f Assemble
1. Install J 34013-114 to J 34013-B. Use wing nuts to
secure J 34013-114 to J 34013-B mounting holes
C-H (lower left comer) and P (upper right comer)
for driver-side shock absorber assembly and to
>----23 secure J 34013-114 to J 34013-B mounting holes
A-X-P (upper left comer) and C-H (lower right
24------1 comer) for passenger-side shock absorber assembly
(Figures 17 and 18).
A MATCHING ANGLE BETWEEN SHOCK ABSORBER
ASSEMBLYANDJ 34013-114
2. Install J 34013-114 and J 34013-88.
23 SPRING ASSEMBLY, FRONT 3. Install shock absorber assembly to J 34013-114 and
24 ABSORBER ASSEMBLY, FRONT SHOCK J 34013-88.
PC0021-3C-F·RP

Figure 21 - Driver-Side Shock Absorber Assembly

Installation
CAUTION: Do not over compress front
spring assembly. Severe overloading
may cause tool failure which could
result in bodily injury.
7. Compress front spring assembly approximately
13 mm (0.50 inch) or three or four complete turns
of the screw on J 34013-114.
8. Insert J 39642-1 on shock absorber nut, then insert
J 39642-2 through J 39642-1 to hold shock
absorber rod in place.
rn Important
• Be sure the mounting ears of the shock
absorber assembly are facing downward.
toward the rear of J 34013-B or the shock
absorber assembly will not align properly.
• Be sure to mark with chalk or paint (do not
scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber assembly or the assembly
cannot be reinstalled.
4. Close J 34013-114 and J 34013-88 and engage
locking pin.
5. Make sure upper and lower spring seats are posi-
tioned correctly.
3C~4FRONTSUSPEN~ON
J 34013-115
J 34013-8
J 34013-114
24
A ROD, FRONT SHOCK ABSORBER
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
PC0023-3C·F-RP
Figure 23 - Inserting Modular Shock Assembly
Alignment Rod
l++l
6. Shock absorber assembly to top of J 34013-114.
rn Important
• Be sure the top of the shock absorber assembly
is flat against J 34013-114. The shock absorber
assembly will not be aligned properly if it does
not lay flat against the tool.
7. Turn screw on J 34013-B counterclockwise to raise
shock absorber assembly up to J 34013-114 without
compressing spring assembly. Be sure studs on
shock absorber assembly go through guide holes in
J 34013-114.
rn Important
• Only turn the screw until the shock absorber
assembly is held in J 34013-B by itself. Do not
load the spring assembly.
8. Place J 34013-115 down through top of J 34013-B
through top of shock absorber assembly and onto
shock absorber 1nd.
m Important
• Make sure J 34013-115 is straight with the
shock absorber assembly. If J 34013-115 is
angled, repeat steps 1 through 5 until tool is
straight.
CAUTION: Do not over compress
spring assembly. Severe overloading
may result in tool failure which could
result in t,odily injury.
9. Turn operating screw clockwise to compress spring
assembly until threaded portion of the shock
absorber rod is through the top of the shock absorber
assembly.
10. Remove J 34013-115.
rn Important
• When installing front shock absorber nut,
always replace it with a new one. Never
install the same nut that has been
removed.
11. Insert new shock absorber nut on shock absorber
rod.
NOTICE: Do not turn the shock absorber rod when
tightening the shock absorber nut or the shock
absorber assembly could be damaged. Keep the
shock absorber rod in a stationary position when
tightening the shock absorber nut.
12. Place J 39642-1 on shock absorber nut.
13. Insert J 39642-2 through J 39642-1 and tighten
shock absorber nut.
14. Tighten shock absorber nut while holding onto
J 39642-2.
15. Remove shock absorber assembly from J 34013-B.
lnstall or Connect
NOTICE: See "Notice" on page 3C-1 of this
section.
1. Position shock absorber and spring assembly
(24 and 23) to lower control arm assembly (17).
2. Bolts/screws (15) and nuts (22).
l~I Tighten
• Bolts/screws (15) and nuts (22) to 65 N•m
(48 lb. ft.).
3. Lower ball stud assembly to steering knuckle assem-
bly. Refer to "Control Arm Ball Stud Assembly
Replacement" in this section.
4.
5.
Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
Tire and wheel assembly. Refer to SECTION 3E.
6. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
7. Lower vehicle.
8. Hand tighten bolts/screws (26) and nuts (25).
l~ITighten
• Bolts/screws (26) to 50 N•m (37 lb. ft.).
• Nuts (25) to 43 N•m (32 lb. ft.).
9. Position brake master cylinder assembly (driver-side
only). Refer to SECTION SA.
10. Brake master cylinder nuts (driver-side only). Refer
to SECTION SA.
 FRONT SUSPENSION 3C·15

STABILIZER SHAFT
l++I Install or Connect
Figure24 NOTICE: See "Notice" on page 3C-1 of this
section.
!++I Remove or Disconnect 1. Position bracket assemblies (31) to side rail.
1. Raise and suitably support vehicle. Refer to SEC- 2. Hand start bolts/screws (30).
TION OA.
2. Stabilizer shaft link assembly. Refer to "Stabilizer
l~I Tighten
Shaft Link Assembly" in this section. • Bolts/screws (30) to 55 N•m (41 lb. ft.).
3. Bolts/screws (13). 3. Place insulators (16) over stabilizer shaft (11).
4. Clamps (14). [I] Important
5. Stabilizer shaft (11). • The slit of the insulator must face the front of
6. Insulators (16). the vehicle.
4. Position clamps (14) over insulators (16) and stabi-
·7. Bolts/screws (30). lizer shaft (11).
8. Bracket assemblies (31). 5. Bolts/screws (13).

11

A SIDE RAIL
5 NUT, FRONT STABILIZER SHAFT LINK ASSEMBLY,
23 N•m (17 LB. FT.)
6 KNUCKLE ASSEMBLY, STEERING
7 SLEEVE, FRONT STABILIZER SHAFT LINK ASSEMBLY
11 STABILIZER SHAFT, FRONT
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT,
23 N•m (17 LB. FT.) 12
13 BOLT/SCREW, FRONT STABILIZER SHAFT INSULATOR
CLAMP, 55 N•m (41LB. FT.)
14 CLAMP, FRONT STABILIZER SHAFT INSULATOR
16 INSULATOR, FRONT STABILIZER SHAFT
30 BOLT/SCREW, FRONT STABILIZER SHAFT BRACKET,
55 N•m (41 LB. FT.)
31 BRACKET ASSEMBLY, FRONT STABILIZER SHAFT
44 HUB ASSEMBLY, FRONT WHEEL

Figure 24 - Stabilizer Shaft

3C·16 FRONT SUSPENSION

STEERING KNUCKLE ASSEMBLY

l~I Tighten Figure26
· • Bolts/screws (13) to 55 N•m (41 lb. ft.).
6. Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
l++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
7. Lower vehicle. TION QA.
2. Special security wheel lock nut, if equipped. Refer
STABILIZER SHAFT LINK ASSEMBLY to SECTION 3E.
3. Tire and wheel assembly. Refer to SECTION 3E.
Figure 25 4. Brake caliper assembly and move aside. Refer to

!++I Remove or Disconnect SECTION 5B 1.

5. Brake rotor assembly. Refer to SECTION 5.
1. Raise and suitably support vehicle. Refer to SEC- 6. Wheel speed sensor electrical connector and move
TION QA. aside. Refer to SECTION 5El.
2. Nut (5). 7. Front wheel hub assembly from steering knuckle
3. Link assembly (12). assembly. Refer to "Wheel Hub Assembly" in this
section.
4. Sleeve (7).
8. Power steering gear assembly from steering knuckle
!++I Install or Connect assembly. Refer to SECTION 3B.
9. Stabilizer shaft link assembly. Refer to "Stabilizer
NOTICE: See "Notice" on page 3C-1 of this Shaft Link Assembly" in this section.
section.
10. Front shock absorber bolts/screws. Refer to "Shock
1. Sleeve (7) between lower control arm assembly ( 17) Absorber and Spring Assembly" in this section.
and stabilizer shaft ( 11 ).
11. Separate lower ball stud assembly from steering
2. Link assembly (12) through lower control arm knuckle assembly. Refer to "Control Arm Ball Stud
assembly (17), sleeve (7) and stabilizer shaft (11). Assembly Replacement" in this section.
3. Nut (5). 12. Lower control arm assembly from steering knuckle
assembly. Refer to "Lower Control Arm Assembly"
!~I Tighten in this section.
13. Separate upper ball stud assembly from steering
• Nut (5) to 23 N•m (17 lb. ft.).
knuckle assembly. Refer to "Control Arm Ball Stud
4. Lower vehicle. Assembly Replacement" in this section.
14. Steering knuckle assembly from upper control arm
assembly. Refer to "Upper Control Arm Assembly"
in this section.
5
15. Steering knuckle and hub assemblies (6 and 44).

!-.+I Install or Connect

NOTICE: See "Notice" on page 3C-1 of this
section.
1. Position steering knuckle and hub assemblies (6 and
44) to upper control arm assembly (1).
2. Upper ball stud assembly to steering knuckle assem-
44 bly. Refer to "Control Arm Ball Stud Assembly
Replacement" in this section.
3. Position steering knuckle assembly to lower control
5 NUT, FRONT STABILIZER SHAFT LINK ASSEMBLY, arm assembly. Refer to "Lower Control Arm
23 N•m (17 LB. FT.) Assembly" in this section.
6 KNUCKLE ASSEMBLY, STEERING
7 SLEEVE, FRONT STABILIZER SHAFT LINK ASSEMBLY
4. Lower ball stud assembly to steering knuckle assem-
11 STABILIZER SHAFT, FRONT bly. Refer to "Control Arm Ball Stud Assembly
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT Replacement" in this section.
17 ARM ASSEMBLY, FRONT LOWER CONTROL
44 HUB ASSEMBLY, FRONT WHEEL
5. Front shock absorber bolts/screws. Refer to "Shock
PC0010-3C-F-RP Absorber and Spring Assembly" in this section.
Figure 25 - Stabilizer Shaft Link Assembly 6. Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
 FRONT SUSPENSION 3C·17

15. Check wheel assembly toe alignment. Refer to

SECTION 3A.
UPPER CONTROL ARM ASSEMBLY
Figure27

l+•I Remove or Disconnect

1. Brake master cylinder nuts (driver-side only). Refer
to SECTION SA.
2. Move brake master cylinder assembly aside (driver-
side only). Refer to SECTION SA.
3. Bolts/screws (26) and nuts (25).
4. Raise and suitably support vehicle. Refer to SEC-
TION QA.
5. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
6. Tire and wheel assembly. Refer to SECTION 3E.
7. Stabilizer shaft link assembly. Refer to "Stabilizer
44 Shaft Link Assembly" in this section.
8. Front shock absorber bolts/screws. Refer to "Shock
Absorber and Spring Assembly" in this section.
9. Separate upper ball stud assembly from steering
knuckle assembly. Refer to "Control Arm Ball Stud
1 ARM ASSEMBLY, FRONT UPPER CONTROL Assembly Replacement" in this section.
2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
3 PIN, FRONT UPPER CONTROL ARM COTTER . 10. Steering knuckle assembly (6) from upper control
4 NUT, FRONT UPPER CONTROL ARM, 53 N•m (39 LB. FT.) arm assembly (1).
6 KNUCKLE ASSEMBLY, STEERING
8 NUT, FRONT LOWER CONTROL ARM, 11. Upper control arm assembly (1) and shock absorber
110 N•m (81 LB. FT.) assembly (24) from vehicle.
9 PIN, FRONT LOWER CONTROL ARM COTTER 12. Support steering knuckle assembly (6) with floor
10 STUD ASSEMBLY, FRONT LOWER CONTROL ARM BALL
17 ARM ASSEMBLY, FRONT LOWER CONTROL stands.
20 CROSSMEMBER ASSEMBLY, FRONT 13. Nuts and bolts/screws (37 and 38).
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK 14. Upper control arm assembly (1) from shock
44 HUB ASSEMBLY, FRONT WHEEL absorber assembly. (24)
PC0011-3C-F-RP

Figure 26 - Steering Knuckle Assembly l•+I Install or Connect

NOTICE: See "Notice" on page 3C-1 of this
section.
7. Power steering gear assembly to steering knuckle 1. Position upper control arm assembly (1) to shock
assembly. Refer to SECTION 3B. absorber assembly (24).
8. Front wheel hub assembly to steering knuckle 2. Bolts/screws and nuts (37 and 38).
assembly. Refer to "Wheel Hub Assembly" in this
section.
l~I
rn Important
• Make sure wheel speed sensor electrical 3.
Tighten
• Nuts (38) to 98 N•m (72 lb. ft.).
Upper control arm assembly (1) and shock absorber
connector is reconnected to wheel speed sensor assembly (24) to vehicle.
wire bracket and wheel speed sensor or wires 4. Position steering knuckle assembly (6) to upper
could oeaama:gect- control arm assembly (1).
9. Wheel speed sensor electrical connector. Refer to 5. Upper ball stud assembly to steering knuckle assem-
SECTION 5El. bly. Refer to "Control Artn Ball Stud Assembly
Replacement" in this section.
10. Brake rotor assembly. Refer to SECTION 5.
6. Remove floor stands from steering knuckle assem-
11. Brake caliper assembly. Refer to SECTION SB 1. bly (6).
12. Tire and wheel assembly. Refer to SECTION 3E. 7. Front shock absorber bolts/screws. Refer to "Shock
13. Special security wheel lock nut, if equipped. Refer Absorber and Spring Assembly" in this section.
to SECTION 3E. 8. Stabilizer shaft link assembly. Refer to "Stabilizer
14. Lower vehicle. Shaft Link Assembly" in this section.
3C-18 FRONT SUSPENSION
1 ARM ASSEMBLY, FRONT UPPER CONTROL
2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
3 PIN, FRONT UPPER CONTROL ARM COTIER
4 NUT, FRONT UPPER CONTROL ARM, 53 N•m (39 LB. FT.)
6 KNUCKLE ASSEMBLY, STEERING
22 NUT, FRONT SHOCK ABSORBER LOWER BRACKET,
65 N•m (48 LB. FT.)
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
25 NUT, FRONT SHOCK ABSORBER UPPER MOUNT,
43 N•m (32 LB. FT.)
26 BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT, 50 N•m (37 LB. FT.)
37 BOLT/SCREW, FRONT UPPER CONTROL ARM
38 NUT, FRONT UPPER CONTROL ARM, 98 N•m (72 LB. FT.)
44 HUB ASSEMBLY, FRONT WHEEL
45 MOUNT ASSEMBLY, FRONT UPPER SHOCK ABSORBER
46 SUPPORT, FRONT UPPER CONTROL ARM PC0012_3C-f.RP
Figure 27 - Upper Control Arm Assembly
9. Nuts (25) and bolts/screws (26).
NOTICE: Do not turn the shock absorber assembly
when tightening the upper mount nut or the shock
absorber assembly could be damaged. Keep the
shock absorber assembly in a stationary position
when tightening the nut.
l~I Tighten
• Nuts (25) to 43 N•m (32 lb. ft.).
• Bolts/screws (26) to 50 N•m (37 lb. ft.).
10. Tire and wheel assembly. Refer to SECTION 3E.
11. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
12. Lower vehicle.
13. Position brake master cylinder assembly (driver-side
only). Refer to SECTION SA.
14. Brake master cylinder nuts (driver-side only). Refer
to SECTION SA.
UPPER CONTROL ARM BUSHING
ASSEMBLY
The upper control arm bushing assembly can be serv-
iced separately from the upper control arm assembly.
Figures 27 and 28
Tools Required:
J 21474-5 Control Arm Bushing Receiver
J 21474-18 Upper Control Arm Nut Assembly
J 21474-19 Upper Control Arm Screw
Assembly
J 39872 Half Moon Spacer
J 39930 Upper Control Arm Bushing Receiver/
Installer
l+t+I Disassemble
1. Upper control arm assembly; Refer to "Upper Con-
trol Arm Assembly" in this section.
2. Remove bolts/screws (37) and nuts (38).
3. Separate front upper control arm assembly (1) from
front upper control arm support (46).
4. Remove upper control arm bushing from upper con-
trol arm assembly (1).
A. Thread J 21474-19 through J 39930 (three
tangs on J 39930 should be against head of
screw).
B. Thread J 21474-19 through inside of upper
control arm bushing (it may be necessary to
wiggle J 21474-19 until it slides through bush-
ing).
C. Run smaller end of J 21474-5 onto J 21474-19.
Then, place thrust washer onto J 21474-19
with seams facing toward J 21474-5.
D. Install J 39872 around outside of bushing to
avoid metal distortion during removal.
E. Make sure both J 39930 and J 21474-5 are
properly lined up and install J 21474-18 onto
J 21474-19. Tighten J 21474-19 and
J 21474-18 until bushing is pushed all the way
out (poppirig noise may be heard when bushing
breaks loose from control arm).
l+!+I Assemble
NOTICE: See "Notice" on page 3C-1 of this sec-
tion.
1. Upper control arm bushings.
A. With control arm securely tightened in vise,
thread J 21474-19 through J 39930 with tangs
facing away from screw head.
B. Install new upper control arm bushing onto
J 21474-19 with three indentations facing
toward three tangs on J 39930.
C. Install threaded end of J 21474-19 into upper
control arm from outer side of control arm.
D. Install J 21474-5 onto J 21474-19 from inside
of control arm.

E. Install thrust washer onto J 21474-19 with
seam facing toward control arm bushing.
F. Install J 39872 around outside of bushing to
avoid metal distortion during removal.
G. Install J 21474-18 onto J 21474-19, making
sure that three tanged prongs on J 39930 fit
into indentations of bushing.
H. Tighten assembly until bushing is installed
flush with control arm.
2. Install front upper control arm assembly (1) to front
upper control arm support (46).
3. Bolts/screws (37) and nuts (38).
l~I Tighten
• Nuts (38) to 98 N•m (72 lb. ft.).
4. Upper control arm assembly. Refer to "Upper Con-
trol Arm Assembly" in this section.
WHEEL BEARING ASSEMBLY
The maintenance-free wheel bearing assembly does
not need to be serviced separately from the hub assembly.
Refer to "Wheel Hub Assembly" in this section.
J 21474-5
A
A REMOVING BUSHING
B INSTALLING BUSHING
C WASHER, THRUST
1 ARM ASSEMBLY, FRONT UPPER CONTROL
Figure 28 - Removing and Installing Upper Control Arm Bushing Assembly
FRONT SUSPENSION 3C-19
CROSSMEMBER ASSEMBLY
Figure29
!+..I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Special security wheel lock nuts, if equipped. Refer
to SECTION 3E.
3. Front tire and wheel assemblies. Refer to SECTION
3E.
4. Stabilizer shaft link assemblies. Refer to "Stabilizer
Shaft Link Assembly" in this section.
5. Front shock absorber bolts/screws. Refer to "Shock
Absorber and Spring Assembly" in this section.
6. Separate lower control arm ball stud assemblies
from steering knuckle assemblies. Refer to "Control
Arm Ball Stud Assembly Replacement" in this
section.
7. Front lower control arm bolts/screws and nuts. Refer
to "Lower Control Arm Assembly" in this section.
8. Lower control arm assemblies (17) from cross-
member assembly (20).
9. Steering gear bolts/screws from crossmember
assembly. Refer to SECTION 3B.
10. Engine mount nuts and bolts/screws. Refer to
SECTION 6A2A or 6A3A.
J 39872
J 21474-5
J 21474-18
B
RC0003-3C-F·RP
3C-20 FRONT SUSPENSION

A SIDE RAIL
17 ARM ASSEMBLY, FRONT LOWER CONTROL
18 NUT, FRONT LOWER CONTROL ARM,
115 N•m (85 LB. FT.)
19 BOLT/SCREW, FRONT LOWER CONTROL ARM,
195 N•m (144 LB. FT.)
20 CROSSMEMBER ASSEMBLY, FRONT
21 BOLT/SCREW, FRONT LOWER CONTROL ARM,
130 N•m (96 LB. FT.)
27 NUT, FRONT LOWER CONTROL ARM, 95 N•m
(70 LB. FT.)
32 BOLT/SCREW, FRONT CROSSMEMBER, 125 N•m
(92 LB. FT.)
33 BOLT/SCREW, FRONT CROSSMEMBER, 100 N•m
(74 LB. FT.)
34 NUT, FRONT CROSSMEMBER
RC0012-3C-F-RP
Figure 29 - Front Crossmember Assembly

11. Support front and rear of engine assembly with jack

stands.
12. Front brake pipe assembly. Refer to SECTION 5.
13. Wheel speed sensor electrical connector. Refer to
SECTION 5El.
14. Drivetrain and front suspension frame nut plug.
15. Nuts (34).
16. Bolts/screws (32 and 33).
17. Crossmember assembly (20) and reposition power
steering gear assembly.
1-++I Install or Connect
NOTICE: See "Notice" on page 3C-1 of this
section.
1. Position crossmember assembly (20) to side rails.
2. Crossmember assembly to power steering gear
assembly. Refer to SECTION 3B.
3. Bolts/screws (32 and 33).
l~ITighten
• Bolts/screws (32) to 125 N•m (92 lb. ft.).
• Bolts/screws (33) to 100 N•m (74 lb. ft.).
4. Nuts (34).
5. Drivetrain and front suspension frame nut plug.
[I] Important
• Make sure wheel speed sensor electrical
connector is reconnected to wheel speed sensor
wire bracket and wheel speed sensor or wires
could be damaged.
6. Wheel speed sensor electrical connector. Refer to
SECTION 5El.
7. Front brake pipe assembly. Refer to SECTION 5.
8. Remove jack stands from engine assembly.
9. Engine mount bolts/screws and nuts. Refer to
SECTION 6A2A or 6A3A.
 FRONT SUSPENSION 3C·21

10. Power steering gear bolts/screws. Refer to SECTION
3B.
11. Position lower control arm assemblies ( 17) to cross-
member assembly (20).
12. Front lower control arm bolts/screws and nuts.
13. Lower control arm ball stud assemblies to steering
knuckle assemblies. Refer to "Control Arm Ball
Stud Assembly Replacement" in this section.
14. Front shock absorber bolts/screws. Refer to "Shock
Absorber and Spring Assembly" in this section.
15. Stabilizer shaft link assemblies. Refer to "Stabilizer
Shaft Link Assembly" in this section.
16. Tire and wheel assemblies. Refer to SECTION 3E.
17. Special security wheel lock nuts, if equipped. Refer
to SECTION 3E.
18. Lower vehicle.
19. Align wheel assemblies. Refer to SECTION 3A.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Front Crossmember-to-Drivetrain and Front Suspension
Frame Nut Plug Bolt/Screw ........................................ 100 N•m (74 lb. ft.)
Front Crossmember-to-Side Rail Bolt/Screw ............................. 125 N•m (92 lb. ft.)
Front Lower Control Arm-to-Front Crossmember Assembly Nut
(Horizontal) ...................................................... 95 N•m (70 lb. ft.)
Front Lower Control Arm-to-Front Crossmember Assembly Nut
(Vertical) ....................................................... 115 N•m (85 lb. ft.)
Front Lower Control Arm-to-Front Lower Control Arm Ball Stud
Assembly Nut ... : ............................................... 110 N•m (81 lb. ft.)
Front Shock Absorber Bolt/Screw ...................................... 65 N•m (48 lb. ft.)
Front Shock Absorber Lower Bracket Nut ................................ 65 N•m (48 lb. ft.)
Front Shock Absorber Upper Mount Bolt/Screw ........................... 50 N•m (37 lb. ft.)
Front Shock Absorber Upper Mount Nut ................................. 43 N•m (32 lb. ft.)
Front Stabilizer Shaft Bracket Bolt/Screw ................................ 55 N•m (41 lb. ft.)
Front Stabilizer Shaft Insulator Clamp Bolt/Screw ......................... 55 N•m (41 lb. ft.)
Front Stabilizer Shaft Link Assembly .................................... 23 N•m (17 lb. ft.)
Front Stabilizer Shaft Link Assembly Nut ................................ 23 N•m (17 lb. ft.)
Front Upper Control Arm-to-Front Upper Control Arm Ball Stud
Assembly Nut .................................................... 53 N•m (39 lb. ft.)
Front Upper Control Arm-to-Front Upper Control Arm Support Nut ............ 98 N•m (72 lb. ft.)
Front Wheel Bolt/Screw .............................................. 86 N•m (63 lb. ft.)
3C·22 FRONT SUSPENSION

SPECIAL TOOLS

1.
~ J 24292-B
10.
(}!) J 39642

11. D J 9519-7

J 34013-B
2.

12.
0) J 9519-9

13.
3. J 34013-88 ©mmrnllP J 9519-18

4. J 34013-114 14.

~
J 9519-23

5.
J 34013-115

~
15. J 6627-A

6.
~ J 39549

~
16. J 39872

7.
({) J 39876

8. C{f) J 39930
17.

Co J 39874

18.
r::J J 39875

9. f) J 39931

1. BALL JOINT REMOVER 10. MODULAR SHOCK NUT REMOVAL SET,

2. STRUT SPRING COMPRESSOR 15 mm (0.60 INCH)
3. STRUT COMPRESSOR ADAPTER 11. BALL JOINT REMOVER
4. MODULAR SHOCK ASSEMBLY COMPRESSOR ADAPTER 12. BALL JOINT INSTALLER
5. MODULAR SHOCK ASSEMBLY ALIGNMENT ROD 13. BALL JOINT PRESSING SCREW
6. BALL JOINT/TIE ROD SEPARATOR 14. BALL JOINT "C" CLAMP
7. LOWER CONTROL ARM BUSHING RECEIVER 15. WHEEL STUD REMOVER
8. UPPER CONTROL ARM BUSHING RECEIVER/INSTALLER 16. HALF MOON SPACER
9. LOWER CONTROL ARM BUSHING RECEIVER 17. LOWER CONTROL ARM BUSHING RECEIVER
18. HALF MOON SPACER

RC0005-3C·F-RP
 FRONT SUSPENSION 3C·23

19. @@mmmmmmmm i J 21474-3 22.

O] J 21474-6

20. ( J 21474-4 23.

( J 21474-18

21.
J 21474-5 24. (@m@m@mmo J 21414-19

19. LOWER CONTROL ARM BUSHING SCREW ASSEMBLY

20. LOWER CONTROL ARM BUSHING NUT ASSEMBLY
21. CONTROL ARM BUSHING RECEIVER
22. CONTROL ARM BUSHING RECEIVER
23. UPPER CONTROL ARM NUT ASSEMBLY
24. UPPER CONTROL ARM SCREW ASSEMBLY
RCCJ006.3C-F-RP
 REAR SUSPENSION 3D-1

SECTION 30

REAR SUSPENSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not used, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3D- l
Rear Axle Suspension '. . . . . . . . . . . . . . . . . . . . 3D-1
Diagnosis ...................... Refer to Section 3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3D- l
Rear Axle Housing . . . . . . . . . . . Refer to Section 4B
Jounce Bumper Assembly ............... , . 30-1
Lower Control Arm Bushing Assembly ...... 3D-1
Rear Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Rear Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
Tie Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-4
Lower Control Arm Assembly ............. 30-5
Torque Ann . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Stabilizer Shaft Bracket and Link Assembly . . . 30-9
Shock Absorber Assembly . . . . . . . . . . . . . . . . . 30-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-10
Fastener Tightening Specifications . . . . . . . . . 30-10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11

GENERAL DESCRIPTION
I+-+! Remove or Disconnect
REAR AXLE SUSPENSION 1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
Figure 1
2. Support rear axle assembly ( 13).
The rear axle assembly ( 13) is attached to the vehicle
with a link suspension system. The rear axle housing is 3. Bolts/screws (2).
connected to the floor panel assembly (7) by two lower 4. Bumper assembly (1).
control arm assemblies (6) and a tie rod assembly ( 11 ). A
single torque arm (8) is used in place of an upper control
arm assembly. It is rigidly mounted to the rear axle
!•+! Install or Connect
housing at the rear and through a torque arm bushing NOTICE: See "Notice" on page 30-1 of this
assembly to the transmission assembly at the front. On section.
some vehicles, the torque arm (8) is also mounted to the 1. Bumper assembly ( 1) to bumper reinforcement.
propeller shaft assembly (9) with two bolts/screws. Rear
springs (4) are used to support the weight of the vehicle, 2. Bolts/screws (2).
and ride control is provided by shock absorber assemblies
(10) mounted to the rear of the rear axle housing. A stabi-
lizer shaft (5) is also part of the suspension system.
I~! Tighten
• Bolts/screws (2) to 27 N•m (20 lb. ft.).
The shock absorber assemblies (] 0) are mounted at
the bottom with a nut to brackets welded to the rear of 3. Remove rear axle assembly support.
the rear axle housing, and at the top to the floor panel 4. Lower vehicle.
assembly with a nut. The only service the shock absorber
assemblies require is replacement if they have lost their
resistance, are damaged or are leaking fluid. For shock LOWER CONTROL ARM BUSHING
absorber assembly diagnosis, refer to SECTION 3. ASSEMBLY
Figures 3 and 4
ON-VEHICLE SERVICE
JOUNCE BUMPER ASSEMBLY
rn Important
• If both lower control arm assemblies are being
replaced, remove and replace one control arm
Figure 2 assembly at a time to prevent the rear axle assembly
The jounce bumper assembly is located on top of the. from rolling or slipping sideways, making replace-
rear axle housing. ment difficult.
30·2 REAR SUSPENSION

A LONGITUDINAL REINFORCEMENT
B WITH REAR DISC BRAKES
1 BUMPER ASSEMBLY, REAR SUSPENSION JOUNCE
2 BOLT/SCREW, REAR AXLE BUMPER, 27 N•m (20 LB. FT.)
3 INSULATOR ASSEMBLY, REAR SPRING UPPER
4 SPRING, REAR 6
5 SHAFT, REAR STABILIZER
6 ARM ASSEMBLY, REAR AXLE LOWER CONTROL
7 PANEL ASSEMBLY, FLOOR
8 ARM, REAR AXLE TORQUE
9 SHAFT ASSEMBLY, PROPELLER
10 ABSORBER ASSEMBLY, REAR SHOCK
11 ROD ASSEMBLY, REAR AXLE TIE
12 BRACE ASSEMBLY, REAR AXLE TIE ROD BRACKET
13 AXLE ASSEMBLY, REAR RC1I001·3D·f·RP

Figure 1 - Rear Axle Suspension (Typical)

 REAR SUSPENSION 30·3

J 21474-23

J 21474-5

A PRESS
PC0003-3D-F·RP
Figure 3 - Removing Lower Control Arm Bushing Assembly

A PRESS

A LONGITUDINAL REINFORCEMENT
B REINFORCEMENT, REAR SUSPENSION JOUNCE
BUMPER ASSEMBLY
1 BUMPER ASSEMBLY, REAR SUSPENSION JOUNCE
2 BOLT/SCREW, REAR AXLE BUMPER, 27 N•m (20 LB. FT.)
13 AXLE ASSEMBLY, REAR

PC0002-3D-f.RP
l'C0004-3D-f.RP
Figure 2 - Jounce Bumper Assembly
Figure 4 - Installing Lower Control Arm Bushing Assembly

l++! Remove or Disconnect 2. Place J 21474-5 over flanged side of bushing

assembly.
Tools Required: 3. Bushing assembly into position with J 21474-20.
J 21474-5 Receiver
4. Lower control arm assembly. Refer to "Lower
J 21474-20 Installer Control Ann Assembly" in this section.
J 21474-23 Remover 5. Remove rear axle assembly support.
1. Raise and suitably support vehicle. Refer to SEC- 6. Lower vehicle.
TION OA.
2. Suppon rear axle assembly. REAR SPRINGS
3. Lower control arm assembly. Refer to "Lower
Control Arm Assembly" in this section. Figure 5
4. Place J 21474-5 over flanged side of bushing
assembly. !++I Remove or Disconnect
5. Use arbor press to force bushing assembly out of 1. Raise and suitably support vehicle. Refer to SEC-
arm, using large OD of driver such as J 21474-23 TION OA.
contacting OD of outer sleeve.

!++! Install or Connect

rn Important
• When raising vehicle, do not use twin post type
1. Reverse tool. See Figure 4. hoist.
30·4 REAR SUSPENSION

2. Support rear axle assembly (13) with adjustable

lifting device.
3. Shock absorber nuts from rear axle assembly. Refer
to "Shock Absorber Assembly" in this section.
4. Lower rear axle assembly ( 13).
NOTICE: Do not suspend rear axle assembly by
brake hose assembly. Damage to hose assembly
could result.
5. Upper insulator assembly (15).
6. Rear spring (4).
1 4 ~ -\::::::..,
-:" __.

!++I Install or Connect '

I. Rear spring (4) to rear axle assembly (13).

m Important
• Lower end of rear spring should be facing for-
ward.
• It is important not to chip or damage the corro-
sion protection coating on the rear spring.
Avoid contact with hard steel. If coating has
been chipped or damaged, do not use rear
spring until it has been replaced.
2. Upper insulator ass.embly ( 15) to rear spring (4 ).
3. Raise rear axle assembly ( 13).
4. Shock absorber nuts to rear axle assembly. Refer to
"Shock Absorber Assembly" in this section.
5. Remove rear axle assembly supp01t.
6. Lower vehicle. 4 SPRING, REAR
13 AXLE ASSEMBLY, REAR
14 SEAT, REAR SPRING
REAR SPRING SEAT 15 INSULATOR ASSEMBLY, REAR SPRING UPPER

Figure 5
RC0005-3D-F-RP

!+-+I Remove or Disconnect Figure 5 - Rear Spring and Upper Insulator Assembly

I. Raise and suitably support vehicle. Refer to SEC-

TION OA.
m Important
• When raising vehicle, do not use twin post type
hoist.
2. Support rear axle assembly ( 13) with an adjustable
lifting device.
3. Shock absorber nuts from rear axle assembly Refer
to "Shock Absorber Assembly" in this section ..
4. Lower rear axle assembly (13).
NOTICE: Do not suspend rear axle assembly by
brake hose assembly. Damage to hose assembly
could result.
5. Upper insulator assembly and rear spring. Refer to
"Rear Spring" in this section.
6. Spring seat (14).
!++1 tnstall or Connect
I. Position spring seat ( 14 ).
2. Rear spring and upper insulator assembly. Refer to
3.
"Rear Spring" in this section.
Raise rear axle assembly (13).
4. Shock absorber nut to rear axle assembly. Refer to
"Shock Absorber Assembly" in this section.
5. Remove rear axle assembly support.
6. Lower vehicle.
TIE ROD ASSEMBLY
Figure 6
l+-+I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Support rear axle assembly (13).
3. Bolt/screw (17) and nut (49).
4. Bolts/screws (16 and 18) and nuts (19).
5. Tie rod assembly (11).
 REAR SUSPENSION 30-5

A UNDERBODY BRACE BRACKET (LEFT-HAND SIDE)

B UNDERBODY BRACE BRACKET (RIGHT-HAND SIDE)
11 ROD ASSEMBLY, REAR AXLE TIE
12 BRACE ASSEMBLY, REAR AXLE TIE ROD BRACKET
13 AXLE ASSEMBLY, REAR
16 BOLT/SCREW, REAR AXLE TIE ROD BRACKET,
47 N•m (35 LB. FT.)
17 BOLT/SCREW, REAR AXLE TIE ROD
18 BOLT/SCREW, REAR AXLE TIE ROD BRACKET jv1EwA l
19 NUT, REAR AXLE TIE ROD, 102 N•m (75 LB. FT.)
49 NUT, REAR AXLE TIE ROD, 102 N•m(75 LB. FT.)
PC000&-30-F-RP

Figure 6 - Tie Rod Assembly

6. Brace assembly (12).

!++I Install or Connect !~I Tighten

NOTICE: See "Notice" on page 3D-l of this
section.
1. Position brace assembly (12) to right-hand under-
body brace bracket.
2. Hand tighten one bolt/screw (18) and one nut (19).
3. Position tie rod assembly (11) to right-hand under-
body brace bracket.
4. Hand tighten other bolt/screw (18) and other nut
(19).
5. Bolts/screws (16 and 18) and nuts (19).
!~! Tighten
• Nut (49) to 102 N•m (75 lb. ft.).
7. Rear axle assembly support.
8. Lower vehicle.
LOWER CONTROL ARM ASSEMBLY
Figure 7
m Important
• If both lower control arm assemblies are being
replaced, remove and replace one arm at a time to
prevent rear axle assembly from rolling or slipping
sideways, making replacement difficult.

• Bolts/screws (16) to 47 N•m (35 lb. ft.). !++! Remove or Disconnect

• Nuts (19) to I 02 N•m (75 lb. ft.). 1. Raise and suitably support vehicle. Refer to SEC-
6. Bolt/screw (17) and nut (49). TION OA.
30-6 REAR SUSPENSION
A B
A FRONT OF LOWER CONTROL ARM ASSEMBLY
(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE}
B REAR OF LOWER CONTROL ARM ASSEMBLY
(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE)
C PAN ASSEMBLY, UNDERBODY
6 ARM ASSEMBLY, REAR AXLE LOWER CONTROL
Figure 7 - Lower Control Arm Assembly
2. Support rear axle assembly (13).
3. Bolts/screws (20), nuts (22) and washers (21) from
rear axle assembly (13).
4. Bolts/screws (20), nuts (22) and washers (21) from
underbody pan assembly.
S. Lower control arm assembly (6).
!++I Install or Connect
NOTICE: See "Notice" on page 3D-1 of this
section.
I. Position lower control arm assembly (6) to rear axle
assembly (13) and underbody pan assembly.
m Important
• Do not tighten bolts/screws (20) and nuts (22)
unless the suspension is at curb height position.
2. Bolts/screws (20), nuts (22) and washers (21) to rear
axle assembly (13) from inboard side out.
l~I Tighten
• Bolts/screws (20) to 108 N•m (74 lb. ft.).
• Nuts (22) to 82 N•m (60 lb. ft.).
3. Remove rear axle assembly support.
4. Lower vehicle.
13 AXLE ASSEMBLY, REAR
20 BOLT/SCREW, REAR AXLE LOWER CONTROL ARM,
108 N•m (80 LB. FT.}
21 WASHER, REAR SUSPENSION CONTROL ARM
22 NUT, REAR AXLE LOWER CONTROL ARM,
82 N•m (60 LB. FT.)
PC0007·3D·F·RP
TORQUE ARM
Figures 8 through 10
!++! Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Support rear axle assembly (13) with an adjustable
lifting device.
m Important
• When raising vehicle, do not use twin post type
hoist.
3. Torque arm from propeller shaft assembly, if
equipped with split propeller shaft assembly. Refer
to SECTION 4A.
4. Bolts/screws (23), washers (24) and nuts (25) from
rear axle assembly ( 13).
S. Bolts/screws (28, 29 and 30) and nuts (27) from
automatic transmission assembly, if equipped.
6. Bolts/screws (29 and 30) and nuts (27) from manual
transmission assembly, if equipped.
7. Outer bracket assembly (31 ).
8. Inner bracket assembly (32).
9. Torque arm (8).
 REAR SUSPENSION. 30·7

23
!++-! Install or Connect
13 NOTICE: See "Notice" on page 3D-I of this
section.
1. Position inner bracket assembly (32) through trans-
mission assembly.
2. Position outer bracket assembly (31) to inner
aAD.-'!t::==--24 bracket assembly (32) and loosely install nuts (27),
and bolts/screws (28, 29 and 30).
3. Insert torque arm (8) into bracket assemblies (31 and
32).
4. Nuts (27) and bolts/screws (28, 29 and 30).

24 l~I Tighten
• Nuts (27) to 41 N•m (30 lb. ft.).
• Bolts/screws (28 and 30) to 50 N•m (37 lb. ft.).
• Bolts/screws (29) to 27 N•m (20 lb. ft.).
8 ARM, REAR AXLE TORQUE
5. Position torque arm (8) to rear axle assembly (13).
13 AXLE ASSEMBLY, REAR 6. Bolts/screws (23), washers (24) and nuts (25).
23 BOLT/SCREW, REAR AXLE TORQUE ARM,
130 N•m (96 LB. FT.I
24 WASHER, REAR AXLE TORQUE ARM
25 NUT, REAR AXLE TORQUE ARM, 132 N•m (97 LB. FT.)
l~I Tighten
• Bolts/screws (23) to 130 N•m (96 lb. ft.).
PC0008-3D-F-RP
• Nuts (25) to 132 N•m (97 lb. ft.).
Figure 8 - Torque Arm to Rear Axle Assembly
7. Torque arm to propeller shaft assembly, if equipped
with propeller shaft assembly. Refer to SECTION
4A.
8. Rear axle assembly support.
9. Lower vehicle.

27
8

32
A
AWITH 700 R4 TRANSMISSION
BTRANSMISSION ASSEMBLY, AUTOMATIC
8ARM, REAR AXLE TORQUE 29 BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
26BRACKET ASSEMBLY, CATALYTIC CONVERTER BRACKET, 27 N•m (20 LB. FT.I
HANGER 30 BOLT/SCREW, REAR AXLE TORQUE ARM INNER
27 NUT, REAR AXLE TORQUE ARM BRACKET, BRACKET, 50 N•m (37 LB. FT.)
41 N•m (30 LB. FT.) . 31 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM
28 BOLT/SCREW, REAR AXLE TORQUE ARM INNER OUTER
BRACKET, 50 N•m (37 LB. FT.) 32 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER

Figure 9 - Torque Arm to Automatic Transmission Assembly

3D·8 REAR SUSPENSION

A 5-SPEED
B 6-SPEED
C TRANSMISSION ASSEMBLY, MANUAL B
8 ARM, REAR AXLE TORQUE
26 BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
27 NUT, REAR AXLE TORQUE ARM BRACKET,
41 N•m (30 LB. FT.) 30
29 BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
BRACKET, 27 N•m (20 LB. FT.)
30 BOLT/SCREW, REAR AXLE TORQUE ARM INNER
BRACKET, 50 N•m (37 LB. FT.)
31 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM
OUTER
32 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER

PC0010-3D-F·RP

Figure 10 - Torque Arm to Manual Transmission Assembly

STABILIZER SHAFT
Figures 11 and 12
rn Important
• The stabilizer shaft must be installed with the
!+,+I Remove or Di~connect bend of the shaft facing down.
1. Place insulator (38) over stabilizer shaft (35).
I. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Nut (41).
rn Important
• The slit of the shaft insulator must face the rear
3. Link assembly. Refer to "Stabilizer Shaft Bracket
of the vehicle.
and Link Assembly" in this section.
4. Bolts/screws (33) and nuts (36). 2. Position clamp (37) to insulator (38) and stabilizer
shaft (35).
5. Clamp (37).
3. Position bracket (39) to rear axle assembly (13).
6. Insulator (38).
7. Bracket (34 ). 4. Bolts/screws (33) and nuts (36).
8. Stabilizer shaft (35).
l~I Tighten
!,++I Install or Connect • Nuts (36) to 24 N•m ( 18 lb. ft.).
NOTICE: See "Notice" on page 3D-l of this 5. Stabilizer shaft link nut. Refer to "Stabilizer Shaft
section. Bracket and Link Assembly" in this section.
 REAR SUSPENSION 30·9

13

35

40

~jv1EwA I
37
39

13 AXLE ASSEMBLY, REAR

33 BOLT/SCREW, REAR STABILIZER SHAFT INSULATOR FRTj
CLAMP
34 BRACKET, REAR STABILIZER SHAFT ROD
35 SHAFT, REAR STABILIZER
36 NUT, REAR STABILIZER SHAFT INSULATOR CLAMP, 42
24 N•m (18 LB. FT.)
37 CLAMP, REAR STABILIZER SHAFT INSULATOR
38 INSULATOR, REAR STABILIZER SHAFT

PC0011·30-F-RP

Figure 11 - Stabilizer Shaft

6. Link assembly. Refer to "Stabilizer Shaft Bracket
and Link Assembly" in this section.
7. Lower vehicle.
A PAN ASSEMBLY, UNDERBODY
35 SHAFT, REAR STABILIZER
39 BRACKET, REAR STABILIZER SHAFT
40 BOLT/SCREW, REAR STABILIZER SHAFT LINK,
23 N•m (17 LB. FT.)
41 NUT, REAR STABILIZER SHAFT LINK, 22 N•m (16 LB. FT.)
42 LINK ASSEMBLY, REAR STABILIZER SHAFT

STABILIZER SHAFT BRACKET AND LINK PC0012-3D-F-RP

ASSEMBLY Figure 12 - Stabilizer Shaft B.racket and Link Assembly

Figure 12

!+-+I Remove or Disconnect 4. Link assembly (42) and nut (41).

l. Raise and suitably support vehicle. Refer to SEC-
TION OA. l~I Tighten
2. Nut (41). • Link assembly (42) and nut (41) to 22 N•m
(16 lb. ft.).
3. Link assembly (42).
5. Lower vehicle.
4. Bolts/screws (40).
5. Bracket (39). SHOCK ABSORBER ASSEMBLY
!•+-! Install or Connect Figure 13
NOTICE: See "Notice" on page 3D-1 of this
section. I+-+! Remove or Disconnect
I. Position bracket (39) to underbody pan assembly. 1. Fold down seatback frame assembly.
2. Bolts/screws (40). 2. Quarter trim panel assembly. Refer to SECTION

l~I Tighten
10-6.
3. Pull folding carpet assembly back.
• Bolts/screws (40) to 23 N•m (17 lb. ft.). 4. Raise and suitably support vehicle. Refer to SEC-
3. Position link assembly (42) to bracket (39). TION OA.
30-10 REAR SUSPENSION
l
I
5. Support rear axle assembly (13).
NOTICE: Rear axle assembly must be supported (

I
before removing nut to avoid possible damage to
brake hose lines, tie rod assembly and propeller
shaft assembly.
6. Nut (43).
7. Retainer (44) and upper insulator (45).
8. Retainer (44) and lower insulator (46).
9. Nut (48) from rear axle assembly(13).
/
10. Shock absorber assembly (47).

!++I Install or Connect

NOTICE: See "Notice" on page 30-1 of this
section.
1. Position shock absorber assembly (47) to rear axle
assembly (13).
2. Nut(48).

l~I Tighten
• Nut (48) to 90 N•m (66 lb. ft.).
3. Lower insulator (46) and retainer (44) to shock
absorber assembly (47).
4. Position shock absorber assembly (4 7) through
underbody pan assembly and seat insulator.
5. Upper insulator (45) and retainer (44) to shock
absorber assembly (47).
6. Hand start nut (43).
NOTICE: Turning the shock absorber assembly
while tightening the nut could damage the shock
absorber assembly. To prevent damage, keep the
shock absorber assembly stationary when tightening
the nut.
A
A TYPICAL REAR SHOCK ABSORBER ASSEMBLY
INSTALLATION (RIGHT-HAND SHOWN)
B PAN ASSEMBLY, UNDERBODY
13 AXLE ASSEMBLY, REAR
43 NUT, REAR SHOCK ABSORBER, 17 N•m (13 LB. FT.)
44 RETAINER, REAR SHOCK ABSORBER UPPER
INSULATOR
45 INSULATOR, REAR SHOCK ABSORBER UPPER
46 INSULATOR, REAR SHOCK ABSORBER LOWER
47 ABSORBER ASSEMBLY, REAR SHOCK
48 NUT, REAR SHOCK ABSORBER, 90 N•m (66 LB. FT.)

l~I Tighten
Figure 13 - Shock Absorber Assembly
PC0013-3D-F-RP

• Nut (43) to 17 N•m (13 lb. ft.).

7. Remove rear axle assembly support. 10. Quarter trim panel assembly. Refer to SECTION
8. Lower vehicle. 10-6.
9. Pull folding carpet assembly down into position. 11. Fold seatback frame assembly upright.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Rear Axle Bumper Bolt/Screw ......................................... 27 N•m (20 lb. ft.)
Rear Axle Lower Control Arm Bolt/Screw .............................. 108 N•m (80 lb. ft.)
Rear Axle Lower Control Arm Nut ....... , ............................. 82 N•m (60 lb. ft.)
Rear Axle Tie Rod Bracket-to-Left-Hand Brace Bracket Bolt/Screw ........... 47 N•m (35 lb. ft.)
Rear Axle Tie Rod-to-Left-Hand Brace Bracket Nut ....................... 102 N•m (75 lb. ft.)
Rear Axle Tie Rod-to-Right-Hand Brace Bracket Nut ...................... 102 N•m (75 lb. ft.)
Rear Axle Torque Arm Bolt/Screw ..................................... 130 N•m (96 lb. ft.)
Rear Axle Torque Arm Bracket Nut ..................................... 41 N•m (30 lb. ft.)
Rear Axle Torque Arm Inner Bracket Bolt/Screw (Automatic Transmission
Assembly and Manual Transmission Assembly) ......................... 50 N•m (37 lb. ft.)
Rear Axle Torque Arm Inner Bracket Bolt/Screw (Upper)
(Automatic Transmission Assembly Only) .............................. 50 N•m (37 lb. ft.)
Rear Axle Torque Arm Nut ........................................... 132 N•m (97 lb. ft.)
 REAR SUSPENSION 30·11

Rear Axle Torque Arm Outer Bracket Bolt/Screw .......................... 27 N•m (20 lb. ft.)
Rear Shock Absorber Nut (Lower) ...................................... 90 N•m (66 lb. ft.)
Rear Shock Absorber Nut (Upper) ...................................... 17 N•m (13 lb. ft.)
Rear Stabilizer Shaft Insulator Clamp Nut ................................ 24 N•m (18 lb. ft.)
Rear Stabilizer Shaft Link Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N •m ( 17 lb. ft.)
Rear Stabilizer Shaft Link Nut ......................................... 22 N•m (16 lb. ft.)

SPECIAL TOOLS

1. 2. 3 ..

(fu 9
J 21474-5 J 21474-20 J 21474-23

1. BUSHING RECEIVER
2. BUSHING INSTALLER
3. BUSHING REMOVER
PC0014-30-F-RP
 TIRES AND WHEELS 3E·1

SECTION 3E

TIRES AND WHEELS

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3E-1
Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . 3E- l
All Season Tires . . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
P-Metric Tires .......................... 3E-2
Tire Chain Usage . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
Tire Placard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-3
Wheel Assemblies ....................... 3E-3
Diagnosis ...................... Refer to Section 3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Wheel Assembly Repair .................. 3E-4
Metric Wheel Nuts and Bolts . . . . . . . . . . . . . . . 3E-4
Wheel Bolt Replacement . . . . . . . . . . . . . . . . . . 3E-4
Front Wheel Bolt . . . . . . . . . Refer to Section 3C
Rear Wheel Bolt ........... Refer to Section 4B
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Wheel Assembly Removal and Installation . . . . 3E-4
Tire and Wheel Assembly Rotation . . . . . . . . 3E-7
Tire Mounting and Dismounting . . . . . . . . . . . . 3E-8
Steel Wheel Assembly Mounting
Surface Check . . . . . . . . . . . . . . . . . . . . . . 3E-8
Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-9
Measuring Wheel Assembly Runout . . . . . . . . . 3E-9
Compact Spare Tire Assembly . . . . . . . . . . . . . 3E-9
Balancing Tire and Wheel Assembly ....... 3E-10
General Balance Precautions . . . . . . . . . . . . 3E- l O
Off-Vehicle Balancing . . . . . . . . . . . . . . . . . 3E-10
On-Vehicle Balancing . . . . . . . . . . . . . . . . . 3E-10
Wheel Balance Weights . . . . . . . . . . . . . . . . 3E-11
Correcting Non-Uniform Tires ............ 3E-12
Aluminum Wheel Assemblies ............. 3E-12
Aluminum Wheel Assembly Hub Cap .... 3E-12
Aluminum Wheel Assembly Porosity
Repair ............................ 3E-12
Aluminum Wheel Assembly
Refinishing ........................ 3E-12
Specifications ............................ 3E-14
Fastener Tightening Specifications . . . . . . . . . 3E- l 4
Runout Specifications ................... 3E-14
Tire Pressures .......................... 3E-14

GENERAL DESCRIPTION
The factory-installed tire and wheel assemblies are
designed to operate satisfactorily with loads up to and
including the full load capacity when inflated to the rec-
ommended tire pressures.
Correct tire pressures and driving techniques have
an important influence on tire life. Heavy cornering,
excessively rapid acceleration, and unnecessarily sharp
braking increase tire wear.

REPLACEMENT TIRES
Figure 1
A tire performance criteria (TPC) specification
number is molded in the sidewall near the tire size of all
original equipment tires. This specification number
assures that the tire meets GM's performance standards KC0001·3E·Y·RC
for traction, endurance, dimension, noise, handling, rol-
Figure 1 - Tire Identification
ling resistance, and others. Usually, a specific TPC num-
ber is assigned to each tire size.
Replacement tires should be the same size, load antilock brake system, vehicle ground clearance, and tire
range and construction as the original tires. Replace the clearance to the body and chassis.
original tires with tires of the same TPC specification CAUTION: Do not mix different types of
number. Use of any other tire size or type may seriously tires on the same vehicle, such as
affect ride, handling, speedometer/odometer calibration, radial, bias, and bias-belted tires,
3E·2 TIRES AND WHEELS

except in emergencies because vehicle

handling may be seriously affected and

Tr·
may result in loss of control. This cau- METRIC TIRE SIZES
tion does not apply to the compact
P 235 I 55 R 16
spare furnished with the vehicle. .
Tires should be replaced when: TIRE TYPE
PASSENGER
T ~ R I MDIAMETER
ASPECT RATIO (INCHES)
T TEMPORARY (SECTION HEIGHT) . 14
• They are worn to~ point where 1.6 mm (1/16 incn) LT LIGHT TRUCK (SECTION WIDTH) 15
or less tread ren:ams, ~r. cord. or fabric is showing. SECTION WIDTH 55 16
To help detect this cond1t1on, tires have built-in tread (MILLl:ETERS)
25
60 CONSTRUCTION TYPE

wear .indicat.ors that appear between tread grooves

when tread 1s worn to 1.6 mm (1/16 inch) or less. ~!:
ETC
65 R • RADIAL
B • BIAS - BELTED
D - DIAGONAL (BIAS)
Replace tire when indicators appear in two or more
adJacent grooves at three spots around tire.
• Tread or sidewall is cracked, cut or snagged deeply
enough to expose cord or fabric. ·
• !ire ha~ a bump, bulge or split. Slight sidewall
mdentat1ons are normal and should not affect ride.
• Tire has a puncture, cut or other damage that cannot
be correctly repaired because of size or location of
damage. SECTION
HEIGHT
It is recommended that new tires be installed in pairs
on the same axle. If only one tire is replaced, it should be
paired with the tire having the most tread.

ALL SEASON TIRES

_J
Figure 1 PC0002-3E-F-RP

Most GM vehicles are now equipped· w.ith steel
belted all season radial tires as standard equipme.nt. These
tires qu.alify as snow tires,. with a 37 percent higher aver-
age ratmg for snow traction than non-all season radial
tires used previously. Other performance areas; such as
wet traction, rolling resistance, tread life and air retention
were also improved slightly. These improvemenls wer~
made by changing both tread design and tread com-
pounds. These tires are identified by an "M+S" molded
in the tire sidewall following the size. The suffix "MS" is
also molded in the sidewall after the TPC specification
number.
P-METRIC TIRES
Figure 2
All GM vehicles now use passenger-metric (P-met-
ric) sized tires. P-metric tires are available in two load
ranges: standard load with 210 kPa (30 psi) maximum
pressure and extra load with 240 kPa (35 psi) maximum
pressure. Most passenger vehicle tires are standard load.
Most P-metric tire sizes do not have exact corre-
sponding alpha-numeric tire sizes. For example, a
P205/75Rl 5 is not exactly equ~l in size and load carrying
capacity to an FR 78-15. For this reason, replacement tires
should be of the same TPC specification number (same
size, load range, construction) as those originally on the
vehicle. If P-metric tires must be replaced with other
sizes, a tire dealer should be consulted. Tire companies
can best recommend the closest match of alpha-numeric
to P-metric sizes within their own tire lines.
The metric term for tire pressure is the kilopascal
(kPa). Tire pressure may be printed in both kPa and
pounds per square inch (psi). One psi equals 6.9 kPa.
Figure 2 - Metric Tire Size Format
Refer to the tire placard or "Specifications" in this sec-
tion for tire pressures.
TIRE CHAIN USAGE
Figure 3
NOTICE: Tire chains should not be used with
P245/50ZR 16 or P235/55R 16 tires. The chains
could damage the vehicle. Tire chains are only
recommended for emergency use or when required
by law.
. Due .to limi.ted tire-to-body clearance on certain
vehicles, tire cham usage recommendations have been
published in the Owner's Manual. When chains are to be
~sed, m.ost current GM vehicles require SAE Class "S"
tire chams. These may also be designated as 1100 Series
Type PL tire chains. These chains are specially designed
to limit the "fly off" effect that occurs when the tire and
wheel assembly rotates.
.. Manufacturers of tire chains have a specific chain
size fo~ each tire and wheel assembly to ensure proper fit
when mstalled. Therefore, specific chains should be
obtained for the tire and wheel assemblies on which they
are to be used. Rubber adjusters should not be used to take
up slack or clearance in chains which are loose due to
incorrect size. Always follow the chain manufacturer's
installation instructions.
Use of chains may adversely affect vehicle handling.
When tire chains are installed:
. • Adjust speed to road conditions
• Avoid sharp turns
 TIRES AND WHEELS 3E·3

A .
-"":'M~FG:,,:B~YG;,:,EN:::::E;;-:RA~LM:-::,0:;,,TO~Rs'""c°"oR""P_ _ __
DATE GVRA GAWRFR GAWRRR
' ~--__J LB c::::ua. c:::J:LIII
8 . KG ~KG c::=:::JKG
TYPE "PL"
THIS VEHICLE CONFORMS TO ALL APPLICABLE
1100 SERIES, SAE CLASS "S" D
FEDERAL MOTOR VEHICLE SAFETY AND
BUMPER STANDARDS IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE

TYPE "P'~
1200 SERIES, SAE CLASS "U"

TYPE "RP"
1800 SERIES, LUG-REINFORCED
G33956-3E-AN
Figure 3 - Examples of Passenger Vehicle Tire.Chains
In general, to help prevent chain damage to the
vehicle:
• Install chains on rear tire and wheel assemblies as
tightly as possible, then tighten them again after
driving 0.4 to 0.8 km (1/4 to 1/2 mile). Use of chains
on front tire and wheel assemblies is not recom-
mended; chains may contact and possibly damage
vehicle. If chains are to be used on front tire and
wheel assemblies, be sure there is enough clearance.
• Do not exceed 70 km/h ( 45 mph), or chain manufac-
turer's speed limit, if lower.
• Drive in restrained manner and avoid large bumps,
potholes, severe turns and other maneuvers wh,ich
could cause tire and wheel assemblies to bounceup
and down.
• Follow any other instructions of chain manufacturer
which do not disagree with above.
Additional specific information is published in the
Owner's Manual.
TIRE PLACARD
Figure4
The tire placard .is permanently located on the rear
face of the driver's door, and should be referred to for tire
information. The placard lists the maximum vehicle load,
tire size (including spare), and cold inflation pressure
(including spare).
A DATE
B GROSS VEHICLE WEIGHT RATING
C GROSS AXLE WEIGHT RATING FRONT & REAR
D CERTIFICATION STATEMENT
E VEHICLE IDENTiFICATION NUMBER
F VEHICLE CLASS TYPE: "PASSENGER CAR"
G MAXIMUM OCCUPANTS
H MAXIMUM VEHICLE CAPACITY WEIGHT
I MAXIMUM LOADING AT GVWR
J TIRE SIZE
K SPARE TIRE SIZE
L SPEED RATING
M TIRE PRESSURE WITH MAXIMUM OCCUPANTS FRONT
&REAR
N SPARE TIRE PRESSURE
PC0003-3E·F·RP
Figure 4 - Tire Placard
WHEEL ASSEMBLIES
Wheel assemblies must be replaced if they are bent,
dented, have excessive lateral or radial runout, leak air
through welds, have elongated bolt holes, or if the wheel
nuts will not stay tight. Wheel assemblies with runout
greater than specified may cause objectionable vibrations.
Replacement wheel assemblies must be equivalent
to the original equipment wheel assemblies in load capac-
ity, diameter, rim width, offset, and mounting configura-
tion. A wheel assembly of incorrect size or type may
affect wheel assembly and bearing life, brake cooling,
speedometer/odometer calibration, antilock brake system,
vehicle ground clearance and tire clearance to the body
and chassis.
Steel wheel asse.mblies can be identified by a two- or
three-letter code stamped into the front side of the rim
near the valve stem assembly. Aluminum wheel assem-
blies have the code, part number, and manufacturer ID
cast into the inboard side.
3E·4 TIRES ANO WHEELS

ON-VEHICLE SERVICE POUNDS PER SQUARE INCH (psi)

TO KILOPASCALS (kPa)
WHEEL ASSEMBLY REPAIR
psi kPa psi kPa
Wheel assembly repairs that use welding, heating or
peening are not approved. An inner tube is not an accept- 20 140 55 380
able repair for leaky tire and wheel assemblies. Porosity in 23 160 60 420
aluminum wheel assemblies can be repaired. Refer to 24 170 65 450
26 180 70 480
"Aluminum Wheel Assembly Porosity Repair" in this 190 75 520
28
section. 29 200 80 550
30 210 85 590
METRIC WHEEL NUTS AND BOLTS 32 220 90 620
35 240 95 660
A metric wheel nut is identified by the word "Met- 38 260 100 690
ric" stamped on its face. The wheel bolt has the letter 40 280 105 720
"M" stamped into its end. The thread size of the metric 41 280 110 760
45 310 115 790
wheel nuts and bolts are indicated by a code, such as 120 830
50 340
M12 x 1.5.
CONVERSION: psi x 6.895 = kPa
PCOOOl-3E-F-RP
WHEEL BOLT REPLACEMENT
Figure 5 - Inflation Pressure Conversion
CAUTION: If any wheel bolt is damaged
by a loose-running wheel assembly, all
the bolts for that wheel assembly
should be replaced. A loose-running • Tire bruising or carcass damage.
wheel assembly may break only one • Rapid tread''wear at center of tire.
bolt, but the other bolts may be dam- Tire pressure which is lower than that recommended
aged internally. Replacing only the bro- can cause:
ken bolt and remounting the wheel
assembly may cause further damage • Tire squeal on turns.
and personal injury. • Hard steering.
• Rapid and uneven wear on edge of tread.
Front Wheel Bolt • Tire rim bruises and rupture.
For the front wheel bolt replacement procedure, • Tire cord breakage.
refer to SECTION 3C.
• High tire temperatures.
Rear Wheel Bolt • Reduced handling.
For the rear wheel bolt replacement procedure, refer • High fuel consumption.
to SECTION 48. Unequal tire pressure on same axle can cause:
• Uneven braking.
TIRE INFLATION
• Steering lead.
Figure 5 • Reduced handling.
The pressure recommended for all models is care- • Swerve on acceleration.
fully calculated to give a comfortable ride, responsive
steering, and maximum tread wear, tire life and resistance WHEEL ASSEMBLY REMOVAL AND
to bruises. Valve stem assembly caps or extensions should INSTALLATION
be installed on the valve stem assemblies to keep out dust
and water. Figures 6, 7 and 8
Tire pressure, with tires cold (after vehicle has sat Penetrating oil has not been found to be effective in
for three hours or more, or driven less than one mile), removing tight wheel assemblies. However, if it is used, it
should be checked monthly or before any extended trip. should be applied sparingly to the wheel assembly center-
Set tire pressure to the specifications on the tire placard hole area only.
located on the rear face of driver's door or in "Tire Pres- CAUTION: If penetrating oil gets on the
sures" in this section. Tire pressure will increase about 6.9 vertical surfaces between the wheel
kPa (1 psi) for every 5.5°C (10°F) temperature increase. assembly and the rotor assembly or
For sustained high-speed driving, tires should be set brake drum, it could cause the wheel
at the pressures recommended. Sustained driving at high assembly to work loose as the vehicle
speeds, where permitted by law, is not advised unless is driven, resulting in a loss of control
vehicle has special high-speed tires. and an injury accident. Never use heat
Tire pressure which is higher than that recom-
to loosen a tight wheel assembly. It can
shorten the life of the wheel assembly,
mended can cause: studs, or spindle and bearing assem-
• Hard ride. blies. Wheel nuts must be tightened in
• Reduced handling. sequence and to the proper torque to

A
A WHEEL ASSEMBLY, 16 x 7.5 STEEL
B WHEEL ASSEMBLY, 16 x 8 CAST ALUMINUM
9 BOLT, WHEEL
10 WHEEL ASSEMBLY, TIRE AND
11 NUT, WHEEL, 140 N•m (100 LB. FT.) ..
12 NUT, SPECIAL SECURITY WHEEL LOCK, 140 N•m
(100 LB. FT.)
13 COVER ASSEMBLY; WHEEL TRIM, 6 N•m (53 LB. IN.)
14 NUT, WHEEL, 140 N•m (100 LB. FT.)
15 CAP ASSEMBLY, HUB
Figure 6 - Tire and Wheel Assembly - (Chevrolet)
avoid bending the wheel assembly or
rotor assembly.
Sometimes wheel assemblies can be difficult to
remove due to foreign material or a tight fit between the
wheel assembly centerhole and the rotor assembly. Exces-
sive force such as hammering the wheel assembly or tire
can cause damage and is not recommended. Slight tapping
on the tire sidewall using a large rubber mallet is accept-
able.
The wheel assembly can be removed without dam-
age as follows:
I. Retighten all wheel nuts on affected wheel assem-
bly. Then loosen each nut two turns. Rock vehicle
from side to side. If this is not effective, go to step 2.
2. Rock vehicle from "DRIVE" to "REVERSE"
allowing vehicle to move several feet in each direc-
tion. Apply quick, hard jabs on the brake pedal as-
sembly to loosen wheel ,lssembly. If wheel
assembly still does not loosen, then rock vehicle
again from side to side as hard as possible using one
or more person's body weight. If wheel assembly is
still tight, repeat procedure.
Chevrolet
!++I Remove or Disconnect
I. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Wheel nut caps, if equipped.
3. Hub cap (15) or wheel trim cover assembly (13).
TIRES AND WHEELS 3E·5
10
9
B
PC1009-3E·f·RP
4. Special security wheel lock nut (12), if equipped.
• Use special security wheel lock key, located in
the front floor console assembly.
5. Wheel nuts (11 or 14 ).
• Mark location of the tire and wheel assemblies
( 10) to the hub assembly.
6. Tire and wheel assembly (10).
!.,I Clean
CAUTION: Before installing a wheel
assembly, remove any buildup of corro-
sion on the wheel assembly mounting
surface and brake drum or rotor assem-
bly by scraping and wire brushing.
Installing wheel assemblies without
good metal-to-metal contact at the
mounting surfaces can cause wheel
nuts to loosen, which may later allow
the wheel assembly to come off while
the vehicle is in motion.
• Wheel nuts (11 or 14), bolts (9), wheel assem-
bly (10) and brake drum or rotor assembly
mounting surfaces.
!-++I Install or Connect
NOTICE: See "Notice" on page 3E-l of this
section.
1. Tire and wheel assembly (10).
CAUTION: Never use oil or grease on
bolts or wheel nuts. Tighten the wheel
3E-6 TIRES AND WHEELS

nuts with your fingers until they are 6. Lower vehicle.

snug. Then, tighten the wheel nuts (in
the sequence shown) to the specified Pontiac
torque. Refer to "Specifications" in this
section. Improperly tightened wheel
nuts could eventually allow the wheel
j++! Remove or Disconnect
assembly to come off while the vehicle 1. Raise and suitably support vehicle. Refer to SEC-
is moving, possibly causing loss of TION OA.
control, personal injury and property 2. Wheel nut caps, if equipped.
damage.
3. Hub cap assembly (17 or 18).
2. Wheel nuts (11 or 14).
4. Special security wheel lock nut (12), if equipped.
l~I Tighten • Use special security wheel lock key, located in
the front floor console assembly.
• Nuts (11 or 14) in sequence to 140 N•m (100
lb. ft.) (Figure 8).
5. Wheel nuts ( 11 ).
• Mark location of the tire and wheel assemblies
3. Special security wheel lock nut (12), if equipped. (10) to the hub assembly.
• Use special security wheel lock key located in 6. Tire and wheel assembly (10).
front floor console assembly.

l~I Tighten
li,1 Clean
CAUTION: Before installing a wheel
• Nut (12) to 140 N•m (100 lb. ft.).
assembly, remove any buildup of corro-
4. Hub cap (15) or wheel trim cover assembly ( 13), if sion on the wheel assembly mounting
equipped. surface and brake drum or rotor assem-
bly by scraping and wire brushing.
l~I Tighten Installing wheel assemblies without
good metal-to-metal contact at the
• Cover assembly (13) to 6 N•m (53 lb. in.). mounting surfaces can cause wheel
5. Wheel nut caps, if equipped. nuts to loosen, which may later allow

10
17

A
10
18

A WHEEL ASSEMBLY, 16 x 7.5 ALUMINUM

B WHEEL ASSEMBLY, 16 x 8 STYLED ALUMINUM
9 BOLT, WHEEL
10 WHEEL ASSEMBLY, TIRE AND
11 NUT, WHEEL, 140 N•m (100 LB. FT.) .
12 NUT, SPECIAL SECURITY WHEEL LOCK, 140 N•m
(100 LB. FT.)
17 CAP ASSEMBLY, HUB, 6 N•m (53 LB. IN.) B
18 CAP ASSEMBLY, HUB, 6 N•m (53 LB. IN.)
RC2001-3E-F-RP

Figure 7 - Tire and Wheel Assembly - (Pontiac)

 TIRES AND WHEELS 3E-7

the wheel assembly to come off while

the vehicle is in motion.
• Wheel nuts ( 11 ), bolts (9), wheel assembly
(10) and brake drum or rotor assembly mount-
ing surfaces.

!++! Install or Connect

NOTICE: See "Notice" on page 3E-l of this
section.
1. Tire and wheel assembly ( I 0).
CAUTION: Never use oil or grease on
bolts or wheel nuts. Tighten the wheel
nuts with your fingers until they are
snug. Then, tighten the wheel nuts (in
the sequence shown) to the specified
torque. Refer to "Specifications" in this
KC0044-3E-Y-RC
section. Improperly tightened wheel
nuts could eventually allow the wheel Figure 8 - Five-Hole Wheel Nut Tightening Sequence
assembly to come off while the vehicle
is moving, possibly causing loss of
control, personal injury and property
damage. ..........
2. Wheel nuts ( 11 ). a:
I.I.
l~I Tighten
• Nuts (11) in sequence to 140 N•m (100 lb. ft.)
(Figure 8).
3. Special security wheel lock nut ( 12), if equipped.
• Use special security wheel Jock key located in
front floor console assembly.

!~I Tighten
A

• Nut (12) to 140 N•m (100 lb. ft.).

..........
4. Hub cap assembly ( 17 or 18).

!~I Tighten
I I a:
I.I.

• Cap assembly (17 or 18) to 6 N•m (53 lb. in.).

5. Wheel nut caps, if equipped.
6. Lower vehicle. fI 11
Tire and Wheel Assembly Rotation
Figure 9
I B
I
To equalize wear, rotate tires at intervals specified in A NORMAL FOUR-WHEEL ROTATION PATTERN FOR
SECTION OB. Whenever uneven tire wear is noticed, the TIRES DESIGNED TO ROLL IN EITHER DIRECTION
cause should be investigated. Figure 9 shows the only B SPECIAL FOUR-WHEEL ROTATION PATTERN FOR
methods of tire and wheel assembly rotation recom- DIRECTIONAL TIRES DESIGNED TO ROLL MAINLY IN
ONE DIRECTION
mended.
Due to their design, radial tires tend to wear faster in IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE
the shoulder area, particularly in drive locations. Radial ASSEMBLY IN ROTATION .
tires in non-drive locations may develop an irregular wear
pattern that can generate tire noise. This wear makes regu- PC0004-3E-F-RP
lar rotation especially important.
Figure 9 - Tire and Wheel Assembly Rotation
Always use a four-wheel rotation. After rotation, be
sure to check wheel nut torque and set tire pressure. Never
use oil or grease on wheel assembly bolts or nuts.
3E·8 TIRES AND WHEELS

snaps over safety hump. Do not exceed

280 kPa (40 psi) pressure when inflat-
ing any tire if beads are not seated. If
280 kPa (40 psi) pressure will not seat
beads, deflate, relubricate and inflate.
Overinflation may cause the bead to
break and cause serious personal
injury.
• After mounting, inflate tire so that beads are com-
pletely seated, but never exceed 280 kPa (40 psi).
TIRE LOCATING RING

( ] ] Important
KC0058-3E-Y-RC
• When mounting blackwall tires, be sure the TPC
Figure 1O- Tire Locating Ring specification number faces the outboard side of the
vehicle.
Install the valve stem assembly and inflate to the
pressure specified on the tire placard. Check the locating
On vehicles with P245/50ZR 16 tires, special rota- rings of the tire to be sure they show around the rim
tion provisions must be followed because the tires are flanges on both sides of the wheel assembly.
directional. See Figure 9 for the recommended rotation.
Rotate the tires. If you have directional tires, be sure Steel Wheel Assembly Mounting Surface
the color-coded arrows on the tires point in the direction Check
the tires roll. Balance the tire and wheel assemblies using
nylon-coated wheel balance weights. Adjust tire pressures Figures 11 and 12
and tighten wheel nuts to the specified torque. Refer to 1. Place straight edge (about eight to nine inche.s long)
"Wheel Assembly Removal and Installation" in this with both hands on inboard mounting surface of
section. wheel assembly.
2. Try to rock straight edge up and down.
TIRE MOUNTING AND DISMOUNTING
• The outer ring of mounting surface is nonnally
Figure 10 raised above everything else inside it. If sur-
face has been bent on a tire changer, it will be
Use a tire changing 'machine to mount or dismount raised above outer ring and straight edge will
tires. Follow the equipment manufacturer's instructions. rock on this position.
Do not use hand tools or tire irons to change a tire as they
may damage the tire beads, wheel assembly rim or 3. Repeat steps 1 and 2 at three or four different posi-
flanges. tions on inboard mounting surface.
NOTICE: Do not lubricate the tire beads or wheel 4. If wheel assembly is bent, it must be replaced. Refer
assembly rim with a lubricant containing silicone. to "Wheel Assembly Removal and Installation" in
Silicone will allow the tire to rotate on the wheel this section.
assembly rim, throwing the tire and wheel assembly
out of balance.
NOTICE: Do not attempt to break the tire bead
loose before the tire has completely deflated. It takes
about 70 seconds for the air to completely exhaust
from a large tire. If the valve stem assembly is
removed before this amount of time, the bead break-
er on the tire changing machine could put enough
force on the tire to bend the wheel assembly at the
mounting surface. This could result in vibration,
shimmy and cracking of the wheel assembly. Com-
pletely deflate the tire before attempting to break the
tire bead loose.
Rim bead seats should be cleaned with a wire brush A
or coarse steel wool to remove old rubber and light rust or B
corrosion. Before mounting or dismounting a tire, the
A STRAIGHT EDGE CHECK
bead area should be well-lubricated with GM P/N B OUTER RING
9985555 (50 percent lubricant and 50 percent water) or
equivalent.
PC0006-3E·F·RP
CAUTION: To avoid serious personal
injury, do not stand over the tire when Figure 11 - Steel Wheel Assembly Mounting Surface Check
inflating. The bead may break when it

A ~
~-·£:~.RC~ B
A ORIGINAL WHEEL MOUNTING SURFACE
B BENT WHEEL MOUNTING SURFACE
C STRAIGHT EDGE
D GAP
PC0007-3E-F-RP
Figure 12 - Steel Wheel Assembly Mounting Surface
TIRE REPAIR
There are many different materials and techniques
on the market to repair tires, but not all ~ork on s~me
types of tires. Tire manufacturers hav~ p~bhshed ~eta1led
instructions on how and when to repatr ttres. The mstru~-
tions can be obtained from the tire manufacturer. Repair
of compact spare tire is not recommended.
MEASURING WHEEL ASSEMBLY RUNOUT
Figure 13
Wheel assembly runout should be measured with .an
accurate dial indicator. Measurements may be taken with
the wheel assembly installed on the vehicle, or off the
vehicle using an accurate mounting surface. such a.s a
wheel balancer. Measurements may be taken with or with-
out the tire mounted on the wheel assembly.
Radial runout and lateral runout should be measured
on both the inboard and outboard rim flanges. With the
dial indicator firmly in position, slowly rotate t~e :Vheel
assembly one revolution and record the ~o.tal _md1cator
reading. If any measurement exceeds. spec!f1cat10ns, and
there is a vibration that wheel balancing will not correct,
the wheel assembly should be replaced. Disregard any
indicator readings caused by welds, paint runs, or
scratches.
• Steel Wheel Assemblies
- Radial runout 1.0 I mm (0.040 inch)
- Lateral runout 1.14 mm (0.045 inch)
• Aluminum Wheel Assemblies
- Radial runout 0.76 mm (0.030 inch)
- Lateral runout 0.76 mm (0.030 inch)
COMPACT SPARE TIRE ASSEMBLY
Figure 14
rn Important . . .
• Use of compact spare may result m activating a
wheel sensor fault code. This will result in "ANTI-
LOCK" warning lamp turning on and deactivation
TIRES AND WHEELS 3E·9
MEASURING WHEEL ASSEMBLY RUNOUT
INBOARD SIDE OUTBOARD SIDE
RADIAL RUNOUT
* IF WHEEL ASSEMBLY DESIGN MAKES THIS OUTBOARD
MEASUREMENT IMPOSSIBLE, THE INBOARD SIDE
ONLY MAY BE USED.
TIRE REMOVED FROM WHEEL ASSEM~LY
RADIAL RUNOUT RADIAL RUNOUT
INBOARD SIDE OUTBOARD SIDE
PC0001-3E-B-RP
Figure 13 - Wheel Assembly Runout
of antilock brake system. After replacing compact
spare, recycling ignition switch will reset system.
NOTICE: If the compact spare is used as a rear tire,
do not drive faster than 80 km/h (50 mph). Damage
to the rear axle assembly may occur if the compact
spare is driven faster than 80 km/h (50 mph). This
speed limitation does n?t apply when the compact
spare is used as a front tire.
Some vehicles wiJI be equipped with a high-pressure
compact spare. The compact spare uses a. narrow _4-inch
wide rim, although the wheel assembly d1amet~r 1s usu-
ally one inch larger than the road wheel assembhes.
NOTICE: The compact spare wheel assembly
should not be used with standard tires, snow tires,
wheel covers or trim rings. If such use is attempted,
damage to these items or other parts of the vehicle
may occur. The comp~ct spa_r~ should _be used only
on vehicles that offer 1t as ongmal eqmpment.
Inflation pressure of the compact spare must be peri-
odically checked and maintained at 420 kPa (60 psi). It
can be mounted and dismounted from its wheel assembly
using present tire-changing equipment and procedures.
As with other tires, the beads should completely seat at
280kPa (40 psi).
CAUTION: To avoid serious personal
injury do not stand over tire when
inflati~g. Bead may break when it
snaps over safety hump. Do not exceed
280 kPa (40 psi) pressure when inflat-
ing any tire, including compact spares,
if beads are not seated. If 280 kPa (40
psi) pressure will not seat beads,
3E-10 TIRES AND WHEELS
1 NUT, SPARE WHEEL STOWAGE 5
2 ADAPTER, SPARE WHEEL STOWAGE
3 STEM ASSEMBLY, TIRE VALVE
4 TIRE ASSEMBLY, COMPACT SPARE
5 JACKASSEMBLY
6 COVER ASSEMBLY, JACK STOWAGE
7 BOLT/SCREW, JACK STOWAGE, 6.5 N•m (58 LB. IN.)
8 BOLT/SCREW, SPARE WHEEL STOWAGE
16 NUT, JACK STOWAGE
Figure 14 - Compact Spare Tire Assembly
deflate, relubricate and inflate. Over-
inflation may cause bead to break and
cause serious personal injury.
The compact spare is designed to weigh less than
standard tires and is easier to handle when need arises.
Check inflation pressure as soon as practical after instal-
ling compact spare and adjust to 420 kPa (60 psi).
Replacement of the compact spare should be made only
by an authorized tire dealer.
NOTICE: Do not take the vehicle through an auto-
matic car wash with the compact spare installed. The
vehicle may get caught, which could result in prop-
erty damage.
BALANCING TIRE AND WHEEL ASSEMBLY
Figures 15 and 16
There are two methods used to balance tire and
wheel assemblies: static and dynamic. Static balance is
the equal distribution of weight around the wheel assem-
bly. Wheel assemblies that are statically unbalanced cause
a bouncing action called tramp.
Dynamic balance is the equal distribution of weight
on each side of the centerline so that when the tire spins
there is no tendency for the wheel assembly to move from
side to side. Wheel assemblies that are dynamically unbal-
anced may cause shimmy.
16 PCGG05-3E-F-RP
General Balance Precautions
CAUTION: It is recommended that eye
protection be used to prevent personal
injury.
Deposits of foreign material must be cleaned from
the inside of the wheel assembly. Stones should be
removed from the tread in order to avoid operator injury
during spin balancing and to obtain a good balance. The
tire and wheel assembly should be inspected for any dam-
age, then balanced according to the equipment manufac-
turer's recommendations.
Off-Vehicle Balancing
When balancing tire and wheel assemblies off the
vehicle, use a balancer that pilots the wheel assembly by
the centerhole (not the lug holes) if possible. Always fol-
low the equipment manufacturer's instructions. Some
electronic off-vehicle balancers are more accurate than
the on-vehicle spin balancers, but do not correct for rotor
assembly unbalance. If the vibration is not corrected by
the off-vehicle balance, an on-vehicle balance may also be
needed.
On-Vehicle Balancing
When needed, on-vehicle balancing will help cor-
rect vibrations due to brake drum, rotor assembly, and
wheel cover imbalance.
When balancing on-vehicle, do not remove the bal-
ance weights from the off-vehicle dynamic balance. If
more than one ounce of additional weight is required, it
 TIRES AND WHEELS 3E·11

should be split between the inboard and outboard rim

flanges.
The driven tire and wheel assemblies should be spun
..--,-, using the engine. Limit speed as stated in the following
caution.
CAUTION: On vehicles equipped with
limited slip rear axles, do not attempt to
balance a tire on a drive wheel assem-
bly with the other drive wheel assembly
CL on the ground. The vehicle may drive
·--~
'--
HEAVY
SPOT
OF SPINDLE through this wheel assembly and
cause the vehicle to move unexpect·
edly, resulting in personal injury and
WHEEL ASSEMBLY TRAMP
property damage.
CAUTION: Do not spin the drive wheel
ADD WHEEL BALANCE assemblies faster than 55 km/h (35
WEIGHTS HERE mph) as indicated by the speedometer.
This limit is necessary because the
speedometer indicates only one-half of
the actual wheel speed when one drive
wheel assembly is spinning and the
other drive wheel assembly is stopped.
Personal injury and damage may result
from high-speed spinning.
To distinguish between standard rear axle and lim-
ited slip, raise rear of vehicle so both tires are clear of
CORRECTIVE WHEEL BALANCE WEIGHTS ground. With the transmission in "PARK" (in gear with a
PC6006-3E-D-RP manual transmission) attempt to tutn one wheel assembly
Figure 15 - Static Unbalance Correction by hand. If the wheel assembly can be turned easily, it is a
standard rear axle: if the wheel assembly cannot be turned
easily, it is a limited slip rear axle. Also, check for limited
slip (G80) on the Service Parts Identification label.

Wheel Balance Weights

Figure 17
When static balancing, if more than 28 grams
CL OF SPINDLE
(1.0 ounce) are needed, the wheel balance weights should
be split as equally as possible between the inboard and
outboard flanges.
WHEEL ASSEMBLY SHIMMY
Assemblies with factory aluminum wheel assem-
blies must be balanced using special nylon-coated clip-on
wheel balance weights. These weights are designed to fit
over the thicker inboard and outboard rim flanges of the
aluminum wheel assembly and should be installed with a
nylon-coated hammer.
Adhesive wheel balance weights are also available
for aluminum wheel assemblies. Use the following proce-
ADD WHEEL BALANCE
WEIGHTS HERE
dure to install adhesive wheel balance weights.
Adhesive Wheel Balance Weight Installation
I. Clean wheel assembly by sanding to bare aluminum
where wheel balance weight is to be located.
2. Wipe wheel balance weight attachment area with
mixture of half isopropyl alcohol and half water. Use
CORRECTIVE WHEEL BALANCE WEIGHTS clean cloth or paper towel for this operation.
3. Dry attachment area with hot air. Surface of wheel
assembly should be warm to touch.
PC6007-3E-D-AP 4. Warm adhesive backing on wheel balance weights to
Figure 16 - Dynamic Unbalance Correction room temperature.
5. Remove tape from back of weights. Do not touch
adhesive surface.
3E-12 TIRES AND WHEELS
A CENTERLINE
B INSIDE FLANGE
C CLIP-ON WEIGHT
D ADHESIVE WEIGHT - DYNAMIC
E ADHESIVE WEIGHT- STATIC ONLY
F MOUNTING FACE
PC6008-3E-D-RP
Figure 17 - Aluminum Wheel Balance Weight Placement
6. Apply wheel balance weight and press on with hand
pressure.
7. Secure wheel balance weight with a 70 to 110 N
( 16 to 25 pound) force applied with a roller.
CORRECTING NON-UNIFORM TIRES
There are two ways to correct tires which cause a
vibration even though they are properly balanced. One
method uses an automatic machine which loads the tire
and buffs small amounts of rubber from the stiff spots on
the outer two tread rows. Correction by this method is
usually permanent and, if done properly, does not signifi-
cantly affect the appearance or tire tread life. Tire truing
for free runout with a blade-type machine is notrecom-
mended as this reduces the tread life substantially and
often does not permanently correct the problem.
Another method is to dismount the tire and rotate it
180 degrees on the rim. It is important that this be done
only on tire and wheel assemblies which are known to be
causing a vibration as it is just as likely to cause good tire
and wheel assemblies to vibrate.
Refer to SECTION 3 for more details.
ALUMINUM WHEEL ASSEMBLIES
Aluminum Wheel Assembly Hub Cap
!+-+! Remove or Disconnect
• Hub cap.
- Use flat-bladed tool to pry off hub cap by
inserting tool into slot between rim and hub
cap.
!-++! Install or Connect
• Hub cap.
- Use rubber mallet to fully seat hub cap into
rim.
Aluminum Wheel Assembly Porosity Repair
!++! Remove or Disconnect
I. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Tire and wheel assembly. Refer to "Wheel Assem-
bly Removal and Installation" in this sectron.
3. Locate leaking areas by inflating tire to 280 kPa (40
psi) and dipping tire and wheel assembly into water
bath.
4. Mark leak areas.
5. Mark tire at valve stem assembly.
6. Tire from wheel assembly. Refer to "Tire Mounting
and Dismounting" in this section.
7. Scuff inside rim surface at leak area with number 80
grit sandpaper and clean area with general purpose
cleaner such as 3M part number 08984 or equiva-
lent.
8. Apply 3 mm ( 1/8-inch) thick layer of adhesive/seal-
ant, GM P/N 1052366 or equivalent, to leak test area
and allow six hours of drying time.
!-++I Install or Connect
1. Tire to wheel assembly. Refer to "Tire Mounting
and Dismounting" in this section.
2. Align matchmark on tire with valve stem assembly.
3. Pressurize to 280 kPa (40 psi) and check for leaks.
4. Adjust tire pressure to meet specifications on tire
placard.
5. Balance tire and wheel assemblies. Refer to "Bal-
ancing Tire and Wheel Assembly" in this section.
6. Tire and wheel assembly. Refer to "Wheel Assem-
bly Removal and Installation" in this section.
7. Lower vehicle.
Aluminum Wheel Assembly Refinishing
A protective clearcoat or colorcoat is applied to the
surface of original equipment cast-aluminum wheel
assemblies. A surface break-down condition can begin to
develop if frequent, repeated automatic car wash cleaning
scratches or wears off the factory-applied protective clear-
coat. Once the protective clearcoat is damaged, exposure
to caustic cleaners and/or road salt further causes surface
break-down. The service procedures detail how to strip,
clean and recoat aluminum wheel assemblies that are
affected by the above condition. Select and follow only
those procedures for the conditions that apply to the wheel
assemblies you are refinishing.
Required Materials
• Amchem Alumi Prep number 33, stock number
DX533, or equivalent - cleaning and conditioning
chemical for aluminum.
• Amchem Alodine number 1001, stock number
DX50 I, or equivalent - coating chemical for alumi-
num.
• Ditzler Declear Acrylic Urethane Clear, stock num-
ber DAU-75, or equivalent.

• Ditzler Delthane Ultra-Urethane Additive, stock
number DXR-80, or equivalent.
Initial Preparation
!++! Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
• Matchmark tire for reinstallation of outboard
wheel balance weights after recoating of wheel
assembly.
2. Tire and wheel assembly from vehicle. Refer to
"Wheel Assembly Removal and Installation" in this
section.
3. Outboard wheel balance weights.
jr,! Clean
• Wheel assembly inside and out with water base all-
purpose cleaner. Remove grease or oil with solvent
cleaner.
Accent Color Preparation
• Sand over painted areas that do not require recolor-
ing with number 400-grit wet or dry sandpaper to
promote adhesion of clearcoat.
Surface Damage
CAUTION: Do not use vehicle power to
rotate the wheel assembly while sand-
ing or personal injury may result.
I. Mount wheel assembly on brake lathe and spin
slowly.
NOTICE: Do not use abrasive coarser than 80-grit
or wheel assembly may be damaged.
2. Sand wheel assembly with backing block or pad by
holding abrasive flat to surface of wheel assembly
and moving slowly back and forth from center to
outer edge to remove imperfections.
A. First, sand with number 80-grit sandpaper.
B. Follow with number 150-grit sandpaper.
C. Finish with number 240-grit sandpaper.
Slight Clearcoat Damage on Unpainted Wheel
Assemblies
CAUTION: Use of rubber gloves and
eye protection is necessary to prevent
personal injury.
1. Apply chemical stripper.
A. Allow stripper to penetrate coating.
B. Use a small 1/4-inch detail brush dipped in
stripper to apply material around perimeter and
spoke-like areas.
2. Remove stripper, following manufacturer's recom-
mendations.
TIRES AND WHEELS 3E-13
CAUTION: Do not use vehicle power to
rotate the wheel assembly while sand-
ing or personal injury may result.
3. Sand wheel assembly with number 240-grit sandpa-
per while rotating wheel assembly on slowly spin-
ning brake lathe or by mounting it on vehicle and
spinning by hand.
• This restores machined appearance and pro-
motes adhesion of finish coats.
Recoating Procedure
CAUTION: Use of rubber gloves· and
eye protection is necessary to prevent
personal injury.
1. Clean surface of contaminants by washing with soap
and water.
2. Spray wheel assembly with Amchem number 33 or
equivalent.
A. Let wheel assembly soak for 1 to 3 minutes.
B. Rinse with water and blow dry.
3. Spray wheel assembly with Amchem number 1001
or equivalent.
A. Let wheel assembly soak for I to 3 minutes.
B. Rinse with water and blow dry.
4. Mask off tire.
CAUTION: When applying any two part
component paint system, wear proper
respiratory protection such as Easi-Air
Respirator, part number 06986, or
equivalent. Follow the specific precau-
tions provided by the paint manufactur-
er. Failure to follow these precautions
may cause lung irritation and allergic
respiratory reaction.
5. Finish wheel assembly with Ditzler Declear Acrylic
Urethane Clear and Ditzler Ultra Urethane-Addi-
tive, or equivalents. Refer to labels for specific
directions.
A. First coat - light mist coat, let flash.
B. Second coat - light, let flash.
C. Third coat - heavy duty, wet coat.
6. Let wheel assembly dry for 24 hours or flash for 30
minutes. Force dry at 60°C (140°F) for 30 minutes
and allow to cool for 30 minutes before mounting.
j++l tnstall or Connect
1. Balance tire and wheel assembly. Refer to "Balanc-
ing Tire and Wheel Assembly" in this section.
• Replace original wheel balance weights with
nylon-coated wheel balance weights to avoid
discoloration of wheel assembly.
2. Tire and wheel assembly. Refer to "Wheel Assem-
bly Removal and Installation" in this section.
3. Lower vehicle.
3E-14 TIRES AND WHEELS

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Hub Cap Assembly - 16 x 7.5 Aluminum Wheel Assembly (Pontiac) ........... 6 N•m (53 lb. in.)
Hub Cap Assembly- 16 x 8 Aluminum Wheel Assembly (Pontiac) ............. 6 N•m (53 lb. in.)
Jack Stowage Bolt/Screw ............................................ 6.5 N•m (58 lb. in.)
Special Security Wheel Lock Nut ..................................... 140 N•m (100 lb. ft.)
Wheel Nut - M\2 x 1.5 ............................................. 140 N•m (100 lb. ft.)
Wheel Trim Cover Assembly (Chevrolet) ................................. 6 N•m (53 lb. in.)

RUNOUT SPECIFICATIONS
Maximum Radial Runout
Steel Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.01 mm (0.040")
Aluminum Wheel Assemblies ....................................... 0.76 mm (0.030")
Maximum Lateral Runout
Steel Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 mm (0.045")
Aluminum Wheel Assemblies ....................................... 0.76 mm (0.030")

TIRE PRESSURES
Compact Spare ....................................................... 420 kPa (60 psi)
Front ............................................................... 210 kPa (30 psi)
Rear ................................................................ 210 kPa (30 psi)
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·1

SECTION 3F

STEERING WHEEL AND COLUMN

ON-VEHICLE SERVICE
CAUTION: The procedures in this section must be followed in the order listed to temporarily
disable the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic
trouble codes from setting. Failure to follow procedures could result in possible air bag
. deployment, personal injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3F-2
Steering Column Assembly . . . . . . . . . . . . . . . . 3F-2
Ignition Lock Systems . . . . . . . . . . . . . . . . . . . . 3F-2
Brake Transmission Shift Interlock (BTSI) . . . . 3F-2
Supplemental Inflatable Restraint (SIR) . . . . . . 3F-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-2
Steering Wheel Assembly Controls . . . . . . . . . . 3F-2
Diagnosis ...................... Refer to Section 3
Repairs and Inspections Required
after an Accident ........... Refer to Section 91
Ignition Lock Systems .......... Refer to Section 3
Brake Transmission Shift
Interlock (BTSI) . . . . . . . . . Refer to Section 3F5B
Supplemental Inflatable
Restraint (SIR) ........... Refer to Section 9J-A
Steering Wheel Assembly
Controls ..... : ........ Refer to Section SA-150
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3F-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 3F-2
Disabling the SIR System . . . . . . . . . . . . . . . 3F-4
Enabling the SIR System . . . . . . . . . . . . . . . . 3F-4
Live (Undeployed) Inflatable Restraint
Steering Wheel Module Assembly . . . . . . 3F-4
Deployed Inflatable Restraint Steering
Wheel Module Assembly . . . . . . . . . . . . . . 3F-4
Inflatable Restraint Steering Wheel Module
Assembly Shipping Procedures . . . . . . . . . 3F-5
Inflatable Restraint Steering Wheel Module
Assembly Scrapping Procedures . . . . . . . . 3F-5
Wiring Repairs .... Refer to Sections 8A-5 and 9J-B
Park Lock System . . . . . . . . . . . Refer to Section 7 A
Brake Transmission Shift Interlock
Solenoid Assembly . . . . . . . . Refer to Section 7 A
Ignition Switch and Dimmer
Switch Assembly . . . . . . . . . . . . . . . . . . . . . . 3F-5
Turn Signal Lever Assembly . . . . . . . . . . . . . . . 3F-6
Hazard Warning Switch . . . . . . . . . . . . . . . . . . . 3F-6
Hazard Warning Switch Knob . . . . . . . . . . . . 3F-6
Steering Column Tilt Wheel Release
Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 3F-7
Inflatable Restraint Steering Wheel
Module Assembly . . . . . . . . . . . . . . . . . . . . . 3F-8
Steering Wheel Horn Switch Assembly . . . . . . 3F-9
Steering Wheel Horn Switch
Contact Plate Assembly . . . . . . . . . . . . . . . . 3F-10
Steering Wheel Assembly ................ 3F-10
Centering the SIR Coil
Assembly . . . . . . . . . . . . . . Refer to Section 3F5B
PASS Key Lock Cylinder . . . Refer to Section 3F5B
Radio Control Switch
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-11
Steering Gear Coupling Shaft Assembly ..... 3F-12
Steering Column Assembly Removal ....... 3F-14
Checking Steering Column Assembly
for Accident Damage . . . . Refer to Section 3F5B
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-15
Fastener Tightening Specifications . . . . . . . . . 3F-15
Special Tools ............................ 3F-16
3F·2 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
GENERAL DESCRIPTION
STEERING COLUMN ASSEMBLY
Figure 1
The Jocking, energy-absorbing column assembly
( 15) includes three important features in addition to the
steering function.
1. In a front-end collision, the energy-absorbing col-
umn assembly ( 15) is designed to coJlapse, mini-
mizing the possibility of driver injury.
2. The steering column lock and ignition cylinder
assembly are conveniently mounted on the column
assembly (15).
3. When Jocked, the column-mounted lock acts as a
theft deterrent by preventing the operation of both
ignition and steering.
The turn signal lever assembly (5 or 31) (multifunc-
tion turn signal lever) controls the turn signals, headlamp
high beam, windshield washer and wipers, and, if
equipped, cruise control.
To ensure the energy-absorbing action, use only the
specified bolts/screws and nuts and tighten them to their
specified torques. Apply a thin coat of lithium grease to all
friction points during reassembly.
When the column assembly (15) is removed from
the vehicle, handle it with special care. Using a steering
wheel puller other than the one recommended in this
manual, hitting the end of the steering gear coupling shaft
assembly (9) sharply, leaning on the column assembly
( 15) or dropping the column assembly ( 15) could shear or
loosen the plastic fasteners that keep the column assembly
( 15) rigid.
IGNITION LOCK SYSTEMS
The automatic transmission assembly uses a park
Jock system. This system uses a flexible automatic trans-
mission park Jock cable assembly which is attached at one
end to the automatic transmission control lever assembly
and at the other end to the ignition switch mounted to the
column assembly where it actuates a Jocking pin. This
Jocking pin engages an ignition switch sliding contact
when the lever assembly is in "REVERSE" and does not
allow the ignition switch to move to the "LOCK" posi-
tion. With the lever assembly in "PARK" and the ignition
switch slider in "LOCK," the locking pin engages a cam
on the cable assembly and prevents the lever assembly
from being moved into another position.
A steering column key release lever assembly is
used on vehicles with a manual transmission assembly. A
manual transmission clutch start switch assembly is used
so the manual transmission clutch pedal assembly must be
depressed before the engine assembly will crank.
BRAKE TRANSMISSION SHIFT INTERLOCK
(BTSI)
The brake transmission shift interlock (BTSI) sys-
tem prevents the driver from shifting out of "PARK"
without simultaneously pressing the brake pedal assem-
bly. When energized, the BTSI solenoid assembly locks
the automatic transmission control lever assembly.
When pressure is applied to the brake pedal
assembly, the BTSI solenoid assembly is de-energized
and releases the automatic transmission control lever
assembly.
SUPPLEMENTAL INFLATABLE RESTRAINT
(SIR)
The supplemental inflatable restraint (SIR) helps
supplement the protection offered by the driver's seat belt
assembly by deploying an air bag from the center of the
steering wheel assembly during certain frontal crashes.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. The steering column assembly is
collapsible and should be inspected after an accident
whether or not a deployment has occurred.
The SIR system components in the steering wheel
and steering column assemblies are the inflatable restraint
steering wheel module assembly and the SIR coil
assembly. To obtain a detailed description of these
components, refer to SECTION 91.
LUBRICATION
Apply a thin coat of lithium grease to all friction
points when reassembling components.
STEERING WHEEL ASSEMBLY CONTROLS
Pontiac
Figure 2
Steering wheel assembly controls enable remote
control of the following sound system functions, if
equipped:
• PWR (Power) - Turns radio assembly on or
off.
• VOL (Volume) - Adjusts volume of AM/FM
stereo, cassette tape player or compact disc
player.
• PRESET - Selects preset stations.
• AM/FM - Switches between AM and FM
bands.
• SEEK - Seeks the next station, either up or
down.
• RCL (Recall) - Toggles the display between
frequency and time.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
CAUTION: When performing service on
or around SIR components or SIR
wiring, follow the procedures listed
below to temporarily disable the SIR
system. Failure to follow procedures
could result in possible air bag deploy-
ment, personal injury or otherwise
unneeded SIR system repairs.
The diagnostic energy reserve module (DERM) can
maintain sufficient voltage to cause a deployment for up
to ten minutes after the ignition switch is turned "OFF" or
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·3

1
OR
46

A CONNECTOR, RADIO ASSEMBLY ELECTRICAL 11 CLAMP, STEERING GEAR COUPLING SHIELD

(PONTIAC ONLY) 12 BOOT, STEERING GEAR
B CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL 13 SHIELD, STEERING GEAR COUPLING HEAT
C LEAD, HORN 14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
D BUTION, STEERING GEAR COUPLING HEAT SHIELD 15 COLUMN ASSEMBLY, STEERING
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT 16 BOLT/SCREW, STEERING COLUMN GUIDE,
STEERING WHEEL 25 N•m (18 LB. FT.)
2 WHEEL ASSEMBLY, STEERING 17 GUIDE, STEERING COLUMN
3 BOLT/SCREW, STEERING WHEEL, 2.8 N•m (25 LB. IN.) 18 BOLT/SCREW, HAZARD WARNING SWITCH KNOB
4 NUT, STEERING COLUMN UPPER SUPPORT, 0.7 N•m (6 LB. IN.)
25 N•m (18 LB. FT.) 19 BUTION, HAZARD WARNING SWITCH
5 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP 20 SPRING, HAZARD WARNING SWITCH KNOB
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR 21 KNOB, HAZARD WARNING SWITCH
AND WINDSHIELD WIPER AND WINDSHIELD WASHER 22 NUT, STEERING WHEEL, 43 N•m (32 LB. FT.)
6 LEVER ASSEMBLY, STEERING COLUMN TILT WHEEL 23 SEALER, STEERING COLUMN
RELEASE 31 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
7 BOLT/SCREW, STEERING COLUMN, 10 N•m (89 LB. IN.) DIMMER SWITCH AND WINDSHIELD WIPER AND
8 BOLT/SCREW, INTERMEDIATE STEERING SHAFT, WINDSHIELD WASHER
47 N•m (35 LB. FT.) 46 MODULE ASSEMBLY, INFLATABLE RETRAINT
9 SHAFT ASSEMBLY, STEERING GEAR COUPLING STEERING WHEEL
10 BOLT/SCREW, INTERMEDIATE STEERING SHAFT,
47 N•m (35 LB. FT.)

RC0001 ·3F·F·RP

Figure 1 - Steering Column Assembly with SIR

3F-4 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
''
SEEK
PWR
PC2009-3F·F·RP
Figure 2 - Steering Wheel Assembly Controls - (Pontiac)
the storage battery assembly is disconnected. Many of the
service procedures require disconnection of the "AIR
BAG" fuse and the inflator module circuits from the
deployment loops to avoid an accidental deployment.
Disabling the SIR System
j+-.1 Remove or Disconnect
1. Turn steering wheel assembly so vehicle tire and
wheel assemblies are pointing straight ahead.
2. Turn ignition switch to "LOCK."
3. "AIR BAG" fuse from instrument panel fuse block.
4. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION 8C.
5. Connector position assurance (CPA) and yellow
two-way SIR connector at base of.steering column
assembly.
6. Instrument panel compartment door assembly. Re-
fer to SECTION 8C.
7. Connector position assurance (CPA) and yellow
two-way SIR connector located near yellow 24-way
DERM connector on instrument panel wiring har-
ness assembly:
[I] Important
• With "AIR BAG" fuse removed and ignition switch
in "RUN," "AIR BAG" warning/indicator lamp on
instrument panel cluster assembly will light. This is
normal operation and does not indicate SIR system
fault.
Enabling the SIR System
j++I Install or Connect
1. Turn ignition switch to "LOCK."
2. Yellow two-way SIR connector and connector posi-
tion assurance (CPA) located near yellow 24-way
DERM connector on instrument panel wiring har-
ness assembly.
3. Instrument panel compartment door assembly, refer
to SECTION 8C.
4. Yellow two-way SIR connector and connector posi-
tion assurance (CPA) at base of steering column as-
sembly.
5. Left-hand instrument panel sound insulator assem-
bly, refer to SECTION 8C.
6. "AIR BAG" fuse to instrument panel fuse block.
7. Turn ignition switch to "RUN" and verify "AIR
BAG" warning/indicator lamp flashes seven times
and then turns off. If" AIR BAG" warning/indicator
lamp does not respond as described, refer to
SECTION 91-A.
Live (Undeployed) Inflatable Restraint
Steering Wheel Module Assembly
Special care is necessary when handling and storing
a live (undeployed) inflatable restraint steering wheel
module assembly. The rapid gas generation produced
during deployment of the air bag could cause the inflat-
able restraint steering wheel module assembly, or another
object placed in front of it, to be thrown through the air in
the unlikely event of an accidental deployment.
CAUTION: When carrying a live inflat-
able restraint steering wheel module
assembly, make sure the bag opening
is pointed away from you. Never carry
the inflatable restraint steering wheel
module assembly by the wires or elec-
trical connector on the underside of it.
In case of an accidental deployment,
the bag will then deploy with minimal
chance of injury. When placing a live
inflatable restraint steering wheel
module assembly on a bench or other
surface, always face the bag and trim
cover up, away from the surface. Never
rest a steering column assembly on the
steering wheel assembly with the
inflatable restraint steering wheel mod-
ule assembly face down and steering
column assembly vertical. This is nec-
essary so that a free space is provided
to allow the air bag to expand in the
unlikely event of accidental deploy-
ment.
Deployed Inflatable Restraint Steering Wheel
Module Assembly
After the inflatable restraint steering wheel module
assembly has been deployed, the surface of the air bag
may contain a powdery residue. This powder consists
primarily of corn starch (used to lubricate the bag as it
inflates) and by-products of the chemical reaction.
Sodium hydroxide dust (similar to lye soap) is produced
as a by-product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric moisture
and is converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely that
sodium hydroxide will be present after deployment. As
with many service procedures, you should wear gloves
and safety glasses.
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·5

Inflatable Restraint Steering Wheel Module
Assembly Shipping Procedures
· Service personnel should refer to the latest service
bulletins for proper SIR inflatable restraint steering wheel
module assembly shipping procedures.
Inflatable Restraint Steering Wheel Module
Assembly Scrapping Procedures
During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal of
a live (undeployed) inflatable restraint steering wheel
module assembly. This information covers proper
procedures for disposing of a live inflatable restraint
steering wheel module assembly.
Before a live inflatable restraint steering wheel
module assembly can be disposed of, it must be deployed.
Live inflatable restraint steering wheel module assemblies
must not be disposed of throtlgh normal refuse channels.
CAUTION: Failure to follow proper
supplemental inflatable restraint (SIR)
inflatable restraint steering wheel mod-
ule assembly disposal procedures can
result in air bag deployment which may
cause personal injury. Undeployed
inflatable restraint steering wheel mod-
ule assemblies must not be disposed of
through normal refuse channels. The
undeployed inflatable restraint steering
wheel module assembly contains sub-
stances that can cause severe illness
or personal injury if the sealed con-
tainer is damaged during disposal. Dis-
posal in any manner inconsistent with
proper procedures may be a violation
of federal, state and/or local laws.
If a vehicle is the subject of a Product Liability
Report related to the SIR system and is subject to a
Preliminary Investigation (GM-1241 ), DO NOT
DEPLOY the inflatable restraint steering wheel module
assembly and DO NOT ALTER the SIR system in any
manner. Refer to the applicable service bulletin on SIR
IGNITION SWITCH AND DIMMER SWITCH
ASSEMBLY
Figures 3 and 4
!+-+! Remove or Disconnect
· 1. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION SC.
2. Instrument panel driver knee bolster assembly and
deflector. Refer to SECTION 8C.
3. Disable SIR system. Refer to "Disabling the SIR
System" in this section.
4. Ensure steering column lock and ignition cylinder
assembly is in "LOCK" position.
5. Steering column upper support nuts from steering
column support. Refer to "Steering Column Assem-
bly Removal" in this section.
6. Lower column assembly (15).
7. Electrical connectors from dimmer switch assembly
(25) and ignition switch (24).
8. Dimmer switch actuator rod (27).
9. Bolts/screws (28).
10. Dimmer switch assembly (25).
11. Bolt/screw (26).
12. Ignition switch actuator rod (29).
13. Ignition switch (24).
14. Automatic transmission park lock cable assembly, if
equipped. Refer to SECTION 7 A.
30
I

shipping procedures for details on handling SIR systems

involved with GM-1241. If a vehicle is the subject of a
campaign affecting inflatable restraint steering wheel
module assemblies, DO NOT DEPLOY the inflatable
. L ~,.
restraint steering wheel module assembly. Follow
instructions in the campaign service bulletin for proper
disposition of the inflatable restraint steering wheel 2 4 ~ ~
module assembly. 28 27
If an inflatable restraint steering wheel module
assembly is replaced under warranty, DO NOT DEPLOY
15 COLUMN ASSEMBLY, STEERING
the air bag. The inflatable restraint steering wheel module 24 SWITCH, IGNITION
assembly may need to be returned, undeployed, to Inland 25 SWITCH ASSEMBLY, DIMMER
Fisher Guide. Refer to procedures shown in the 26 BOLT/SCREW, IGNITION SWITCH, 2.5 N•m (22 LB. IN.)
appropriate service bulletin regarding SIR shipping 27 ROD, DIMMER SWITCH ACTUATOR
28 BOLT/SCREW, DIMMER AND IGNITION SWITCH,
procedures. 4 N•m (35 LB. IN.)
In situations which require deployment of a live 29 ROD, IGNITION SWITCH ACTUATOR
(undeployed) inflatable restraint steering wheel modute 30 JACKET, STEERING COLUMN
assembly, deployment may be accomplished inside or
PC0003-3F-F-RP
outside the vehicle. The method employed depehds upon
the final disposition of the particular vehicle. Refer to Figure 3 - Ignition Switch and Dimmer Switch Assembly
SECTION 9J.
3F-6. STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE

14. Instrument panel driver knee bolster assembly and

24
deflector. Refer to SECTION 8C.
15. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION SC.
TURN SIGNAL LEVER ASSEMBLY
Figure 5

l++I Remove or Disconnect

1. Steering column tilt wheel release lever assembly, if
A LOCK POSITION
equipped with cruise control. Refer to "Steering
24 SWITCH, IGNITION
Column Tilt Wheel Release Lever Assembly" in
PC0004-3F-F-RP
this section.
Figure 4 - Ignition Switch Adjustment 2. Access cover, if equipped with cruise control.
3. Electrical connectors, if equipped with cruise con-
trol.
1-++I Install or Connect 4. Turn signal lever assembly (5 or 31) by grasping
firmly and pulling straight out.
NOTICE: See "Notice" on page 3F-1 of this

I.
section.
Automatic transmission park lock cable assembly, if
l++l tnstall or Connect
equipped. Refer to SECTION 7 A. 1. Position tang on turn signal lever assembly (5 or 31)
to notch in column assembly ( 15).
2. Ensure ignition switch (24) is in "LOCK" position.
• Move switch slider to extreme right position
and then move slider one detent left.
[I] Important
• Be sure the wiper switch is in the "OFF" posi-
3. Ensure steering column lock and ignition cylinder tion before installing turn signal lever assem-
assembly is in "LOCK" position. bly (5 or 31).
4. Ignition switch (24) to jacket (30). 2. Turn signal lever assembly (5 or 31) to column
5. Ignition switch actuator rod (29) to ignition switch assembly (15).
(24).
6. Bolt/screw (26). [I] Important
• Be sure the turn signal lever assembly (5 or 31)
l~I Tighten is fully seated.
• Bolt/screw (26) to 2.5 N•m (22 lb. in.). 3. Electrical connectors, if equipped with cruise
control.
7. Position dimmer switch assembly (25) to ignition
4. Access cover, if equipped with cruise control.
switch (24 ).
5. Steering column tilt wheel release lever assembly, if
8. Bolts/screws (28). equipped with cruise control. Refer to "Steering
Column Tilt Wheel Release Lever Assembly" in
~ Adjust this section.
• Dimmer switch assembly (25).
HAZARD WARNING SWITCH
- Press switch mechanism slightly to insert
The hazard warning switch does not require removal
3/32-inch drill bit.
of the steering column assembly for replacement. For
- Move dimmer switch assembly (25) to service information, refer to SECTION 3F5B.
remove lash.
Hazard Warning Switch Knob
l~I Tighten Figure 6
• Bolts/screws (28) to 4 N•m (35 lb. in.).
9. Dimmer switch actuator rod (27). j++I Remove or Disconnect
I 0. Electrical connectors to dimmer switch assembly 1. Bolt/screw ( 18).
(25) and ignition switch (24 ).
2. Button ( 19), spring (20) and knob (21 ).
11. Raise column assembly ( 15).
12. Steering column upper support nuts to steering col-
umn support. Refer to "Steering Column Assembly
(-++! Install or Connect
Removal" in this section. NOTICE: See "Notice" on page 3F-1 of this
13. Enable SIR system. Refer to "Enabling the SIR section.
System" in this section. 1. Knob (21 ), spring (20) and button (19).
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·7

15

31

A WITHOUT CRUISE CONTROL

B WITH CRUISE CONTROL 5
C TANG
D NOTCH
E CONNECTOR, LEVER ASSEMBLY ELECTRICAL
F CONNECTOR, COLUMN ASSEMBLV ELECTRICAL
5 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
15 COLUMN ASSEMBLY, STEERING
31 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND WINDSHIELD WIPER AND
WINDSHIELD WASHER PC0005-3F-F-RP
Figure 5 - Turn Signal Lever Assembly

15
5
OR
31

5 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP

DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
6 LEVER ASSEMBLY, STEERING COLUMN TILT WHEEL
RELEASE
18 BOLT/SCREW, HAZARD WARNING SWITCH KNOB, 15 COLUMN ASSEMBLY, STEERING
0.7 N•m (6 LB. IN.) 31 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
19 BUTTON, HAZARD WARNING SWITCH DIMMER SWITCH AND WINDSHIELD WIPER AND
20 SPRING, HAZARD WARNING SWITCH KNOB WINDSHIELD WASHER
21 KNOB, HAZARD WARNING SWITCH
PC0006-3F·F·RP PC2007·3F-F-RP

Figure 6 - Removing Hazard Warning Switch Knob Figure 7 - Steering Column Tilt Wheel Release Lever
Assembly (Typical)

STEERING COLUMN TILT WHEEL RELEASE

LEVER ASSEMBLY
Figure 7
2. Bolt/screw (18).
!++I Remove or Disconnect
I~! Tighten • Grip tilt wheel release lever assembly (6) firmly and
• Bolt/screw (18) to 0.7 N•m (6 lb. in.). twist counterclockwise.
3F·8 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
!++I Install or Connect
• Grip tilt wheel release lever assembly (6) firmly,·and
twist clockwise.
INFLATABLE RESTRAINT STEERING
WHEEL MODULE ASSEMBLY
Figures 8 and 9
!++I Remove or Disconnect
1. Disable SIR system. Refer to "Disabling the SIR
System" in this section.
2. Loosen bolts/screws (3) from back of steering wheel
assembly (2) using number 30 TORX® driver (or
equivalent) until inflatable restraint steering wheel
module assembly (1 or 46) can be released from
steering wheel assembly (2).
3. Inflatable restraint steering wheel module assembly
( 1 or 46) from steering wheel assembly (2).
CAUTION: When carrying a live
!++I Install or Connect
inflatable restraint steering wheel
module assembly, make sure the bag
opening is pointed away from you.
Never carry the inflatable restraint
.steering wheel module assembly by the
wires or electrical connector on the
underside of it. In case of an accidental
deployment, the bag will then deploy
with minimal chance of injury. When
placing a live inflatable restraint
15
A CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 N•m (25 LB. IN.)
15 COLUMN ASSEMBLY, STEERING
32 RETAINER, INFLATABLE RESTRAINT STEERING WHEEL
MODULE WIRING HARNESS ELECTRICAL CONNECTOR
Figure 8 - Removing Inflatable Restraint Steering Wheel Module Assembly - (Chevrolet)
steering wheel module assembly on a
bench or other surface, always face the
bag and trim cover up, away from the
su.rface. Never rest a steering column
assembly on the steering wheel
assembly with the inflatable restraint
steering wheel module assembly face
down and steering column assembly
vertical. This is necessary so to that a
free space is provided to allow the air
bag to expand in the unlikely event of
accidental deployment.
4. SIR coil assembly electrical connector and retainer
(32) from inflatable restraint steering wheel module
assembly ( 1 or 46).
5. Radio control switch electrical connector from
inflatable restraint steering wheel module assembly
( 1 or 46), if equipped.
6. Horn lead from column assembly (15).
NOTICE: See "Notice" on page 3F- l of this
section.
1. Horn lead to column assembly ( 15).
2. Radio control switch electrical connector to inflat-
able restraint steering wheel module assembly (1 or
46), if equipped.
3. SIR coil assembly electrical connector and retainer
(32) to inflatable restraint steering wheel module
assembly ( 1 or 46).
!VIEWA I
PC1008-3F·F·RP
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·9

A LEAD, HORN
B CONNECTOR, RADIO ASSEMBLY ELECTRICAL
C CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 N•m (25 LB. IN.)
15 COLUMN ASSEMBLY, STEE-RING
32 RETAINER, INFLATABLE RESTRAINT STEERING WHEEL
MODULE WIRING HARNESS ELECTRICAL CONNECTOR
46 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
PC2008-3F-F-RP
Figure 9 - Removing Inflatable Restraint Steering Whe~l'Module Assembly - (Pontiac)

4. Secure SIR coil assembly electrical connector to STEERING WHEEL HORN SWITCH
steering wheel assembly (2) by inserting thick sec- ASSEMBLY
tion of wire into existing retainers.
5. Position inflatable restraint steering wheel module ·
Chevrolet
assembly (1 or 46) to steering wheel assembly (2). Figure 10
[I] Important !+·4 Remove or Disconnect
• Ensure wiring is not exposed or trapped 1. Inflatable restraint steering wheel module assembly.
between inflatable restraint steering wheel Refer to "Inflatable Restraint Steering Wheel
module assembly ( I or 46) and steering wheel Module Assembly" in this section.
assembly (2).
·2. Bolt/screw (50).
6. Bolts/screws (3 ). 3. Horn switch assembly (52) from inflatable restraint

I~! Tighten ·"' steering wheel module assembly (1).

A. Lift up on edge of module cover at horn button
• Bolts/screws (3) to 2.8 N•m (25 lb. in.). to access horn switches.
7. Enable SIR system. Refer to "Enabling the SIR B. Press lock tang.
System" in this section. C. Remove horn switch.
3F·10 STEERING WHEEL AND COLUMN ON·VEHICLE SERVICE
D. Repeat for remaining horn switch and remove
horn switch assembly (52).
1-++I Install or Connect
NOTICE: See "Notice" on page 3F- l of this sec-
tion.
I. Horn switch assembly (52) to inflatable restraint
steering wheel module assembly (I).
A. Lift up on edge of module cover at horn button.
B. InstaJJ horn switch assembly (52).
C. Repeat for remaining horn switch assembly
(52).
2. Bolt/screw (50).
l~I Tighten
• Bolt/screw (50) to 1.9 N•m (17 lb. in.).
3. Inflatable restraint steering wheel moduJe assembly.
Refer to "Inflatable Restraint Steering Wheel Mod-
ule Assembly" in this section.
STEERING WHEEL HORN SWITCH
CONTACT PLATE ASSEMBLY
Pontiac
Figure 11
l+-+I Remove or Disconnect.
I. Inflatable restraint steering wheel_ module assembly.
Refer to "Inflatable Restraint Steering Wheel Mod-
ule Assembly" in this section.
2. Bolts/screws (37 and 38 or 45).
3. Horn switch contact plate assembly (40 or 44) from
inflatable restraint steering wheel module assembly
( I or 46). ··
!-++I Install or Connect
NOTICE: See "Notice" on pag·e 3F-l of this sec-
tion.
I. Position horn switch plate assembly (40 or 44) to
inflatable restraint steering wheel module assembly
( 1 or 46).
2. Bolts/screws (37 and 38 or 45).
l~ITighten
• Bolts/screws (37) to 2.8 N•m (25 lb. in.).
• Bolts/screws (38) to 1.9 N•m (17 lb. in.).
• Bolts/screws (45) to 2.8 N•m (25 lb. in.).
3. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel Mod-
ule Assembly" in this section.
STEERING WHEEL ASSEMBLY
Figure 12
Tools Required:
A CONNECTOR, SIR COIL ~SSEMBLY ELECTRICAL
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 N•m (25 LB. IN.)
15 COLUMN ASSEMBLY, STEERING
22 NUT, STEERING WHEEL, 43 N•m (32 LB. FT.)
50 BOLT/SCREW, STEERING WHEEL, 1.9 N•m (17 LB. IN.)
51 NUT, STEERING WHEEL
52 SWITCH ASSEMBLY, STEERING WHEEL HORN
RCt001·3F-F-RP
Figure 1O- Steering Wheel Horn. Switch Assembly -
(Chevrolet)
' J 1859-A Steer'ing Wheel Puller
J 38720 Steering Wheel Puller Bolts (Part of
J 1859-A)
!+-+! Remove or Disconnect
I. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel
Module Assembly" in this section.
2. Nut (22).
NOTICE: When removing the steering wheel
assembly, use only the specified steering wheel
puller. Under no conditions should the end of the
steering column shaft be hammered on, as
hammering could loosen the plastic injections which
maintain steering column assembly rigidity.
NOTICE: When attaching J 1859-A and J 38720 to
the steering wheel assembly, use care to prevent
threading J 38720 (bolts) all the way through the
steering wheel hub into the SIR coil assembly and
damaging the SIR coil assembly.
3. Horn lead.
4. Steering wheel assembly (2), using J 1859-A and
J 38720.
5. Steering wheel horn switch contact plate assembly
(Pontiac only). See "Steering Wheel Horn Switch
Contact Plate Assembly" in this section.

3---@,l,,
41 44
A WITH RADIO CONTROL SWITCH ASSEMBLY
B WITHOUT RADIO CONTROL SWITCH ASSEMBLY
C CONNECTOR, RADIO CONTROL SWITCH ELECTRICAL
D CONTACT, STEERING WHEEL HORN
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 N•m (25 LB. IN.)
37 BOLT/SCREW, STEERING WHEEL HORN SWITCH
CONTACT PLATE SHOULDER, 2.8 N•m (25 LB. IN.)
38 BOLT/SCREW, RADIO CONTROL SWITCH,
1.9 N•m (17 LB. IN.)
39 SWITCH ASSEMBLY, RADIO CONTROL
Figure 11 - Steering Wheel Horn Switch Contact Plate Assembly and Radio Control Switch Assembly - (Pontiac)
!++! Install or Connect
NOTICE: See "Notice" on page 3F-1 of this
section.
I. Route SIR coil assembly electrical connector to
steering wheel assembly (2).
2. Steering wheel horn switch contact plate assembly
(Pontiac only). See "Steering Wheel Horn Switch
Contact Plate Assembly" in this section.
3. Steering wheel assembly (2).
rn Important
t Align block tooth on steering wheel assembly
(2) with block tooth on steering column shaft
within one female serration.
4. Hom lead.
5. Nut (22).
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F-11
40
39
~ ~ ~ D : : : : : __ _ C
A
46
40 PLATE ASSEMBLY, STEERING WHEEL HORN SWITCH
CONTACT
41 NUT, STEERING WHEEL
42 FILLER, INFLATABLE RESTRAINT STEERING WHEEL
TRIM
43 BOLT/SCREW, INFLATABLE RESTRAINT STEERING
• WHEEL MOUNTING PLATE, 1.9 N•m (17 LB. IN.)
44 PLATE ASSEMBLY, STEERING WHEEL HORN SWITCH
CONTACT
45 BOLT/SCREW, STEERING WHEEL HORN SWITCH
CONTACT PLATE SHOULDER, 2.8 N•m (25 LB. IN.)
46 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
PC2014-3F-F-RP
I~! Tighten .
• Nut (22) to 43 N•m (32 lb. ft.).
6. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel
Module Assembly" in this section.
RADIO CONTROL SWITCH ASSEMBLY
Pontiac
Figure 11
!++! Remove or Disconnect
I. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel Mod-
ule Assembly" in this section.
2. Steering wheel horn switch contact plate assembly
from inflatable restraint steering wheel module
3F-12 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
A CONNECTOR, RADIO ASSEMBLY ELECTRICAL
(PONTIAC ONLY)
B CONNECTOR, SIR COIL ASSEMBLY, ELECTRICAL
C LEAD, HORN
2 WHEEL ASSEMBLY, STEERING
5 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
Figure 12 - Steering Wheel Assembly
assembly. See "Steering Wheel Horn Switch Con-
tact Plate Assembly" in this section.
3. Radio control switch assembly (39) from inflatable
restraint steering wheel module assembly (I).
!++-! Install or Connect
1. Radio control switch assembly (39) to inflatable
restraint steering wheel module assembly ( 1).
2. Steering wheel horn switch contact plate assembly
to inflatable restraint steering wheel module assem-
bly. See "Steering Wheel Horn Switch Contact Plate
Assembly" in this section.
!++-I Install or Connect
3. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel Mod-
ule Assembly" in this section.
STEERING GEAR COUPLING SHAFT
ASSEMBLY
Figure 13
!+-+I Remove or Disconnect
NOTICE: Ensure the tire and wheel assemblies are
pointing straight ahead and the steering wheel
assembly is locked. Failure to do so may cause the
steering wheel assembly to rotate, causing damage
to the SIR coil assembly.
6 LEVER ASSEMBLY, STEERING COLUMN TILT WHEEL
RELEASE
15 COLUMN ASSEMBLY, STEERING
22 NUT, STEERING WHEEL, 43 N•m (32 LB. FT.)
31 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND WINDSHIELD WIPER AND
WINDSHIELD WASHER
RC0003·3f·F·RP
I. Bolt/screw (10) from gear assembly (33).
2. Clamp ( 11) from boot ( 12).
3. Shaft assembly (9) from gear assembly (33).
4. Boot (12) from shaft assembly (9).
5. Shield (13) from shaft assembly (9) and column
assembly ( 15) on 5.7L LTl engine only.
6. Bolt/screw (8) from column assembly ( 15).
7. Shaft assembly (9) from column assembly (15).
NOTICE: See "Notice" on page 3F-l of this
section.
1. Position shaft assembly (9) to column assembly
(15).
2. Bolt/screw (8)
l~I Tighten
• Bolt/screw (8) to 47 N•m (35 lb. ft.).
3. Position boot (12) to shaft assembly (9) and secure
with clamp (11). Do not close clamp (11).
4. Position shaft assembly (9) to body rail.
5. Remove clamp (11) from boot (12) and place over
steering gear assembly casting.
6. Position shaft assembly (9) to gear assembly (33).
7. Bolt/screw (10).
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F-13

11

A BUTTON, STEERING GEAR COUPLING HEAT SHIELD

B CASTING, STEERING GEAR ASSEMBLY
8 BOLT/SCREW, INTERMEDIATE STEERING SHAFT,
47 N•m (35 LB. FT.)
9 SHAFT ASSEMBLY, STEERING GEAR COUPLING
10 BOLT/SCREW, INTERMEDIATE STEERING SHAFT,
47 N•m (35 LB. FT.)
11 CLAMP, STEERING GEAR COUPLING SHIELD
12 BOOT, STEERING GEAR
13 SHIELD, STEERING GEAR COUPLING HEAT
14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
15 COLUMN ASSEMBLY, STEERING
33 GEAR ASSEMBLY, STEERING
34 CROSSMEMBER ASSEMBLY, FRONT
35 ARM ASSEMBLY, FRONT LOWER CONTROL

PC0011 ·3F·F·RP

Figure 13 - Steering Gear Coupling Shaft Assembly

3F·l4 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
l~I Tighten
• Bolt/screw (10) to 47 N•m (35 lb. ft.).
8. Position shield (13) to shaft assembly (9) and col-
umn assembly (15) on 5.7L LTl engine only.
9. Shield (13) by inse11ing button into hole in column
assembly (15) on 5.7L LTl engine only.
STEERING COLUMN ASSEMBLY REMOVAL
Figures 14 and 15
NOTICE: The tire and wheel assemblies must be
straight ahead and the steering column assembly
locked before disconnecting the steering column
assembly or steering gear coupling shaft assembly
from the steering gear assembly. Failure to do so will
cause the SIR coil assembly to become uncentered,
which will cause damage to the SIR coil assembly.
NOTICE: When the steering column assembly is
removed from the vehicle, it is extremely
susceptible to damage. Dropping the column
asi>embly on its end could collapse the steering shaft
assembly or loosen plastic injections that keep the
column assembly rigid. Leaning on the column
assembly could cause steering column jacket to bend
or deform. Any of the above conditions could impair
column assembly's collapsible design. If the
steering wheel assembly must be removed, use only
the specified steering wheel puller and steering
A NUT, WELD
4 NUT, STEERING COLUMN UPPER SUPPORT,
25 N•m (18 LB. FT.)
7 BOLT/SCREW, STEERING COLUMN, 10 N•m (89 LB. IN.)
14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
15 COLUMN ASSEMBLY, STEERING
17 GUIDE, STEERING COLUMN
36 WASHER, STEERING COLUMN
Figure 14 - Removing Steering Column Assembly
wheel puller bolts. Never hammer on the end of the
steering shaft because hammering could loosen
plastic injections that keep the column assembly
rigid.
!+-+I Remove or Disconnect
1. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION 8C.
2. Instrument panel driver knee bolster assembly and
deflector. Refer to SECTION 8C.
3. Disable SIR system. Refer to "Disabling the SIR
System" in this section.
4. Steering wheel assembly, if column assembly is to
be replaced. Refer to "Steering Wheel Assembly"
in this section.
5. Intermediate steering shaft bolt/screw from steering
gear coupling shaft assembly and column assembly.
Refer to "Steering Gear Coupling Shaft Assembly"
in this section.
6. Bolts/screws (7) attaching cover assembly (14) to
dash panel assembly.
7. Cover assembly (14) from dash panel assembly.
8. Electrical connectors.
9. Nuts (4) from steering column support.
10. Automatic transmission park lock cable assembly
from ignition switch, if equipped. Refer to SEC-
TION 7A.
11. Column assembly ( 15) from vehicle.
14
PC0012·3f..F·RP
 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F·15

3. Nuts (4) to steering column support.

B c
l~I Tighten
• Nuts (4) to 25 N•m (18 lb. ft.).
4. Intermediate steering shaft bolt/screw to steering
gear coupling shaft assembly. Refer to "Steering
Gear Coupling Shaft Assembly" in this section.

rn Important
• When installing the cover assembly (14) to the
dash panel assembly, the lower bolt/screw (7)
A LOWER
must be installed first followed in order by the
B OUTBOARD outboard bolt/screw (7) and inboard bolt/screw
C INBOARD (7). Refer to Figure 15.
14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
5. Position cover assembly (14) to dash panel assem-
PC0013-3F-F-RP bly.
Figure 15 - Steering Column BolVScrew Installation
Sequence 6. Bolts/screws (7).

!++! Install or Connect l~I Tighten

NOTICE: If a service replacement steering column
assembly is being installed, do not remove the anti-
rotation pin until after the column assembly has been
connected to the steering gear assembly. Removing
the antirotation pin before the column assembly is
connected to the steering gear assembly may
damage the SIR coil assembly.
NOTICE: See "Notice" on page 3F-1 of this
section.
I. Position column assembly ( 15) into vehicle.
2. Automatic transmission park lock cable assembly to
ignition switch, if equipped. Refer to SECTION 7A.
• Bolts/screws (7) to 10 N•m (89 lb. in.).
7. Electrical connectors.
8. Steering wheel assembly, if column assembly is re-
placed. Refer to "Steering Wheel Assembly" in this
section.
9. Enable SIR system. Refer to "Enabling the SIR Sys-
tem" in this section.
10. Instrument panel driver knee bolster assembly and
deflector. Refer to SECTION 8C.
11. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION 8C.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Dimmer and Ignition Switch Bolt/Screw .................................. 4 N•m (35 lb. in.)
Hazard Warning Switch Knob Bolt/Screw ................................ 0.7 N•m (6 lb. in.)
Ignition Switch Bolt/Screw ........................................... 2.5 N•m (22 lb. in.)
Inflatable Restraint Steering Wheel Mounting Plate
Bolt/Screw (Pontiac Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Intermediate Steering Shaft-to-Steering Column Assembly Bolt/Screw ......... 47 N•m (35 lb. ft.)
Intermediate Steering Shaft-to-Steering Gear Assembly Bolt/Screw ............ 47 N•m (35 lb. ft.)
Radio Control Switch Bolt/Screw (Pontiac Only) . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Steering Column Bolt/Screw .......................................... 10 N•m (89 lb. in.)
Steering Column Guide Bolt/Screw ..................................... 25 N•m (18 lb. ft.)
Steering Column Upper Support Nut .................................... 25 N•m (18 lb. ft.)
Steering Wheel Bolt/Screw (Pontiac Only) .............................. 2.8 N•m (25 lb. in.)
Steering Wheel Horn Switch Contact Plate Shoulder
Bolt/Screw (Pontiac Only) ......................................... 2.8 N•m (25 lb. in.)
Steering Wheel Nut .................................................. 43 N•m (32 lb. ft.)
Steering Wheel-to-Inflatable Restraint Steering Wheel Module Assembly
Bolt/Screw (Chevrolet Only) ....................................... 2.8 N•m (25 lb. in.)
Steering Wheel-to-Steering Wheel Horn Switch Assembly
Bolt/Screw (Chevrolet Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
3F-16 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE

SPECIAL TOOLS

~001111111111111101111
J 1859-A J 38720
~10111111111111111111111

Q STEERING WHEEL PULLER

0 STEERING WHEEL PULLER BOLTS (PART OF J 1859-A)

NC1003-3F·B·RP
 TILT STAG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·1

SECTION 3F5B

SUPPLEMENTAL INFLATABLE RESTRAINT

{SIR) TILT STEERING COLUMN
FLOOR SHIFT
UNIT REPAIR
CAUTION: The procedures in this section must be followed In the order listed to temporarily disable
the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic codes from setting.
Failure to follow procedures could result in possible air bag deployment, personal injury, or
otherwise unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily
come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to
help prevent personal injury and/or damage to the vehicle or components. Unless instructed
otherwise, the ignition switch must be in the "off" or "lock" position.

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

CONTENTS
Steering Column, Parts . . . . . . . . . . . . . . . . . 3F5B-2 Sub Section C - Mid Column ............ 3F5B-ll
Sub Section A - Upper Column . . . . . . . . . . . 3F5B-4 Steering Column Housing Assembly
Disabling The SIR System Steering Wheel Lock Shoe
Enabling The SIR System Switch Actuator Sector
Intl Restraint Coil Assembly Switch Actuator Rack
Shaft Lock Bearing Assembly
Turn Signal Cancelling Cam Asm Lock Bolt
Upper Bearing Spring Strg Column Housing Support Asm
Upper Bearing Inner Race Seat Steering Shaft Assembly
Inner Race Sub Section D - Lower Column . . . . . . . . . . 3F5B-15
Turn Signal Switch Assembly Dimmer Switch Assembly
Buzzer Switch Assembly Dimmer Switch Adjustment
Strg Col Pass Key Lock Cylinder Set Ignition Switch Assembly
Centering Intl Restraint Coil Ignition Switch Adjustment
Sub Section B - Housing Cover . . . . . . . . . . . 3F5B-9 Adapter & Bearing Assembly
Lock Housing Cover Assembly Accident Damage ..................... 3F5B-18
Col Hsg Cover End Cap Specifications ....................... 3F5B-18
Pivot & (Pulse) Switch Assembly Fastener Torques .................. 3F5B-18
Dimmer Switch Rod Actuator Special Tools. . . . . . . . . . . . . . . . . . . . . . . . 3F5B-19
Tilt Spring Assembly
3F5B·2
_ _;__:_.:=.!..~~C~OL~UUNNIT
TILT STRG REPAIR {SIR,FLR SHFT)

C93F02-0

Figure 1 - Tilt Steenng

. Column
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·3

1- NUT, HEX LOCKING (M14x1 .5) 50- GUIDE, SPRING

2- RING, RETAINING 51- SPRING, WHEEL TILT
3- COIL ASM, INFL RESTRAINT 52- RETAINER, SPRING
4- WASHER, WAVE 55- SHAFT ASM, STEERING COLUMN
5- RING, RETAINING 56- SHAFT .ASM, RACE & UPPER
6- LOCK, SHAFT 57- SPHERE, CENTERING
7- CAM ASM, TURN SIG CANCEL 58- SPRING, JOINT PRELOAD
8- SPRING, UPPER BEARING 59- SHAFT ASM, LOWER STEERING
9- SCREW, BNDG HD CR RECESS 61- SCREW, SUPPORT
10-SCREW, RD WASH HD (M4.2x1.41) 62- SUPPORT ASM, STAG COL HSG
11-ARM ASM, SIGNAL SWITCH 71- SHROUD, STAG COLUMN HOUSING
12- SWITCH ASM, TURN SIGNAL 72- JACKET ASM, STAG COL
13-SEAT, UPPER BRG INNER RACE 76- ACTUATOR ASM, IGNITION SWITCH
14- RACE, INNER 77- ROD, DIMMER SWITCH
15-SCREW, PAN HD SOC TAP 78- SCREW, WASH HD (#10-24X.25)
16- SWITCH ASM, BUZZER 79- SCREW, HEX WASH HD TAP
18-SCREW, LOCK RETAINING 80- SWITCH ASM, IGNITION
19- COVER ASM, LOCK HOUSING 82- SCREW, FLT HD (#10-24X.31)
20- LOCK CYLINDER SET, STRG COL 83- SWITCH ASM, DIMMER
PASS KEY 86- ADAPTER, LOWER BEARING
21-ACTUATOR, DIMMER SW ROD 87- BEARING ASM
22- PIN, SWITCH ACTUATOR PIVOT 88- RETAINER, BEARING ADAPTER
23- SWITCH ASM, PIVOT & (PULSE) 89- CLIP, LOWER BEARING ADAPTER
24- BASE PLATE, COL HSG CVR END
25- CAP, COL HSG COVER END Service Kits
26- PROTECTOR, WIRING
27- SHROUD, CONNECTOR 201- RACK SERV KIT, COL SECTOR &
30- HOUSING ASM, STRG COLUMN -INCLUDES: 14,31,33,44,47,48
31-BEARING ASM 202- SPRING SERV KIT, TILT COLUMN
32- BOLT, LOCK -INCLUDES: 13, 14,39,50,51,52
33- SPRING, LOCK BOLT 203- COIL SERV KIT, INFL RESTRAINT
34- SHOE, STEERING WHEEL LOCK -INCLUDES: 3,4,27
35- SHOE, STEERING WHEEL LOCK 204- SPHERE SERV KIT, TILT COLUMN
36- SHIELD, WIRE PROTECTOR -INCLUDES: 57,58
37- SHAFT, DRIVE 205- GREASE SERV KIT, (SYNTHETIC)
38- PIN, DOWEL
39- PIN, PIVOT
40- SPRING, SHOE
41- SPRING, RELEASE LEVER
42- PIN, RELEASE LEVER
43- LEVER, SHOE RELEASE
44- RACK, SWITCH ACTUATOR
45- SPRING, RACK PRELOAD
46- HOUSING, STRG COLUMN
47- SECTOR, SWITCH ACTUATOR
48- SCREW. HEX WASHER HEAD
Figure 2 - Tilt Steering Column - Legend
3F5B-4 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

SUB SECTION A· UPPER COLUMN ENABLING THE SIR SYSTEM

INCLUDES: I-++! Install or Connect
DISABLING THE SIR SYSTEM
ENABLING THE SIR SYSTEM • Tum ignition switch to "LOCK" and remove key.
INFL RESTRAINT COIL ASSEMBLY
SHAFT LOCK 1. Yellow 2-way SIR connector and CPA retainer
TURN SIGNAL CANCELLING CAM ASM
UPPER BEARING SPRING located near the yellow 24-way DERM harness
UPPER BEARING INNER RACE SEAT connector.
INNER RACE 2. 1/P compartment door assembly, refer to SECTION
TURN SIGNAL SWITCH ASSEMBLY SC.
BUZZER SWITCH ASSEMBLY 3. Yellow 2-way SIR connector and CPA retainer at
STRG COL PASS KEY LOCK CYL SET base of steering column.
CENTERING INFL RESTRAINT COIL 4. Lower sound insulatorpanel-LH, refer to SECTION
SC.
Tools Req11ired: 5. "AIR BAG" fuse to I/P fuse block.
J 23653-C Lock Plate Compressor
• Tum ignition switch to "RUN" and verify that
SERVICE PRECAUTIONS the "AIR BAG" warning lamp flashes 7 times
and then turns ."OFF". If it does not operate as
CAUTION: When performing service on or described, perform the "SIR Diagnostic System
around SIR components or SIR wiring, follow Check" in SECTION 9J-A.
the procedures listed below to temporarily
disable the SIR system. Failure to follow [I] Important
procedures could result In possible air bag
deployment, personal Injury or otherwise • Before doing any service procedures in this section,
unneeded SIR system repairs. disabling the SIR system and removal of Inflator
The DERM can maintain sufficient voltage to Module and Steering Wheel is needed. Columns
cause a deployment for up to 2 minutes after the equipped with Supplemental Inflatable Restraint
ignition switch is turned "OFF" or the battery is (SIR) and Redundant Steering Wheel Control
disconnected. Many of the service procedures require (RSWC) will have Inflatable Restraint coils with
disconnection of the "AIR BAG" fuse and the inflator two wire leads. (SIR) wire leads are yellow with a
module circuits from the deployment loops to avoid an yellow connector shroud. (RSWC) wire leads are
grey with black connectors. (Refer to "Disabling
accidental deployment. the SIR System" in this section and service
procedures in section 3F).
DISABLING THE SIR SYSTEM
l+-+I Remove or Disconnect I+-+! Remove or Disconnect
Figures 1 through 9 and 13
• Tum the steering wheel so that the vehicle's
wheels are pointing straight ahead. NOTICE: Place ignition to "LOCK" position to prevent
• Tum the ignition switch to "LOCK" and remove uncentering coil assembly (3).
key. 1. Disable the SIR system; Refer to "Disabling the
1. "AIR BAG" fuse from I/P fuse block. SIR System" in this Section.
2. Lowersondinsulatorpanel-LH. Refer to SECTION 2. Negative (-) battery cable.
SC.
3. Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector at base of steering
column.
4. I/P compartment door assembly, refer to SECTION SC.
5. Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector located near the yellow

rn
•
24-way DERM harness connector.
Important
With the "AIR BAG" fuse removed and ignition
2 RING, RETAINING
3 COIL ASM, INFL RESTRAINT
switch "ON", the "AIR BAG" warning lamp will be 4 WASHER, WAVE
"ON". This is normal operation and does not indicate
Figure 3 - Removing Coil Assembly Off Shaft
an SIR system malfunction.
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3FSB·5

3. Coil assembly retaining ring (2).

4. Inflatable restraint coil assembly (3).
• Let switch hang freely ifremoval is not needed. 10
• To remove coil (3), do steps 5 through 17 in this
section.

5. Wave washer (4). 12

6. Shaft lock retaining ring (5) using J 23653-C to push
down shaft lock (6). MULTI·
• Dispose of ring (5). FUNCTION
LEVER 9
7. Shaft lock (6).
8. Turn signal cancelling cam assembly (7). 9 SCREW, BINDING HD CROSS RECESS
10 SCREW, RD WASH HD (M4.2X1 .41)
9. Upper bearing spring (8). 11 ARM ASM, SIGNAL SWITCH
12 SWITCH ASM, TURN SIGNAL
Figure 6 - Turn Signal Switch Removal Preparation

EXTRA 16. Turn signal switch assembly (12).

RETAINING
RINGS
• Let switch hang freely if removal is not needed.
• To remove switch (12): ·

A. Turn signal switch connector from bulkhead

J 23653-C connector.
5 RING, RETAINING B. Wiring protector (26).
6 LOCK, SHAFT C. Gently pull wire harness through column.
Figure 4 - Removing Shaft Lock Retaining Ring

14

~
13·~~

8
7
.
6 LOCK, SHAFT
7 CAM ASM, TURN SIG CANCELLING
8 SPRING, UPPER BEARING
13 SEAT, UPPER BEARING INNER RACE
14 RACE, INNER
TURN SIGNAL
Figure 5 - Removing Components from Upper Shaft SWITCH CONNECTOR
26 PROTECTOR, WIRING

10. Upper bearing inner race seat (13).
11. Inner race (14).
12. Tum signal to "RIGHT TURN" position (up).
13. Multi-function lever and hazard knob assembly.
(See Section 3F)
14. Screw (10) and signal switch arm (11).
15. Tum signal switch screws (9).
Figure 7 - Removing Turn Signal Switch
NOTICE: Coil assembly (3) will become uncentered if:
1) Steering column is separated from steering gear
and is allowed to rotate, or
2) Centering spring is pushed down, letting hub
rotate while coil (3) is removed from steering
column. (If this occurs, see Figure 13)
3F5B·6 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

21. Lock retaining screw (18).

22. Pass key lock cylinder (20) and harness.
• To remove lock cylinder (20):

A. Terminal connector from bulkhead

connector.
B. Wiring protector (26).
26 C. Attach a length of mechanics wire to
terminal to aid in reassembly.
GREY (RSWC) WIRE LEAD D. Retaining clip from housing cover (19)
and gently pull wire harness through
BLACK (RSWC) CONNECTOR
column.
BLACK TERMINAL CONNECTOR

26 PROTECTOR, WIRING
27 SHROUD, CONNECTOR

Figure 8 - Removing Coil Assembly Switch

!-++! Install or Connect
Figures 1, 1othrough 15 and 26

NOTICE: See "Notice" on page 3F5B-1 of this section.

17. lnflatablerestraintcoilassembly(3)withwireharness
from column assembly.
NOTICE: Ensure all fasteners are securely seated before
A. Wiring protector (26).
applying needed torque. Failure to do may result in
B. Attach two lengths of mechanics wire to
component damage or malfunctioning of steering column.
coil terminal connectors to aid in
reassembly.
C. Gently pull wires through column.
NOTICE: Route wire from pass key lock cylinder as
shown _and snap retaining clip into hole in housing (19).
(See Figures 10 and 11) Failure to do so may result in
component damage of malfunction of pass key lock
cylinder.

16 SWITCH ASM, BUZZER

Figure 9 - Removing Buzzer Switch RETAINING

CLIP

WIRE
18 SCREW, LOCK RETAINING HARNESS
20 LOCK CYLINDER SET, STRG COL
18. Key from pass key lock cylinder set (20). (PASS KEY)
19. Buzzer switch assembly (16).
Figure 10 - Installing Pass Key Lock Cylinder Set
20. Reinsert key in pass key lock cylinder (20).
• Key in "LOCK'' position.
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·7

RETAINING
CLIP
WIRE
HARNESS
INFL RESTRAINT COIL ASM AND
20 LOCK CYLINDER SET, STRG COL TURN SIGNAL SWITCH WIRE HARNESSES
(PASS KEY) THROUGH HERE. 5 O'CLOCK POSITION.
Figure 11 - Routing Pass Key Wire Harness Figure 12 - Wire Harnesses through Column

8. Tum signal switch assembly (12) and screws (9).

1. Pass key lock cylinder (20).

l~!Tighten
A. Wire terminal through column and snap
retaining clip into hole in housing.
B. Lock cylinder (20) connector to vehicle wire • Tighten screws (9) to 3.4 N·m (30 lb.in.).
harness.
9. Signal switch arm (11) with screw (10).

2. Lock retaining screw (18). !~!Tighten

• Tighten screw (10) to 2.3 N·m (20 lb.in.).

!~!Tighten
• Tighten screw (18) to 2.5 N·m (22 lb.in.).
3. Key from pass key lock cylinder set (20).
4. Buzzer switch assembly (16).
5. Reinstall key in pass key lock cylinder set (20).
• Key in "OFF-LOCK" position.
6. Tum signal switch assembly (12) wire harness
through steering column.
A. Let switch hang freely.
B. Switch connector to bulkhead connector.
7. Coil assembly (3) wire harness through column.
• Let coil hang freely.
10. Hazard knob assembly and multi-function lever.
(See Section 3F)
11. Inner race (14).
12. Upper bearing inner race seat (13).
13. Upper bearing spring (8).
14. Tum signal cancelling cam assembly (7).
• Lubricate with grease, synthetic (service kit).
15. Shaft lock (6).
16. New shaft lock retaining ring (5) using J 23653-C to
push down shaft lock (6).
• Ring (5) must be firmly seated in groove on
shaft.
NOTICE: Set steering shaft so that block tooth on upper
steering shaft (56) is at the 12 o'clock position, wheels on
vehicle should be straight ahead, then set ignition switch
to "LOCK" position, to ensure no damage to coil assembly
(3). (See Figure 26 for steering shaft orientation)
17. Wave washer (4).
3F5B·8 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

NOTICE: Coil assembly (3) will become uncentered if:

6 3

1) Steering column is separated from steering gear

and is allowed to rotate, or --=-
2) Centering spring is pushed down, letting hub
rotate while coil is removed from column. (If
this occurs, see Figure 13)
KEEP LOWER WIRES TIGHT WHILE
SEATING SIR COIL ASM HEAD IN
STEERING COLUMN.

3 COIL ASM, INFL RESTRAINT

6 LOCK, SHAFT
STYLE
A LOCKING Figure 14 -Routing Coil Assembly Wires
TAB

SPRING
LOCK NOTICE: Sir coil assembly wires must be kept tight with
no slack while installing SIR coil assembly. Failure to do
so may cause wires to be kinked near shaft lock area and
COIL cut when steering wheel is turned.
HUB

18. Ensure coil assembly (3) hub is centered.

19. Coil assembly (3).
STYLE A. Pull wires tight while positioning SIR coil to
B steering shaft.
LOCKING
TAB
B. Align opening in coil with horn tower and
SPRING
"locating bump" between two tabs on housing
LOCK cover.
C. Seat coil assembly into steering column.

COIL
HUB PROJECTIONS ON
HOUSING COVER
USED FOR ALIGNMENT
PERFORM THE FOLLOWING STEPS TO CENTER COIL ASSEMBLY OF COIL ASSEMBLY
A WHEELS STRAIGHT AHEAD. INSTALL COIL
B REMOVE COIL ASSEMBLY. ASS EMBLY OVER
C HOLD COIL ASSEMBLY WITH CLEAR BOTTOM UP TO SEE COIL SHAFT AND
RIBBON. HORN TOWER.
D NOTE: THERE ARE TWO DIFFERENT STYLES OF COILS. ONE
ROTATES CLOCKWISE AND THE OTHER ROTATES COUNTER·
CLOCKWISE.
E WHILE HOLDING COIL ASSEMBLY, DEPRESS SPRING LOCK TO 2 RING, RETAINING
ROTATE HUB IN DIRECTION OF ARROW UNTIL IT STOPS. 3 COIL ASSEMBLY
F THE COIL RIBBON SHOULD BE WOUND UP SNUG AGAINST 7 CAM ASM, TURN SIG CANCEL
CENTER HUB.
G ROTATE COIL HUB IN OPPOSITE DIRECTION APPROXIMATELY Figure 15 - Coil Assembly Installed
TWO AND A HALF (2·1/2) TURNS. RELEASE SPRING LOCK
BETWEEN LOCKING TABS IN FRONT OF ARROW.
Figure 13 - Centering Coil Assembly 20. Coil assembly retaining ring (2).
• Ring (2) must be firmly seated in groove on
shaft.

NOTICE: If a new coil assembly (3) is being installed, NOTICE: Gently pull lower coil assembly, tum signal,
assemble pre-centered coil assembly (3) to steering column. pass key,and pivot & (pulse) wires to remove any wire
Remove centering tab and dispose. (See Figure 13) kinks that may be inside steering column assembly.
Failure to do so may cause damage to wire harness.
 TILT STAG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·9

21. Wiring protector (26).

22. Refer to Section 3F to complete remaining steering
column assembly.
23. Negative(-) battery cable.
24. If all service operations are completed, enable the
SIR system; refer to "Enabling the SIR System" in
this Section.

CRUISE CONTROL
WIRE CONNECTIONS
24 BASE PLATE, COL HSG CVR END
SUB SECTION B • HOUSING COVER Figure 16 - Cruise Control Equipped
Figures 1,2, 16 through 20 Steering Columns

INCLUDES:
LOCK HOUSING COVER ASS EMBLY
rn Important
. COL HSG COVER END CAP
. PIVOT & (PULSE} SWITCH ASSEMBLY • Remove cruise control and multi-function lever
connectors from base plate (24) and disconnect.
DIMMER SWITCH ROD ACTUATOR
• Remove multi-function lever. (See Section 3F)
TILT SPRING ASSEMBLY

Tools Required: 15 12 O'CLOCK

J 23653-C Lock Plate Compressor

I~ ! Important
• Before doing any service procedures in this section,
removal of Inflator Module and Steering Wheel is 15 SCREW, PAN HD SOC TAP
needed. (Refer to service procedures in Section 3F) Figure 17 - Lock Housing Cover Screw Positions

(I]

•
Important

Remove only those components necessary to do

:1
repairs. 77 ;~

24~ ........~
CRUISE
25
I+..! Remove or Disconnect 19 COVER ASM, LOCK HOUSING
\ CONTROL
PLUG
21 ACTUATOR, DIMMER SW ROD
24 BASE PLATE, COL HSG CVR END
1. Do all steps, "Remove or Disconnect", Sub Section A. 25 CAP, COL HSG COVER END
2. Housing cover end cap (25). 77 ROD, DIMMER SWITCH
Figure 18 - Removing Lock Housing Cover
3F5B·10 TILT STRG COL UNIT REPAIR (SIR,FLR SHFn

3.
4.
Cover screws (15).
Tilt lever. (See Section 3F)
I-++! Install or Connect
5. Lock housing cover assembly (19).
6. Base plate (24) and dimmer switch rod actuator NOTICE: See "Notice" on page 3F5B-1 of this section.
(21).
7. Wire protector shield (36). NOTICE: Ensure all fasteners are securely seated before
applying needed torque. Failure to do so may result in
component damage or malfunctioning of steering column.
19

1. Spring guide (50) and spring (51).

• Lubricate with lithium grease.

2. Spring retainer (52).

• Using a cross recess screwdriver push retainer
C C 0 - - - - CRUISE
CONTROL down and turn clockwise to lock in place.
CONNECTOR
19 COVER ASM, LOCK HOUSING
22 PIN, SWITCH ACTUATOR PIVOT 3. Pivot & (pulse) switch assembly (23) to lockhousing
23 SWITCH ASM, PIVOT & (PULSE) cover assembly (19).
Figure 19 - Removing Pivot & (Pulse) Switch 4. Switch actuator pivot pin (22) to switch (23) and
cover (19).
5. Pivot & (pulse) switch wire harness through steering
column.
• Switch connector to bulkhead connector.
• Wire protector shield (36).

6. Dimmer switch rod actuator (21) to base plate (24).

• Lubricate with lithium grease.

50 GUIDE, SPRING
7. Base plate (24) to lock housing cover assembly (19).
51 SPRING, WHEEL TILT • Bottom edge of dimmer switch rod actuator
52 RETAINER, SPRING (21) must rest on bend in dimmer switch rod
Figure 20 - Removing Tilt Spring Assembly (77).

8. Lock housing cover assembly (19).

8. Switch actuator pivot pin (22). 9. Screws (15). Tighten screw in 12 o'clock position
9. Pivot & (pulse) switch assembly (23). first, screw in 8 o'clock position second, and screw
in 3 o'clock position third.
• Let switch hang freely ifremoval is not needed.
• To remove switch (23):
!~!Tighten
A. Pivot & (pulse) switch connector from
bulkhead connector.
• Tighten screws (15) in same order to 9.0 N·m
B. Gently pull wire harness through column.
(80 lb.in.).
10. Spring retainer (52).
10. Install multi-function lever. (See Section 3F)
• Using a cross recess head screwdriver, push
11. Plug multi-function lever and cruise control
retainer down and turn counterclockwise to
connectors together and mount on base plate (24).
release.
12. Housing cover end cap (25).
13. Do all steps, "Install or Connect", Sub Section A.
11. Spring (51) and spring guide (50).
 TILT STAG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·11

SUB SECTION C • MID COLUMN IL•! Inspect

INCLUDES: • Steering column for accident damage. (See
STEERING COLUMN HOUSING ASM Figure 34)
STEERING WHEEL LOCK SHOE
4. Do steps 3 through 22, "Remove or Disconnect",
SWITCH ACTUATOR SECTOR Sub Section A.
SWITCH ACTUATOR RACK 5. Do steps 2 through 10, "Remove or Disconnect",
BEARING ASSEMBLY Sub Section B.
LOCK BOLT
STEERING COL HSG SUPPORT ASM
STEERING SHAFT ASSEMBLY

Tools Required:
J 23653-C Lock Plate Compressor
J 21854-01 Pivot Pin Remover
J 22635 Lock Shoe and Release Lever Pin
Remover and Installer
J 8092 Driver Handle
J 38639 Strg Col Housing Bearing Installer 39 PIN, PIVOT
Figure 21 - Removing Pivot Pin

rn Important 6. Pivot pins (39) using J 21854-01.

• Before doing any service procedures in this section,
removal of Inflator Module and Steering Wheel is
needed. (Refer to service procedures in Section 3F)
• Reinstall tilt lever. (See Section 3F)
7. Steering column housing assembly (30).
• Pull back on tilt lever and pull steering column
housing assembly (30) down and away from
column.

!+-+! Remove or Disconnect !f ! Important

Figures 1 through 28,30 and 34
• Remove only those components necessary to do
1. Disable the SIR system; refer to "Disabling the repairs.
SIR System" in this Section.
2. Negative(-) battery cable.
3. Steering column from vehicle. (See Section 3F)

NOTICE: Once steering column is removed from vehicle,

46
the column is extremely susceptible to damage. Dropping
steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design. 32 BOLT, LOCK
If it is necessary to remove steering wheel, use only the 37 SHAFT, DRIVE
specified steering wheel puller. Under no conditions 38 PIN, DOWEL
44 RACK, SWITCH ACTUATOR
should the end of shaft be hammered on as hammering
46 HOUSING, STRG COLUMN
could loosen plastic injections which maintain steering 48 SCREW, HEX WASHER HEAD
column rigidity.
Figure 22 - Lock Housing Cover Components, Exterior
3F5B·12 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

F. Release lever pin (42) using J 22635.

G. Switch actuator sector (47).
J 22635
H. Drive shaft (37).
I. Rack preload spring (45).
J. Switch actuator rack (44) to actuator sector
35 (47).
34
K. Bearing assembly (31) lubricated with
lithium grease to column housing (46)
43 using J 38639 and J 8092.
L. Lock bolt (32).
M. Lock bolt spring (33). (See Figure 30)
36 N. Hex head screw (48).

31 BEARING ASM
34 SHOE, STEERING WHEEL LOCK
35 SHOE, STEERING WHEEL LOCK
31
!~!Tighten
36 SHIELD, WIRE PROTECTOR
42 PIN, RELEASE LEVER
43 LEVER, SHOE RELEASE • Tighten screw (48) to 4.0 N·m (35 lb.in.).
Figure 23 - Lock Housing Cover
Components, Interior

!+!-+! Disassemble
J 8092
Steering Column Housing Assembly
J 38639
A. Bearing assembly (31).
B. Hex head screw (48).
31
C. Lock bolt spring (33).
D. Lock bolt (32).
46
E. Switch actuator rack (44) an.d rack preload
spring (45).
F. Drive shaft (37).
G. Switch actuator sector (47). 31 BEARING ASM
I. Release lever pin (42) using J 22635. 46 HOUSING, STRG COLUMN
J. Shoe release lever (43). Figure 24 - Installing Bearings
K. Release lever spring (41).
L. Dowel pin (38) using J 22635.
M. Lock shoes (34) and (35). 8. Lower bearing adapter clip (89).
N. Shoe springs (40). 9. Bearing adapter retainer (88).
10: Lower bearing adapter (86) and bearing assembly
(87).
!-+*+! Assemble 11. Steering column shaft assembly (55).

Steering Column Housing Assembly

A. Shoe springs (40).

ll1t! Inspect
B. Lock shoes (34) and (35).
C. Dowel pin (38) using J 22635. • Steering column shaft assembly (55) for accident
D. Release lever spring (41). damage. (See Figure 34)
E. Shoe release lever (43).
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·13

rn Important BLOCK TOOTH

120'CLOCK
POSITION
• Mark upper shaft assembly (56) and lower steering
shaft asm (59) to ensure proper assembly. Failure to
assemble properly will cause steering wheel to be
turned 180 degrees. (See Figures 25 and 26)

BOLT
HOLE
120'CLOCK
56 POSITION
59 BOTTOM
END VIEW
ROTATE 56 SHAFT ASM, RACE & UPPER
57 SPHERE, CENTERING

TILT90°
AND SEPARATE
» SPHERE
90°
AND
LIFT
59 SHAFT ASM, LOWER STEERING
Figure 26 - Correct Upper to Lower Shaft Orientation

ALIGNMENT 56
!+*+! Assemble
MARK
Steering Column Shaft Assembly
56 SHAFT ASM, RACE & UPPER
57 SPHERE, CENTERING
58 SPRING, JOINT PRELOAD A. Joint preload spring (58) to two centering
59 SHAFT ASM, LOWER STEERING
sphere (57).
Figure 25 - Removing Steering Shaft Components B. Centering sphere (57).
• Lubricate with lithium grease, slip

rn Important
into upper shaft assembly (56), and
rotate sphere 90 degrees.
C. Uppershaftassembly(56)tolowersteering
shaft assembly (59).
• Remove only those components necessary to do
• Line up marks and tilt assemblies 90
repairs.
degrees to each other.

l+I Disassemble 62

Steering Column Shaft Assembly

A. Upper shaft assembly (56), lower steering

shaft assembly (59).
• Tilt 90 degrees to each other and
disengage.
B. Centering sphere (57) from upper shaft
assembly (56).
• Rotate sphere 90 degrees and slip
61 SCREW, SUPPORT
out. 62 SUPPORT ASM, STRG COL HSG
C. Joint preload spring (58) from centering 71 SHROUD, STAG COLUMN HSG
sphere (57). 77 ROD, DIMMER SWITCH

Figure 27 - Removing Column Housing Support

3F5B·14 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

3. Four support screws (61).

12. Support screws (61).
13. Columnhousingsupportassembly(62)withdimmer ~Tighten
switch rod (77) from steering column jacket assembly
(72).
• Rod (77) from support (62). • Tighten screws (61) to 8.8 N·m (77 lb.in.)

14. Steering column housing shroud (71).

4. Dimmer switch rod (77) to housing support (62).
5. Actuator assembly (76) to housing support (62).

34

83
72 JACKET ASM, STRG COL
78 SCREW, WASH HD (#10-24X.25) 39
79 SCREW, HEX WASH HD TAP
80 SWITCH ASM, IGNITION
82 SCREW, FLT HD (#10-24X.31) SHOE MUST ENGAGE
83 SWITCH ASM, DIMMER WITH DOWEL PINS
Figure 28 - Removing Ignition and Dimmer Switches 34 SHOE, STRG WHEEL LOCK
35 SHOE, STRG WHEEL LOCK
39 PIN, PIVOT
44 RACK, SWITCH ACTUATOR
15. Hex head tapping screw (79). 46 HOUSING, STRG COLUMN
16. Washer head screw (78). 62 SUPPORT ASM, STRG COL HSG
76 ACTUATOR ASM, IGN SWITCH
17. Dimmer switch assembly (83).
• Dimmer switch (83) from vehicle wire harness. Figure 29 - Installing Column Housing
to Housing Support
18. Flat head screw (82).
• Ignition switch assembly (80) from ignition
switch actuator assembly (76).
6. Steering shaft assembly (55) to jacket assembly
(72).
• Lubricate with lithium grease.
I-+~! Install or Connect
Figures 1 through 32 7. Tilt lever. (See Section 3F)
8. Column housing assembly (30) to column.
• Position column housing assembly (30) and
NOTICE: See "Notice" on page 3F5B-1 of this section. align switch actuator rack (44) with pin on end
of ignition switch actuator assembly (76).
NOTICE: Ensure all fasteners are securely seated before • Pull back on tilt lever, pushing column housing
applying needed torque. Failure to do so may result in assembly (30) onto column housing support
component damage or malfunctioning of steering column. assembly (62).
• Release tilt lever to lock shoes (34) and (35)
1. Steering column housing shroud (71 ). onto dowel pins.
2. Column housing support (62) to jacket assembly • Remove tilt lever. (See Section 3F)
(72).
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·15

32 BOLT, LOCK
NOTICE: Once steering column is removed from vehicle,
33 SPRING, LOCK BOLT the column is extremely susceptible to damage. Dropping
44 RACK, SWITCH ACTUATOR steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design.
If it is necessary to remove steering wheel, use only the
specified steering wheel puller. Under no conditions
76 should the end of shaft be hammered on as hammering
47 SECTOR, SWITCH ACTUATOR
76 ACTUATOR ASM, IGN SWITCH could loosen plastic injections which maintain steering
column rigidity.
Figure 30 - Actuator Assembly to Actuator Rack
Installed
!l'l'! Inspect
• Steering column for accident damage. (See
9. Pivot pins (39). Figure 34)
• Lubricate with lithium grease.
• Press pin until firmly seated, two places.

10. Lower bearing adapter (86) and bearing assembly Dimmer Switch Assembly
(87).
• Lubricated with lithium grease.
!++! Remove or Disconnect
Figures 1,2,28 and 34
11. Bearing adapter retainer (88).
12. Lower bearing adapter clip (89).
13. Do steps 1 through 12, "Install or Connect", Sub 1. Disable the SIR system; refer to "Disabling the
Section B. SIR System" in this Section.
14. Do steps, 1 through 21 "Install or Connect", Sub 2. Negative(-) battery cable.
Section A. 3. Steering column from vehicle. (See Section 3F)
15. To install ignition and dimmer switch assemblies, 4. Hex head tapping screw (79).
do all steps Ignition Switch Assembly, "Install or 5. Washer head screw (78).
Connect", Sub Section D. 6. Dimmer switch assembly (83) from rod (77).
• Vehicle wire harness from dimmer switch (83).

SUB SECTION D • LOWER COLUMN !++! Install or Connect

Figures 1,2,28 and 31
INCLUDES:
DIMMER SWITCH ASSEMBLY
DIMMER SWITCH ADJUSTMENT NOTICE: See "Notice" on page 3F5B-1 of this section.
IGNITION SWITCH ASSEMBLY
NOTICE: Ensure all fasteners are securely seated before
IGNITION SWITCH ADJUSTMENT applying required torque. Failure to do so may result in
ADAPTER & BEARING ASSEMBLY component damage or malfunctioning of steering column.
3F5B·16 TILT STRG COL UNIT REPAJR (SIR,FLR SHFT)

1. Dimmer switch assembly (83).

2. Hex head tapping screw (79) and washer head screw Ignition Switch Assembly
(78).
• Tighten finger tight.
!++! Remove or Disconnect
Figures 1,2,28 and 34

1. Disable the SIR system; refer to "Disabling the

SIR System" in this section.
2. Negative (-) battery cable.
3. Steering column from vehicle. (See Section 3F)
4. Hex head tapping screw (79).
5. Washer head screw (78).

~-
6. Dimmer switch assembly (83) from rod (77).
3/32" 7. Flat head screw (82).
/ DRILLBIT
8. Ignition switch assembly (80) from ignition switch
83 SWITCH ASM, DIMMER actuator assembly (76).
• Vehicle wire harness from ignition switch
Figure 31-Adjusting Dimmer Switch
assembly (80).

~Adjust

• Dimmer switch (83). (See Figure 31) !++! Install or Connect

A. Place 3/32-inch drill bit in hole on switch
to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.
Figures 1,2,28,31 and 32
NOTICE: See "Notice" on page 3F5B-1 of this section.
NOTICE: Ensure all fasteners are securely seated before
applying needed torque. Failure to do so may result in
component damage or malfunctioning of steering column.

1. Lock cylinder (20) to "OFF-LOCK" position.

~Tighten NOTICE: Install ignition switch (80) to jacket (72) with

switch in "OFF-LOCK'' position. (See Figure 32) New
• Tighten screw (79) to 2.5 N·m (22 lb.in.) ignition switch will be pinned in "OFF-LOCK" position.
Remove plastic pin after switch is assembled to column.
Failure to do so may cause switch damage.

~Tighten MOVE SWITCH SLIDER TO EXTREME RIGHT POSITION

AND THEN MOVE SUDER ONE DETENT TO THE LEFT
'OFF·LOCK'

• Tighten screw (78) to 4.0 N·m (35 lb.in.).

80

3. Vehicle wire harness to dimmer switch (83).

4. Steering column to vehicle. (See Section 3F)
5. Negative(-) battery cable.
6. If all service operations are completed, enable the 80 SWITCH ASM, IGNITION
SIR system; refer to "Enabling the SIR System" in
this section. Figure 32 - Adjusting Ignition Switch
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B·17

~Adjust Adapter & Bearing Assembly

• Ignition switch assembly (80). I++! Remove or Disconnect

Figures 1,2,33 and 34
A. Move switch slider to extreme right
position. 1. Disable the SIR system; refer to "Disabling the
B. Move switch slider one detent to left "OFF- SIR System" in this section.
LOCK" position. 2. Negative (-) battery cable.
3. Steering column from vehicle. (See Section 3F)
2. Ignition switch assembly (80) to actuator assembly 4. Lower bearing adapter clip (89).
(76). 5. Bearing adapter retainer (88).
3. Flat head screw (82). 6. Lower bearing adapter (86) and bearing assembly
(87).
~Tighten

• Tighten screw (82) to 3.7 N·m (33 lb.in.).

86

87 \ ()

. . \_ Ji)-®
4. Dimmer switch assembly (83) to rod (77).
5. Hex head tapping screw (79) and washer head screw
(78).

~~
• Tighten finger tight.
72

~Adjust

• Dimmer switch (83). (See Figure 31)
A. Place 3/32-inch drill bit in hole on switch
to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.
~Tighten
• Tighten screw (79) to 2.5 N·m (22 lb.in.)
~Tighten
72 JACKET ASM, STAG COL
86 ADAPTER, LOWER BEARING
87 BEARING ASM
88 RETAINER, BEARING ADAPTER
89 CLIP, LOWER BEARING ADAPTER
Figure 33 - Removing Lower Bearing Assembly
I++! Install or Connect
Figures 1,2 and 33
NOTICE: See "Notice" on page 3F5B-1 of this section.
NOTICE: Ensure all fasteners are securely seated before
applying needed torque. Failure to do so may result in
component damage or malfunctioning of steering column.

• Tighten screw (78) to 4.0 N·m (35 lb.in.). 1. Lower bearing adapter (86) and bearing assembly
(87).
6. Steering column to vehicle. (See Section 3F) • Lubricate inner surface with lithium grease.
7. Vehicle wire harness to dimmer switch assembly
(83). 2. Bearing adapter retainer (88).
8. Vehicle wire harness to ignition switch assembly 3. Lower bearing adapter clip (89).
(80). 4. Steering column to vehicle. (See Section 3F)
9. Negative(-) battery cable. 5. Negative(-) battery cable.
10. If all service operations are completed, enable the 6. If all service operations are completed, enable the
SIR system; refer to "Enabling the SIR System" in SIR system; refer to "Enabling the SIR System" in
this Section. this Section.
3F5B·18 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE

NOTICE: Vehicles Involved In accidents resulting In frame damage,

major body or sheet metal damage, or where the steering column has
I
been Impacted, or where supplemental Inflatable restraints systems
deployed may also have a damaged or mlsallgned steering column.
I
CHECKING PROCEDURE I
JACKET ASM, STEERING COLUMN I
• Check capsules on steering column bracket assembly; all must be
securely seated In bracket slots and checked for any loose
I VIEWA
(CAPSULES)
conditions when pushed or pulled by hand (View A). If not, bracket
should be replaced Hbracket Is bolted to the Jacket assembly or the
I CHECK FOR ANY LOOSE CONDITION WHEN
PUSHED OR PULLED BY HAND.
Jacket assembly should be replaced Hbracket Is welded to Jacket
assembly. I
~
• Check for Jacket assembly collapse by measuring the distance
from the lower edge of upper Jacket to a defined point on the lower
CHECK FOR SHEARED INJECTE.D
Jacket (View C). If measured dimensions are not within
specifications, a new Jacket must be Installed. I PLASTIC AT THESE LOCATIONS.

STEERING SHAFT ASM

I VIEWB
(STEERING SHAFT)
• Visually Inspect steering shaft for sheared Injected plastic (View B).
If steering shaft shows sheared plastic, a new steering shaft must
be Installed. I
• Any frame damage that could cause a bent steering shaft must
have steering shaft runout checked In the following manner: Using I ----.-------
a dlal Indicator at lower end of steering shaft, have steering wheel
rotated. Runout must not exceed 1.59mm. I
NOTICE: Inflatable restraint coll assembly must be removed from
steering column and allowed to hang freely before shaft Is rotated. Failure
I
to do so could damage coll assembly.
I
I
I VIEW c (METHOD TO DETERMINE COLUMN COLLAPSE)
WITH LOWER BEARING REMOVED
I MEASURE DISTANCE BETWEEN ARROWS.

Figure 34 - Checking Steering Column for Accident Damage

SPECIFICATIONS
FASTENER TORQUES
1 Steering Wheel-to-Shaft Nut ................................................ 41.0 N·m (30 lb.ft.)
9 Turn Signal Switch Connecting Screws ......................................... 3.4 N·m (30 lb.in.)
10 Turn Signal Switch Actuator Assembly Screw ................................... 2.3 N·m (20 lb.in.)
15 Lock Housing Cover Screws ................................................. 9.0 N·m (80 lb.in.)
18 Lock Retaining Screw ...................................................... 2.5 N·m (22 lb.in.)
48 Lock Bolt Spring Screw .................................................... 4.0 N·m (35 lb.in.)
61 Support-to-Jacket Screws ................................................... 8.8 N·m (77 lb.in.)
78 Upper dimmer Switch Mounting Screw .......................... ; .............. 4.0 N·m (35 lb.in.)
79 Lower dimmer Switch Mounting Screw ........................................ 2.5 N·m (22 lb.in.)
82 Ignition Switch Mounting Screw .............................................. 3.7 N·m (33 lb.in.)
 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B-19

J 23653-C

1 PIVOT PIN REMOVER

2 LOCK SHOE AND RELEASE LEVER PIN REMOVER AND INSTALLER
3 DRIVER HANDLE
4 STEERING COLUMN HOUSING BEARING INSTALLER
5 LOCK PLATE COMPRESSOR

Figure 35 - Special Tools


SECTION 4A
PROPELLER SHAFT
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description ........................ 4A-1
Propeller Shaft Assemblies ................ 4A-1
Center Support Bearing ................... 4A-1
Universal Joint .......................... 4A-1
Propeller Shaft Joint ...................... 4A-3
Diagnosis ................................ 4A-3
Road Test .............................. 4A-3
Coast Test .............................. 4A-3
Diagnosis of Propeller Shaft Assembly and
Universal Joint ........................ 4A-5
On-Vehicle Service ........................ 4A-5
Propeller Shaft Assembly Runout
Measurement ......................... 4A~5
Differential Drive Pinion Gear Yoke
Runout Measurement ................... 4A-5
Propeller Shaft Assembly Balance Check ..... 4A-7
GENERAL DESCRIPTION
PROPELLER SHAFT ASSEMBLIES
Figure 1
Torque is transmitted from the transmission assem-
bly to the rear axle assembly through one or more of the
propeller shaft assemblies (5, 6 and 10) and universal joint
assemblies. The 3.4L L32 engine utilizes a two-piece
propeller shaft assembly (6 and 10), while the 5.7L LTl
engine utilizes a one-piece propeller shaft assembly (5).
All propeller shaft assemblies (5, 6 and 10) have uni-
versal joints to accommodate angle variations between the
transmission assembly and the rear axle assembly and/or
the rear axle assembly position caused by suspension
motion. The propeller shaft assemblies (5, 6 and 10) are
connected to the transmission assembly with a splined slip
yoke assembly (1 or 24) and to the rear axle assembly with
a companion flange (fixed yoke). On the two-piece pro-
peller shaft assembly (6 and 10), the rear portion of the
front propeller shaft assembly (6) contains the center sup-
port bearing (7) and spline coupling. The spline coupling
has internal splines which accept the rear propeller shaft
assembly (10). The center support bearing (7) is pressed
onto the OD of the coupling. On the front of the rear pro-
peller shaft assembly (10) there is a propeller shaft joint
(9) (sometimes called a constant velocity (CV) joint) that
fits into the spline coupling of the front propeller shaft
assembly (6).
PROPELLER SHAFT 4A·1
Propeller Shaft Assembly Balancing . . . . . . . . . 4A-7
Hose Clamp Method ................... 4A-7
Strobe Light Method . . . . . . . . . . . . . . . . . . . 4A-8
One and Two-Piece Propeller Shaft Assembly
Replacement .......................... 4A-9
Unit Repair .............................. 4A-12
Two-Piece Propeller Shaft Assembly ....... 4A-12
Center Support Bearing Replacement ....... 4A-12
Universal Joints ........................ 4A-13
Nylon Injected Ring Type .............. 4A-l 3
Snap Ring Type ...................... 4A-13
Specifications ............................ 4A-15
General Specifications ................... 4A-15
Fastener Tightening Specifications ......... 4A-15
Special Tools ............................ 4A-15
NOTICE: If a vehicle is to be undercoated, the
propeller shaft assembly must be kept free of
undercoating material. Undercoating material
or any other foreign material will upset the
propeller shaft balance and produce serious
vibration.
rn Important
• Before propeller shaft assembly removal, reference
mark the propeller shaft assembly to ensure phased
installation alignment. Some propeller shaft assem-
blies have alignment marks or arrows stamped on
the shaft at the time of production. ·
CENTER SUPPORT BEARING
Figure 1
The center support bearing (7) supports the driveline
when the two-piece propeller shaft assembly (6 and 10)
are used. The center support bearing (7) is a ball-type
bearing mounted in a rubber cushion that is mounted to
the torque arm assembly. The center support bearing (7) is
pre-lubricated and sealed by the manufacturer.
UNIVERSAL JOINT
Figure 1
The universal joint is basically two Y-shaped yokes
connected by a crossmember called a spider (2). The spi-
der (2) is shaped like a cross having arms of equal length
4A·2 PROPELLER SHAFT

A SHAFT ASSEMBLY, ONE-PIECE PROPELLER

B SHAFT ASSEMBLY, TWO-PIECE PROPELLER
C TRUNNIONS
D COUPLING, SPLINE
E DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
1 YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
3 BEARING, PROPELLER SHAFT UNIVERSAL JOINT
SPIDER
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
5 SHAFT ASSEMBLY, PROPELLER
6 SHAFT ASSEMBLY, FRONT PROPELLER
7 BEARING, PROPELLER SHAFT CENTER SUPPORT
8 SEAL, REAR PROPELLER SHAFT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER
24 YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP

PC0001-4A·F·RP

Figure 1 - Propeller Shaft Assembly Components


called trunnions. The spider (2) allows the two yoke shafts
to operate at any angle to each other. Universal joints are
lubricated for life.
When torque is transmitted through any ordinary
universal joint, the drive pinion gear yoke fluctuates
slightly in speed. In other words, although the propeller
shaft slip yoke assembly (1 or 24) rotates at a constant
speed, the differential drive pinion gear yoke speeds up
and slows down twice per revolution. This fluctuation of
the pinion gear yoke is in direct proportion to the angle
through which the universal joint is operating; the greater
the angle, the greater the fluctuation.
Whenever two universal joints are used, this fluctua-
tion effect can be eliminated by staggering the joints so
that the two yokes are 90 degrees apart, provided the two
joints are transmitting torque through the same angle.
Therefore, when two universal joints are used, the
angles through which they operate must be very nearly the
same. This allows the alternate acceleration and decelera-
tion of one joint to be offset by the alternate deceleration
and acceleration of the second joint. When the two joints
do not run at approximately the same angle, operation is
rough and an objectionable vibration is produced.
Universal joints are designed to handle the effects of
various loadings and rear axle windup during accelera-
tion. Within the designed angle variations the universal
joint will operate efficiently and safely. When the design
angle is changed or exceeded, the operational life of the
joint may decrease.
The universal joint spider bearings (3) used are the
needle roller type. The needle roller bearings are held in
place on the trunnions by round bearing caps. Production
universal joint spider bearings (3) are retained by nylon
injected rings instead of conventional retainer (snap) rings
(4). All service replacement universal joints use retainer
(snap) rings (4).
If it becomes necessary to replace a universal joint,
the entire propeller shaft assembly (5, 6 or 10) must I?e
removed from the vehicle. Care should be taken to avoid
jamming or bending any parts of the assembly.
PROPELLER SHAFT JOINT
Figure 1
The propeller shaft joint (9) (sometimes called a
constant velocity (CV) joint) is used on the two-piece pro-
peller shaft assembly (6 and 10). The propeller shaft joint
(9) allows the driveline angle to be adjusted according to
the up and down movement of the vehicle without disturb-
ing the power flow.
DIAGNOSIS
The following major component groups are usually
the cause of or are related to vibration:
• Engine assembly and mounts.
• Transmission assembly.
• Tires, wheels and brake drum assemblies.
• Propeller shaft assemblies and universal joints.
Before road testing a vehicle, check the following:
PROPELLER SHAFT 4A-3
• All fasteners for tightness at universal joint, wheel
nuts and engine mounts.
• Tire air pressure.
• Load conditions.
ROAD TEST
Figure2
Road test the vehicle to verify the complaint. Record
the speed and rpm at which the greatest vibration occurs.
The vibration is likely to be in the steering wheel or in the
seat bottom. The road test can be helpful in locating the
vibration source.
COAST TEST
Figure2
NOTICE: When performing a "Coast Test" on a
vehicle equipped with an automatic transmission
assembly, caution must be taken when returning
selector lever from "NEUTRAL" to "DRIVE" to
avoid transmission damage. When shifting from
"NEUTRAL" to "DRIVE," remember to:
1. Maintain engine speed at 1500 rpm.
2. Brake to 40 km/h (25 mph).
3. Return selector to "DRIVE."
Drive the vehicle past the vibration speed, shift into
"NEUTRAL" and coast back through the vibration
speed. During a coast test, two kinds of vibration normally
occur: a shaking or a buzzing. A shaking vibration is usu-
ally a problem with the tires or a wheel and brake drum or
brake rotor assembly. A buzzing vibration is usually a
driveline problem.
To determine whether a propeller shaft assembly is
causing the problem, drive the vehicle through the speed
range and note at which speed (vehicle and/or engine) the
problem is most pronounced. A tachometer may be used.
Shift the transmission assembly into a lower gear range
and drive the vehicle at the same engine speed as when the
problem was most pronounced in direct drive. Note the
effect on the problem.
To determine the engine speed if a tachometer is not
used, divide vehicle speed by the transmission gear ratio
in which the problem occurs.
Example: With the HYDRA-MATIC 4L60 auto-
matic transmission in 2 range, divide by 1.63. If the prob-
lem is most pronounced in direct drive at 88 km/h (55
mph) the same engine speed would be produced in 2 range
at 55 km/h (55/1.63 = 34 mph).
If the problem is still present at the same engine
speed whether in direct drive or in the lower gear range, a
propeller shaft assembly cannot be at fault since a propel-
ler shaft speed varies. If the problem decreases or is elimi-
nated in a different gear range at the same engine speed, a
propeller shaft assembly may be at fault. Refer to "Pro-
peller Shaft Assembly Runout Measurement," "Diagno-
sis of Propeller Shaft Assembly and Universal Joint" and
Figure 2.
 PROPELLER SHAFT ASSEMBLY DIAGNOSIS f
"'Cl
DRIVE VEHICLE TO DETERMINE ~
"'Cl
PROBLEM & SPEED m
(ACCELERATION - ROAD - ENGINE) r-
r-
m
::D
DRIVE AT ROAD SPEED ON IMPACT BOOM CJ)
SMOOTH ROAD ROUGH ROAD :::c
l>
:!I
RIDE AND EVALUATE AT 345 kPa (50 PSI) TIRE PRESSURE
CHECK TIRES, SUSPENSION
AND/OR BODY COMPARTMENT

PROBLEM NOT IMPROVED PROBLEM IMPROVED

"Tl
<Ci"
c: PLACE VEHICLE ON HOIST,
co REMOVE REAR TIRE AND
SEE TIRE CHECK
I\)
I WHEEL ASSEMBLIES AND
"'O VERIFY PROBLEM SPEED
0
~ -~~~~~~~....._~~~~
I IPROBLEM IMPROVED I I CHECK AND/OR BALANCE TIREAND WHEEL ASSEMBLIES I
~
(/)
::r 40-72 KM/H (25-45 MPH) VISUAL EXAMINATION
~
~
en 11 MISSING
<D
DAMAGED PROPELLER UNDERCOATING BALANCE BURRS OR NICKS ON 11 EXCESSIVELOOSENESS
3 SHAFT ASSEMBLY ON PROPELLER SHAFT WEIGHT SUPPORT YOKE AND/OR PINION YOKE AT SLIP YOKE SPLINE
O" ASSEMBLY
'< TIGHT JOINTS
0
~- REPLACE PROPELLER SHAFT 11 CLEAN PROPELLER SHAFT I IBALANCE PROPELLER SHAFTI I REWORK OR REPLACE REPLACE NECESSARY
:::,
ASSEMBLY ASSEMBLY ASSEMBLY PARTS
0
!e. IMPACT YOKE WITH
o" HAMMER OR REPLACE EVALUATE ON HOIST
()
::r PROBLEM NOT IMPROVED 1 - - - - - _ , '--------1PROBLEMIMPROVED 1-----1 ROAD TEST
Ill
;::::i.
ROAD TEST
88 KM/H (55 MPH)

ROTATE SHAFT 180 DEGREES AT PINION YOKE

PROBLEM NOT IMPROVED I I EVALUATE I I PROBLEM IMPROVED - - - .

WORN UNIVERSAL JOINT OUT OF BALANCE DRIVELINE, EXCESSIVE

PINION YOKE OR PROPELLER SHAFT ASSEMBLY RUNOUT

I REPLACE UNIVERSAL JOINT

BALANCE PROPELLER SHAFT ASSEMBLY IN VEHICLE

ROAD TEST
 PROPELLER SHAFT 4A·5

DIAGNOSIS OF PROPELLER SHAFT ASSEMBLY AND UNIVERSAL JOINT

PROBLEM
Leak at front propeller shaft (An 1. Rough outside surface on propeller
occasional drop of lubricant
leaking from the slip yoke is
normal and requires no
attention.)
Knock in driveline; clunking
noise when vehicle is operated
under float condition at 16 km/h
(10 mph) in high gear or
"NEUTRAL."
Ping, snap, or clinking noise in
driveline.
Scraping noise
POSSIBLE CAUSE
shaft slip yoke.
2. Fault rear transmission oil seal.
1. Worn or damaged universal joints.
2. Differential side gears worn.
1. Loose rear axle upper or lower
control arm bolt/screw.
2. Worn or damaged universal joints.
1. Slinger rubbing on rear axle
assembly.
2. Brake drum assembly, if equipped,
contacting backing plate.
CORRECTION
1. Replace transmission seal if cut by
burrs on slip yoke. Minor burrs can
be smoothed by careful use of
crocus cloth or honing with a fine
stone. Replace slip yoke if outside
surface is rough or burred badly.
2. Replace the rear transmission oil
seal. Bring transmission fluid up to
proper level after correction.
1. Replace universal joints.
2. Replace differential side gears as
required.
I. Tighten bolt/screw to specified
torque.
2. Replace universal joints.
1. Straighten slinger to remove
interference.
2. Replace brake drum assembly or
backing plate.

ON-VEHICLE SERVICE 1. Raise vehicle on a twin post hoist so that the rear is

rn Important
• The driveline components in this vehicle have been
factory system balanced. System balance provides a
smoother running driveline operation. However, it is
essential that the positions of all driveline compo-
nents relative to the propeller shaft assembly and
rear axle assembly be observed and ACCU-
RATELY REFERENCE MARKED PRIOR TO
DISASSEMBLY. These components include the
propeller shaft assemblies, rear axle assemblies,
differential drive pinion gear yoke, output shaft, etc.
ALL COMPONENTS MUST BE REAS-
SEMBLED INTO THE EXACT RELATION-
SHIP TO EACH OTHER AS THEY WERE
WHEN REMOVED. Additionally, the published
specifications and torque values, as well as any
measurements made prior to disassembly must be
followed to maintain the factory balance.
PROPELLER SHAFT ASSEMBLY RUNOUT
MEASUREMENT
Figure3
Tool Required:
J 8001 Dial Indicator Set
Noise or vibration at high speed could be caused by
a bent propeller shaft assembly. The propeller shaft
assembly could have been damaged by rough handling or
a collision. Check for propeller shaft assembly straight-
ness.
supported on the rear axle housing assembly and the
wheels can spin. Refer to SECTION OA.
2. Mount J 8001 on a movable support that is high
enough to permit contact of the indicator button with
the propeller shaft assembly (5, 6 or 10), or mount
J 8001 to a magnetic base and attach to a smooth
place on the vehicle underbody. Readings are to be
taken at points indicated in Figure 3.
3. With transmission in "NEUTRAL," check for run-
out by turning a rear wheel to rotate the propeller
shaft assembly (5 or 6 and 10).
4. If runout exceeds 1.40 mm (0.055 inch), disconnect
propeller shaft assembly (5 or 10) at differential
drive pinion gear yoke and rotate the propeller shaft
assembly (5 or 10) 180 degrees. Reinstall propeller
shaft assembly (5 or 10). Check runout again.
5. If runout is still over specifications at the differential
drive pinion gear yoke end, differential drive pinion
gear yoke runout should be measured. Refer to "Dif-
ferential Drive Pinion Gear Yoke Runout Measure-
ment" in the following procedure. If run-out is still
over specifications, replace the propeller shaft
assembly (5, 6 or 10), but only after checking for
vibration or noise.
6. Lower vehicle.
DIFFERENTIAL DRIVE PINION GEAR YOKE
RUNOUT MEASUREMENT
Figure4
Tools Required:
J 35819 Runout Gage
J 8001 Dial Indicator Set
4A·6 PROPELLER SHAFT

5
J

A D

A ONE-PIECE PROPELLER SHAFT ASSEMBLY RUNOUT
CHECK
B ONE-PIECE PROPELLER SHAFT ASSEMBLY FRONT
RUNOUT MEASUREMENT POINT
c ONE-PIECE PROPELLER SHAFT ASSEMBLY CENTER
RUNOUT MEASUREMENT POINT
D ONE-PIECE PROPELLER SHAFT ASSEMBLY REAR
RUNOUT MEASUREMENT POINT
E TWO-PIECE PROPELLER SHAFT ASSEMBLY RUNOUT
CHECK
F TWO-PIECE PROPELLER SHAFT ASSEMBLY CENTER
RUNOUT MEASUREMENT POINT
G TWO-PIECE PROPELLER SHAFT ASSEMBLY FRONT
RUNOUT MEASUREMENT POINT
H TWO-PIECE PROPELLER SHAFT ASSEMBLY REAR
RUNOUT MEASUREMENT POINT
J DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
1 YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
5 SHAFT ASSEMBLY, PROPELLER
6 SHAFT ASSEMBLY, FRONT PROPELLER
7 BEARING, PROPELLER SHAFT CENTER SUPPORT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER
24 YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP PC0003-4A·F·RP

Figure 3 - Checking Propeller Shaft Assembly Runout

1. Raise the vehicle on a twin post hoist so the rear is

supported on the rear axle housing and the wheels
can spin. Refer to SECTION OA.
2. Remove propeller shaft assembly. Refer to "One
and Two-Piece Propeller Shaft Replacement" in this
section.
3. Measure pinion gear yoke runout using J 35819 and
J 8001. Record runout and mark high and low points
of pinion gear yoke.
4. If pinion gear yoke runout is 0.15 mm (0.006 inch)
or less, remove the pinion gear yoke balance weight,
if used. No further action is required.
5. If pinion gear yoke runout is greater than 0.15 mm
(0.006 inch), but less than 0.28 mm (0.011 inch) and
the balance weight is at or near the low point of pin-
ion gear yoke runnout, no further action is required.
If balance weight is not at or near the low point of
pinion gear yoke runout, remove the weight.
6. If pinion gear runout is over 0.28 mm (0.011 inch),
but no greater than 0.38 mm (0.015 inch) and the
balance weight is at or near the low point of pinion
gear yoke runout, no further action is required.
7. If the balance weight is not at or near the low point
of pinion gear runout, remove the weight and rotate A MAXIMUM INDICATOR READING
the pinion gear yoke until runnout is 0.25 mm (0.010
inch) or less.
8.If impossible to achieve 0.25 mm (0.010 inch) or PCOOCJ4-4A-f.RP
less runout, install a new pinion gear yoke and Figure 4 - Differential Drive Pinion Gear Yoke Runout
recheck for 0.25 mm (0.010 inch) or less runout.

Refer to SECTION 4B for pinion gear yoke replace-
ment.
• Service replacement pinion gear yoke may be
equipped with balance weights. These weights
should not be removed.
9. Install propeller shaft assembly. Refer to "One and
Two-Piece Propeller Shaft Assembly Replacement"
in this section.
10. Lower vehicle.
PROPELLER SHAFT ASSEMBLY BALANCE
CHECK
l++I Remove or Disconnect
NOTICE: See "Notice" on page 4A-1 of this sec-
tion.
1. Raise vehicle on twin post hoist so wheels can spin.
Refer to SECTION OA.
2. Both rear tire and wheel assemblies. Refer to SEC-
TION 3E.
3. Install wheel nuts with flat sides against rear brake
drum or rotor assemblies.
lt"I Inspect
A. Propeller shaft assembly, universal joint, and
attachments for mud, undercoating or loose
fasteners.
15!) Clean
• Propeller shaft assembly, universal joint,
and attachments.
l~I Tighten
• Any loose attachments or fasteners to
specifications. Refer to "Specifications"
in this section.
CAUTION: Do not run the vehicle faster
than 88 km/h (55 mph). Stay clear of the
universal joint and balance weight
areas to avoid possible personal injury.
Do not run the vehicle on the hoist for
extended periods due to the danger of
overheating the transmission assem·
bly or engine assembly.
B. Run vehicle in gear at speed where disturbance
peaks. Observe intensity of disturbance.
NOTICE: On vehicles with an automatic transmis-
sion assembly, allow the driveline components to
stop rotating with the transmission assembly in
"NEUTRAL" before placing the transmission
assembly in "PARK" or parts may be damaged.
C. Stop engine assembly.
4. Propeller shaft assembly from pinion gear yoke
only. Refer to "One and Two-Piece Propeller Shaft
Assembly Replacement" in this section.
PROPELLER SHAFT 4A·7
• Rotate propeller shaft assembly 180 degrees
from original position.
l++I Install or Connect
1. Propeller shaft to pinion gear yoke. Refer to "One
and Two-Piece Propeller Shaft Assembly Replace-
ment" in this section.
2. Remove wheel nuts.
3. Tire and wheel assemblies. Refer to SECTION 3E.
4. Determine position that gives best driveline
response by road testing vehicle for final check of
propeller shaft balance.
5. If balance is unacceptable, refer to "Propeller Shaft
Assembly Balancing" in this section.
PROPELLER SHAFT ASSEMBLY
BALANCING
Hose Clamp Method
Figures 5 through 7
1. Place vehicle on twin post hoist so that rear of
vehicle is supported on rear axle housing and rear
wheels are free to rotate. Refer to SECTION OA.
2. Remove both rear tire and wheel assemblies. Refer
to SECTION 3E. Install wheel nuts with flat sides
next to rear brake drum or rotor assemblies.
3. Mark and number propeller shaft assembly (5) at
four points, 90 degrees apart, at rear of propeller
shaft assembly (5) just forward of balance weight.
4. Install two clamps ( 11) on rear of propeller shaft
assembly (5) and slide them rearward until clamps
( 11) stop at nearest balance weight welded to tube.
• Align both clamps (11) at any one of four
marks made on propeller shaft assembly (5) in
step 3 and tighten.
A REFERENCE MARKS
5 SHAFT ASSEMBLY, PROPELLER
PC8005-4A·D·RP
Figure 5 - Propeller Shaft Assembly Reference Marks
(One-Piece Propeller Shaft Assembly Shown, Two-Piece
Propeller Shaft Assembly Similar)
4A·8 PROPELLER SHAFT
CAUTION: Do not run the vehicle faster
than 88 km/h (55 mph). Stay clear of the
universal joint and balance weight
areas to avoid possible personal injury.
Do not run the vehicle on the hoist for
extended periods due to the danger of
overheating the transmission assem-
bly or engine assembly.
5. Run vehicle through speed range to 81-88 km/h
(50-55 mph). Note amount of imbalance felt at front
of rear axle housing assembly.
6. Loosen clamps (11) and rotate clamp heads 90
degrees to next mark on propeller shaft assembly
(5). Tighten clamps (11) and repeat step 5.
7. Repeat step 6 until vehicle has been run with clamp
heads located at all four marks on propeller shaft
assembly (5).
A REFERENCE MARK - 180° FROM HOSE CLAMP HEADS
5 SHAFT ASSEMBLY, PROPELLER
11 CLAMP, HOSE
A
PC0007 -4A-F-RP
Figure 6 - Balance Hose Clamps (One-Piece Propeller Shaft
Assembly Shown, Two-Piece Propeller Shaft Assembly
Similar)
5 SHAFT ASSEMBLY PROPELLER
11 CLAMP, HOSE
PC0008-4A·F-RP
Figure 7 - Rotating Balance Hose Clamps (One-Piece
Propeller Shaft Assembly Shown, Two-Piece Propeller Shaft
Assembly Similar)
8. Position clamps (11) lat point of least imbalance.
Rotate clamp heads away from each other 45
degrees, one on each side of the position.
A. Run vehicle and note if balance has improved.
B. In some cases it may be necessary to use one
clamp (11) or possibly three clamps (11) in
order to obtain good balance.
C. Replace propeller shaft assembly (5) if three
clamps ( 11) do not improve balance.
9. Continue to rotate clamps (11) apart in smaller angu-
lar increments until imbalance is at its minimum.
10. Remove wheel nuts.
11. Install tire and wheel assemblies. Refer to SEC-
TION 3E.
12. Lower vehicle.
13. Road test vehicle to check final balance.
• A small vibration felt while vehicle is on hoist
may not be noticed on road test.
Strobe Light Method
Figures 5 through 9
If a strobe-light type wheel balancer is used, it will
help in the balancing of the propeller shaft assembly. The
balance pick-up unit should be placed directly under the
nose of the rear axle housing assembly and as far forward
as possible. Make up an extension for the balance pick-up
unit by using 3/8-inch tube and compression fittings (Fig-
ure 8).
1. Place vehicle on twin post hoist so rear of vehicle is
supported on rear axle housing assembly and rear
wheels are free to rotate. Lower rear hoist and allow
rear axle assembly to rest on jackstands.
2. Remove both rear tire and wheel assemblies. Refer
to SECTION 3E. Install wheel nuts with flat sides
next to rear brake drum or rotor assemblies. System
is now released and free to respond to propeller shaft
assembly (5).
3. Mark and number propeller shaft assembly (5) at
four points, 90 degrees apart, at rear of propeller
shaft assembly (5) just forward of balance weights.
4. Place strobe light wheel balancer pick-up under pin-
ion gear yoke in contact with rear axle housing
assembly and as far forward as possible.
CAUTION: Do not run the vehicle faster
than 88 km/h (55 mph). Stay clear of the
universal joint and balance weight
areas to avoid possible personal injury.
Do not run the vehicle on the hoist for
extended periods due to the danger of
overheating the transmission or the
engine assemblies.
5. Run vehicle in gear at speed where disturbance is at
its peak.
6. Allow driveline to stabilize by holding at steady
speed.
7. Point strobe light up at spinning propeller shaft
assembly (5) and note position of one of the refer-
ence numbers.

\ \
\ C. If strobe light shows three clamp heads at top
\
' of propellenhaft assembly (5), remove propel-
LOCALLY
FABRICATED
TOOL
NOTE: LOCALLY FABRICATED EXTENSION FOR BALANCER
PICK-UP CONSISTS OF 3/8" TUBE AND
COMPRESSION FITTINGS
LC0008-4A-F-RP
Figure 8 - Pick-Up Unit at Differential Drive Pinion Gear Yoke
NOTICE: On vehicles with an automatic transmis-
sion assembly, allow the driveline components to
stop rotating with the transmission assembly in
"NEUTRAL" before placing the transmission
assembly in "PARK" or parts may be damaged.
8. Shut off engine assembly.
9. Position propeller shaft assembly (5) so reference
numbers will be in same position as was noted while
propeller shaft assembly (5) was rotating.
• When strobe light flashed, heaviest point of
propeller shaft assembly (5) was at bottom (6
o'clock). To balance propeller shaft assembly
(5), it would be necessary to apply balancing
weights (hose clamps) 180 degrees away from
heaviest point or at top of propeller shaft
assembly (5) (12 o'clock).
10. Install two screw-type clamps (11) on propeller shaft
assembly (5) as close to rear as possible. Position
both clamp heads 180 degrees from heaviest point of
propeller shaft assembly (5) as indicated by strobe
light. Tighten clamps (11).
PROPELLER SHAFT 4A·9
11. Run vehicle through speed range 81-88 km/h (50-55
mph).
A. If disturbance is not gone and strobe light
shows clamp heads at bottom (6 o'clock) of
propeller shaft assembly (5), go to step 12.
B. If strobe light shows two clamp heads at top of
propeller shaft assembly (5), add one more
clamp ( 11) and check.
ler shaft assembly (5) and rotate 180 degrees
on pinion gear yoke (14). Check again, without
clamps (11).
D. Repeat balancing, starting with step 10.
rn Important
• Do not use more than three. clamps ( 11) to
balance propeller shaft assembly (5).
E. If propeller shaft assembly (5) still needs more
than three clamps (11) at same clock position,
replace propeller shaft assembly (5).
F. If clamps ( 11) are also 180 degrees from their
original position after rotating propeller shaft
assembly (5) 180 degrees, pinion gear yoke
( 14) is out of balance and must be replaced.
G. If strobe light shows clamps (11) at bottom of
propeller shaft assembly (5), but disturbance
still exists, go to step 12.
12. Rotate two of clamps (11) equally away from each
other toward top (one on each side of the position) in
small increments until best balance is achieved. In
some cases it may be necessary to use one clamp
(11) or possibly three clamps (11) in order to obtain
good balance. Replace propeller shaft assembly (5)
if three clamps ( 11) do not correct problem.
13. Remove wheel nuts.
14. Install tire and wheel assemblies. Refer to SEC-
TION 3E.
15. Remove strobe light and lower vehicle.
16. Road test vehicle to check final balance.
• A small vibration felt while vehicle is on hoist,
may not be noticed on road test.
ONE AND TWO-PIECE PROPELLER SHAFT
ASSEMBLY REPLACEMENT
Figure 10
l++I Remove or Disconnect
NOTICE: Do not strike or drop the propeller shaft
assembly, or allow the universal joints to bend to
extreme angles, as this might fracture a joint inter-
nally.
1. Raise and suitably support vehicle. Refer to SEC-
.TION OA.
2. Mark relationship of propeller shaft assembly (5 or
10) to pinion gear yoke (14).
3. Bolts/screws (16) from center support bearing (7), if
removing two-piece propeller shaft assembly.
4A·10 PROPELLER SHAFT
A B
A DETERMINE POINT OF IMBALANCE
B ADD HOSE CLAMPS 180° FROM POINT OF IMBALANCE
UNTIL THEY BECOME HEAVY SPOT
C ROTATE TWO CLAMPS EQUALLY AWAY FROM EACH
OTHER UNTIL BEST BALANCE IS ACHIEVED
D HEAVYSPOT
11 CLAMP, HOSE
Figure 9 - Positioning Hose Clamps to Achieve Best Balance
4. Center support bearing (7) and washers ( 17) from
torque arm assembly (18), if removing two-piece
propeller shaft assembly.
5. Four bolts/screws (12).
6. Two retainers (13).
7. Propeller shaft assembly (5 or 6 and 10) by with-
drawing slip yoke assembly (1 or 24) from transmis-
sion assembly, moving propeller shaft assembly (5
or 6 and 10) rearward and passing it under housing
assembly (15).
• Support propeller shaft assembly (5 or 6 and
10) during removal.
• If bearing caps are loose, tape them together to
prevent dropping and losing needle roller bear-
ings.
8. Separate two-piece propeller shaft assembly, if nec-
essary. Refer to "Two-Piece Propeller Shaft Assem-
bly" in this section.
ll'l'I Inspect
1. Transmission output shaft splines for burrs.
2. Outer diameter of slip yoke assembly (1 or 24) for
burrs.
3. Splines of slip yoke assembly (1 or 24) for damage,
twisting or wear. They should agree in number and
fit with transmission output shaft splines.
4. Pinion gear yoke (14) at universal joint cap connect-
ing surface for burrs or foreign material.
l++I Install or Connect
NOTICE: See "Notice" on page 4A-1 of this sec-
tion.
NOTICE: The propeller shaft assemblies must be
supported carefully during handling to avoid jam-
ming or bending any of the parts.
PCOOG&-4A-F-RP
NOTICE: To prevent transmission seal damage, do
not place any tool between the propeller shaft slip
yoke and splines.
1. Assemble two-piece propeller shaft assembly. Refer
to "Two-Piece Propeller Shaft Assembly" in this
section.
2. Slip yoke assembly (1 or 24) onto transmission out-
put shaft after lubricating spline with approximately
18 gm (0.6 ounce) of propeller shaft slip yoke lubri-
cant GM P/N 1050169, or equivalent.
3. Rear of propeller shaft assembly (5 or 10) to pinion
gear yoke (14).
rn Important
• When making the rear propeller shaft assembly
connection, be sure to align the mark on pinion
gear yoke (14) with the mark on propeller shaft
assembly (5 or 10).
4. Rear universal joint to pinion gear yoke (14), mak-
ing sure bearing caps are properly seated.
5. Two retainers (13).
6. Four bolts/screws (12).
l~I Tighten
• Bolts/screws (12) evenly to 22 N•m (16 lb. ft.).
7. Washers (17) and center support bearing (7) to
torque arm assembly (18), if installing two-piece
propeller shaft assembly.
8. Bolts/screws (16) to center support bearing (7), if
installing two-piece propeller shaft assembly.
l~I Tighten
• Bolts/screws (16) to 50 N•m (37 lb. ft.).
9. Lower vehicle.
 PROPELLER SHAFT 4A-11

15

15

A SHAFT ASSEMBLY, ONE-PIECE PROPELLER

B SHAFT ASSEMBLY, TWO-PIECE PROPELLER
C DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
1 YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
5 SHAFT ASSEMBLY, PROPELLER
6 SHAFT ASSEMBLY, FRONT PROPELLER
7 BEARING, PROPELLER SHAFT CENTER SUPPORT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER
12 BOLT/SCREW, PROPELLER SHAFT
13 RETAINER, PROPELLER SHAFT
14 YOKE, DIFFERENTIAL DRIVE PINION GEAR
15 HOUSING ASSEMBLY, REAR AXLE
16 BOLT/SCREW, PROPELLER SHAFT
17 WASHER, PROPELLER SHAFT
18 ARM ASSEMBLY, REAR AXLE TORQUE
24 YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP

PC001o-4A·F·RP

Figure 1O- Propeller Shaft Assemblies

4A· 12 PROPELLER SHAFT

UNIT REPAIR has not engaged into groove in propeller shaft

assembly (6). Again, align propeller shaft
TWO-PIECE PROPELLER SHAFT assemblies (6 and 10) and push them together
ASSEMBLY by hand.
3. Remove propeller shaft assembly (6) from vise.
Figures 1 and 11
Tools Required: CENTER SUPPORT BEARING
J 33008 Axle Shaft Remover REPLACEMENT
J 2619-01 Slide Hammer Figure 11

Iii Disassemble l++I Remove or Disconnect

1. Place propeller shaft assembly (6) horizontally in a
vise.
2. Propeller shaft assembly (6) from propeller shaft
assembly (10).
A. Screw J 33008 onto J 2619-01.
B. Place J 33008 on propeller shaft joint (9)
between propeller shaft joint bell area and pro-
peller shaft assembly (6).
C. Using J 2619-01, drive propeller shaft assem-
bly (10) from propeller shaft assembly (6).
3. Shaft seal (8) from rear propeller shaft assembly
(10).
• Discard shaft seal (8).
1++1 Install or Connect
l+!+I Assemble
1. New shaft seal (8) to rear propeller shaft assembly
(10).
2. Propeller shaft assembly (6) to propeller shaft
assembly (10).
• Align propeller shaft assemblies (6 and 10) and
push them together by hand. If propeller shaft
assemblies (6 and 10) can be separated by
hand, then snap ring on propeller shaft joint (9)
1. Two-piece propeller shaft assembly. Refer to "One
and Two-Piece Propeller Shaft Assembly Replace-
ment" in this section.
2. Front propeller shaft assembly from rear propeller
shaft assembly. Refer to "Two-Piece Propeller Shaft
Assembly" in this section.
3. Center support bearing (7).
• Stand propeller shaft assembly (6) on end in
press with center support bearing (7) supported
by press bars.
• Press propeller shaft assembly (6) down and
off center support bearing (7).
1. Center support bearing (7).
• Press center support bearing (7) onto propeller
shaft assembly (6) using press.
2. Front propeller shaft assembly to rear propeller shaft
assembly. Refer to "Two-Piece Propeller Shaft
Assembly" in this section.
3. Two-piece propeller shaft assembly. Refer to "One
and Two-piece Propeller Shaft Assembly Replace-
ment" in this section.

6 SHAFT ASSEMBLY, FRONT PROPELLER

7 BEARING, PROPELLER SHAFT CENTER SUPPORT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER

PC0011-4A-F-RP

Figure 11 - Separating the Two-Piece Propeller Shaft Assembly

 PROPELLER SHAFT 4A-13

UNIVERSAL JOINTS
When taking apart a propeller shaft assembly, two
types of universal joints may be found: nylon injected ring
and snap ring.
NOTICE: Never clamp propeller shaft tubing in a
vise, as the tube may be dented. Always clamp on
one of the yokes and support the shaft horizontally.
Avoid damaging the propeller shaft slip yoke sealing
surface. Nicks may damage the bushing or cut the
transmission extension housing seal. Mark the slip
joint and propeller shaft to ensure correct reas-
sembly.

Nylon Injected Ring Type

Figures 12 through 14
Tools Required: A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
J 9522-3 U-Joint Bearing Separator 19 CAP, BEARING
J 9522-5 U-Joint Bearing Spacer Remover
PC0013-4A-F-RP

l+f+I Disassemble Figure 13 - Installing Universal Joint Bearing Spacer

1. Support propeller shaft assembly in a horizontal
position in line with base plate of a press.
2. Place universal joint so that lower ear of shaft yoke
is supported on a 1 1/8-inch socket.
3. Lower bearing cap (19) out of yoke ear by placing
J 9522-3 on open horizontal bearing caps (19) and
pressing lower bearing cap ( 19) out of yoke ear. This
shears nylon injected ring on lower bearing cap ( 19).
If bearing cap (19) is not completely removed, lift
J 9522-3 and insert J 9522-5 between seal (23) and
bearing cap (19). Complete removal of bearing cap
(19) by pressing it out of yoke.
4. Rotate propeller shaft assembly. Shear opposite
nylon injected ring.
5. Opposite bearing cap (19) out of yoke.
6. Spider (2) from yoke.
J 9522-3
Remover
• There are no bearing retainer grooves in pro-
duction bearing caps ( 19), therefore, they can-
not be reused.
• If front universal joint is being replaced,
remove pair of bearing caps ( 19) from propel-
ler shaft slip yoke in same manner.
l~I Clean
• Yoke in area locating retainer ring (4) to insure
proper assembly.
• All sheared nylon from universal joint cup
bore
m Important
• Production universal joints of this type cannot
be reassembled. Nylon injected ring types are
replaced by external snap ring types.
When reassembling a propeller shaft assembly,
always install a complete universal joint service kit. This
kit includes one pregreased spider (2), four service bear-
ing cap assemblies with seals (23), needle roller bearings
(21), delrin round washers (20), delrin flat washers (22),
grease and four retainer rings ( 4 ). Make sure that the seals
(23) are in place on the service bearing caps ( 19) to hold
the needle roller bearings (21) in place during handling.

l+!+I Assemble
For universal joint assembly procedure, refer to
"Snap Ring Type" in the following procedure.
A 11/s SOCKET
TO SUPPORT YOKE
EAR (MUST CLEAR Snap Ring Type
BEARING CAP)
2 SPIDER, PROPELLER SHAFT---- Figures 12 through 17
UNIVERSAL JOINT PC0012-4A-F-RP
Tools Required:
Figure 12 - Pressing Out Universal Joint Bearing J 9522-3 U-Joint Bearing Separator
4A·14 PROPELLER SHAFT

23 4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER

A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
19 CAP, BEARING
20 WASHER, DELRIN ROUND
21 BEARING, NEEDLE ROLLER
22 WASHER, DELRIN FLAT
23 SEAL
PC0014-4A-F-RP
Figure 14 - Service Universal Joint
J 9522-5 U-Joint Bearing Spacer Remover
NOTICE: Use care not to loosen or damage dust
seals. If dust seals are loose or damaged, replace the
entire universal joint.
These universal joints are designed for extended life
and do not require periodic inspections or lubrication.
When these joints are taken apart, repack bearings and
lubricant reservoir at the end of trunnions with chassis
lubricant GM PIN 1052356 or GM PIN 1052497, or
equivalent.
l+!+I Assemble
Ii) Disassemble
1. Retainer rings (4 ). If retainer ring (4) does not
readily snap out C?f grooves, tap end of bearing cap
(19) hghtly to relieve pressure against retainer ring
(4).
BEARING RETAINER
PC0016-4A·F-RP
Figure 16 - Installing Propeller Shaft Universal Joint Spider
Bearing Retainer Ring
2. Support propeller shaft assembly in a horizontal
position in line with base plate of a press.
3. Place universal joint so lower ear of yoke is sup-
ported on a 1 1/8-inch socket.
4. Lower bearing cap (19) out of yoke ear. Place
J 9522-3 on open horizontal bearing cap (19). If
bearing cap (19) is not completely removed, lift
J 9522-3 and insert J 9522-5 between seal (23) and
bearing cap (19) being removed. Complete removal
of bearing cap ( 19) by pressing it out of yoke.
5. Rotate propeller shaft assembly and press opposite
bearing cap (19) out of yoke.
6. Spider (2) from yoke.
1. One bearing cap (19) part way into one side of yoke.
Turn this yoke ear to the bottom.
• Insert J 9522-3 seating trunnion in bearing cap
(19).
2. Opposite bearing cap (19) part way.
IL•l 1nspect
• Both trunnions to ensure positioning is straight
and true into bearing caps (19).

A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
,-
19 CAP, BEARING STRIKE TUBE YOKE
PC0015-4A·F-RP EAR IN THIS AREA KC0210-4A-B-RP

Figure 15 - Partially Inserted Bearing Cap Figure 17 - Seating Propeller Shaft Universal Joint Spider
Bearing Retainer Ring
 PROPELLER SHAFT 4A·15

3. Press against opposite bearing caps (19), working clears inside of yoke.
spider (2) all of the time to ensure free movement of
trunnions in bearings. 5. Retainer ring (4) by pressing into place.

ll'l'I Inspect • Continue pressing until opposite side can be

• Needle roller bearings (21) for binding. If
binding, one or more needle roller bearings
(21) has probably tipped under end of trun-
nion.
4. Stop pressing when one bearing retainer groove
snapped into place. If needed, strike yoke
firmly with a hammer to aid in seating the
retainer rings (4 ). This springs yoke ears
slightly. ·
6. Repeat steps 1 through 5 for other half of universal
joint.

SPECIFICATIONS
GENERAL SPECIFICATIONS
One-Piece Propeller Shaft Assembly Runout
Front Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055 ")
Center Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055")
Rear Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055")
Two-Piece Propeller Shaft Assembly Runout
Front Propeller Shaft Assembly Center Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055")
Rear Propeller Shaft Assembly Front Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055")
Rear Propeller Shaft Assembly Rear Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055")

FASTENER TIGHTENING SPECIFICATIONS

Propeller Shaft-to-Center Support Bearing Bolt/Screw ...................... 50 N•m (37 lb. ft.)
Propeller Shaft-to-Differential Yoke Bolt/Screw ........................... 22 N•m (16 lb. ft.)

SPECIAL TOOLS

1.
2
· (!Qu
/ /
, I
1 J 9522-5

4. J 8001
5.

~~
6.

J 33008

1. U-JOINT BEARING SEPARATOR

2. U-JOINT BEARING SPACER REMOVER
3. RUNOUT GAGE
4. DIAL INDICATOR SET
5. SLIDE HAMMER
6. AXLE SHAFT REMOVER
PC0017·4A·f.RP

SECTION 48
REAR AXLE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
reused, and those requiring thread locking compound will be c.alled out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description ........................ 4B-1
Standard Rear Axle Assembly .............. 4B-l
Operation ............................ 4B-3
Limited Slip Rear Axle Assembly ........... 4B~3
Rear Axle Assembly Identification .......... 4B-5
Maintenance and Lubrication .............. 4B-5
Diagnosis ................................ 4B-5
Rear Axle Noises . . . . . . . . . . . . . . . . . . . . . . . . 4B-6
Gear Noise ........................... 4B-6
Bearing Noise ........................ 4B-7
Rear Axle Shaft Bearing Noise . . . . . . . . . . . 4B-7
Knock at Low Speeds .................. 4B-7
Backlash Clunk ....................... 4B-7
Limited Slip Rear Axle Assembly . . . . . . . . . . . 4B-7
Checking Limited Slip Operation . . . . . . . . . 4B-7
Rear Axle Standard and Limited Slip
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8
Inspection and Diagnosis . . . . . . . . . . . . . . . . . . 4B-8
Differential Ring Gear Tooth
Nomenclature ....................... 4B-9
Tooth Contact Pattern Test ............... 4B-9
Effects of Increasing Load on
Tooth Contact Pattern . . . . . . . . . . . . . . . . 4B-9
Adjustments Affecting Tooth Contact . . . . . . 4B-9
Effects of Differential Drive Pinion
Gear Position on Tooth Pattern . . . . . . . . 4B-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 4B-12
Rear Axle Lubricant Fill and Check ........ 4B-12
Rear Axle Housing Cover and Gasket ....... 4B-12
GENERAL DESCRIPTION
STANDARD REAR AXLE ASSEMBLY
Figures 1 through 4
The rear axle assembly is the semi-floating hypoid
type in which the vehicle weight is carried on the housing
assembly (16). The rear axle assembly is designed for use
with an open driveline and coil spring assemblies. The
rear axle assembly has a hypoid type ring gear (20) with
the centerline of the drive pinion gear (23) below the
centerline of the ring gear (20).
All parts necessary to transmit power from the
propeller shaft to the rear tire and wheel assemblies are
enclosed in the housing assembly (16). A removable steel
cover (43) bolted to the rear of the housing assembly (16)
REAR AXLE 48·1
Rear Axle Shaft ........................ 4B-12
Rear Axle Shaft Bearing Assembly
and/or Bearing Seal . . . . . . . . . . . . . . . . . . . 4 B-13
Differential Drive Pinion Gear
Yoke and Seal ........................ 4B-14
Rear Axle Assembly .................... 4B-15
Rear Wheel Bolt/Screw .................. 4B-16
Unit Repair .............................. 4B-17
Differential Case . . . . . . . . . . . . . . . . . . . . . . . 4 B-18
Speed Sensor Reluctor Wheel ............. 4B-20
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash ............ 4B-20
Differential Bearing Assembly
Preload Adjustment ................... 4B-21
Differential Drive Pinion Gear ............ 4B-22
Differential Drive Pinion Gear
Outer Bearing Assembly . . . . . . . . . . . . . 4B-23
Differential Drive Pinion Gear
Inner Bearing Assembly ............. 4B-23
Differential Drive Pinion Gear Depth ....... 4B-24
Differential Case (Limited Slip) ........... 4B-26
Rear Axle Housing Replacement ........... 4B-26
R~a'. A~le Assembly with Disc Brakes ...... 4B-27
Spec1f1cat10ns ............................ 4B-28
Fastener Tightening Specifications ......... 4B-28
General Specifications . . . . . . . . . . . . . . . . . . . 4B-29
Limits for Fitting and Adjusting . . . . . . . . . . . 4B-29
Rear Axle Assembly Usage . . . . . . . . . . . . . . . 4B-29
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-29
permits service of the rear axle assembly without remov-
ing the entire assembly from the vehicle.
A universal joint connects the rear end of the pro-
peller shaft to the yoke (3). The yoke (3) has a splined end
which fits over and drives the drive pinion gear (23). Two
preloaded tapered roller bearing assemblies support the
drive pinion gear (23) in the housing assembly (16). The
races of the inner bearing assembly (18) and the outer
bearing assembly (7) are a tight press fit in the housing
assembly (16). The inner bearing assembly (18) is a tight
press fit onto the drive pinion gear (23). The outer bearing
assembly (7) combines a light press fit to a close sliding
fit on the yoke end of the. pinion gear stem. The races of
the inner and outer bearing assemblies ( 18 and 7) are
pressed against shoulders recessed in the housing assem-
bly (16).
48-2 REAR AXLE

L..--------~-----...1 PC0001·4B-F-RP

Figure 1 - Standard Rear Axle Assembly

 REAR AXLE 48·3

A DIFFERENTIAL ASSEMBLY 36 GEAR, DIFFERENTIAL PINION

B OPTIONAL DISC BRAKE ASSEMBLY 37 WASHER, DIFFERENTIAL PINION GEAR THRUST
1 NUT, DIFFERENTIAL DRIVE PINION GEAR 38 WASHER, DIFFERENTIAL SIDE GEAR THRUST
2 WASHER, DIFFERENTIAL DRIVE PINION GEAR 39 WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR 40 GEAR, DIFFERENTIAL SIDE
5 DEFLECTOR, DIFFERENTIAL DRIVE PINION GEAR DIRT 41 BOLT/SCREW, REAR AXLE HOUSING
6 SEAL, DIFFERENTIAL DRIVE PINION GEAR 43 COVER, REAR AXLE HOUSING
7 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION 44 BEARING ASSEMBLY, REAR AXLE SHAFT
GEAR OUTER 45 GASKET, REAR AXLE HOUSING COVER
9 PLUG, REAR AXLE HOUSING DRAIN 46 PLATE, REAR BRAKE BACKING
15 SPACER, DIFFERENTIAL DRIVE PINION GEAR BEARING 48 BOLT/SCREW, REAR BRAKE BACKING
16 HOUSING, ASSEMBLY, REAR AXLE 49 SEAL, REAR AXLE SHAFT BEARING
17 VENT, REAR AXLE 54 LOCK, REAR AXLE SHAFT
18 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION 58 DRUM ASSEMBLY, REAR BRAKE
GEAR INNER 59 BRAKE ASSEMBLY, REAR
19 SHIM, DIFFERENTIAL DRIVE PINION GEAR 61 BOLT/SCREW, REAR WHEEL
20 GEAR, DIFFERENTIAL RING 63 SHAFT REAR AXLE (DRUM BRAKE ASSEMBLIES)
22 CAP, DIFFERENTIAL CARRIER BEARING 64 NUT, REAR BRAKE BACKING PLATE
23 GEAR, DIFFERENTIAL DRIVE PINION 65 PLATE, REAR BRAKE CALIPER ASSEMBLY MOUNTING
24 SHIM, DIFFERENTIAL BEARING 66 BOLT/SCREW, CALIPER ASSEMBLY MOUNTING
25 SPACER, DIFFERENTIAL BEARING 67 SHIM, AXLE TUBE FLANGE
26 BOLT/SCREW, DIFFERENTIAL BEARING CAP 68 NUT, REAR BRAKE CALIPER MOUNTING PLATE
28 BOLT/SCREW, DIFFERENTIAL RING GEAR 69 CALIPER ASSEMBLY, REAR BRAKE
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT 70 SHAFT, REAR AXLE (DISC BRAKE ASSEMBLIES)
LOCK 71 ROTOR ASSEMBLY, REAR BRAKE
32 BEARING ASSEMBLY, DIFFERENTIAL 72 BOLT/SCREW, REAR BRAKE BACKING PLATE
33 CASE, DIFFERENTIAL 73 BOLT/SCREW, SENSOR PLUG MOUNTING
34 MAGNET, REAR AXLE HOUSING CHIP COLLECTING 75 SENSOR ASSEMBLY, WHEEL SPEED
35 SHAFT, DIFFERENTIAL PINION GEAR

PC0002-48-F-RP

Figure 2 ~ Standard Rear Axle Assembly - Legend

Tightening nut ( 1) compresses a collapsible spacer
( 15) that bears against the outer bearing assembly (7) and
a shoulder on the pinion stem. This spacer (15) is used to
enable automatic bearing preload adjustment and main-
tain a preload on both inner and outer bearing assemblies
( 18 and 7). Adjustment of the fore-and-aft position of the
drive pinion gear (23) is obtained by placing selective
shims (19) between the head of the drive pinion gear (23)
and the inner bearing assembly ( 18).
The case (33) is one piece and is supported in the
housing assembly (16) by two tapered roller side bearing
assemblies (32). These are preloaded by inserting shims
(24) between the bearing assemblies (32) and the housing
assembly (16). The case (33) is positioned for proper dif-
ferential ring gear-to-differential drive. pinion gear back-
lash by varying the shim thickness from side to side. The
ring gear (20) is bolted to the case (33). A speed sensor
reluctor wheel (39) is press fit to the case (33). A wheel
speed sensor assembly (75) is mounted to the housing
assembly (16) (Figure 1) or the mounting plate (65)
(Figure 3). This sensor provides wheel speed information
to the electronic brake control module (EBCM) assembly.
For further information, refer to SECTION 5El.
Two side gears (40) have splined bores for driving
the axle shafts (63 or 70). They are positioned to turn in
counterbored cavities in the case (33). The pinion gears
(36) have smooth bores and are held in position by a solid
pinion gear shaft (35), mounted and locked in the case
(33). All four gears are in mesh with each other. The pin-
ion gears (36) turn freely on the pinion gear shaft (35),
acting as idler gears when the rear wheel assemblies are
turning at different speeds. The pinion gears (36) and side
gears (40) are backed by steel thrust washers (37 and 38).
Operation
When the vehicle turns a corner, the differential
assembly allows the outer rear tire and wheel assembly to
tum faster than the inner tire and wheel assembly. The
inner tire and wheel assembly, turning slower with respect
to the outer tire and wheel assembly, slows its differential
side gear (as the axle shaft is splined to the side gear). The
differential pinion gears roll around the slowed differen-
tial side gear, driving the other differential side gear tire
and wheel assembly faster.
LIMITED SLIP REAR AXLE ASSEMBLY
Limited slip rear axle assemblies have several defi-
nite operating characteristics. An understanding of these
characteristics is necessary to aid diagnosis.
The energizing force comes from the thrust side of
the gears. Consequently, a free spinning tire and wheel
assembly may not have enough resistance to driving
torque to apply the clutch packs or cones. If this occurs,
applying the parking brake a few notche.s will provide
enough resistance to energize the cones.
Energizing the cones is independent of acceleration;
therefore, a very slow application of the throttle on start-
ing is recommended to provide maximum traction by pre-
venting "break away" of either rear tire and wheel
assembly.
48-4 REAR AXLE

RC0001·4B·F·RP

Figure 3 - Rear Axle Assembly Equipped With Traction Control (Acceleration Slip Regulation)
 REAR AXLE 48·5

A DIFFERENTIAL ASSEMBLY 35 SHAFT, DIFFERENTIAL PINION GEAR

B OPTIONAL DISC BRAKE ASSEMBLY 36 GEAR, DIFFERENTIAL PINION
C WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR 37 WASHER, DIFFERENTIAL PINION GEAR THRUST
1 NUT, DIFFERENTIAL DRIVE PINION GEAR 38 WASHER, DIFFERENTIAL SIDE GEAR THRUST
2 WASHER, DIFFERENTIAL DRIVE PINION GEAR 40 GEAR, DIFFERENTIAL SIDE
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR 41 BOLT/SCREW, REAR AXLE HOUSING
5 DEFLECTOR, DIFFERENTIAL DRIVE PINION GEAR DIRT 43 COVER, REAR AXLE HOUSING
6 SEAL, DIFFERENTIAL DRIVE PINION GEAR 44 BEARING ASSEMBLY, REAR AXLE SHAFT
7 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION G'EAR 45 GASKET, REAR AXLE HOUSING COVER
OUTER 46 PLATE, REAR BRAKE BACKING
9 PLUG, REAR AXLE HOUSING DRAIN 48 BOLT/SCREW, REAR BRAKE BACKING
15 SPACER, DIFFERENTIAL DRIVE PINION GEAR BEARING 49 SEAL, REAR AXLE SHAFT BEARING
16 HOUSING, ASSEMBLY, REAR AXLE 54 LOCK, REAR AXLE SHAFT
17 VENT, REAR AXLE 58 DRUM ASSEMBLY, REAR BRAKE
18 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION GEAR 59 BRAKE ASSEMBLY, REAR
INNER 61 BOLT/SCREW, REAR WHEEL
19 SHIM, DIFFERENTIAL DRIVE PINION GEAR 63 SHAFT REAR AXLE (DRUM BRAKE ASSEMBLIES)
20 GEAR, DIFFERENTIAL RING 64 NUT, REAR BRAKE BACKING PLATE
22 CAP, DIFFERENTIAL CARRIER BEARING 65 PLATE, REAR BRAKE CALIPER ASSEMBLY MOUNTING
23 GEAR, DIFFERENTIAL DRIVE PINION 66 BOLT/SCREW, CALIPER ASSEMBLY MOUNTING
24 SHIM, DIFFERENTIAL BEARING 67 SHIM, AXLE TUBE FLANGE
25 SPACER, DIFFERENTIAL BEARING 68 NUT, REAR BRAKE CALIPER MOUNTING PLATE
26 BOLT/SCREW, DIFFERENTIAL BEARING CAP 69 CALIPER ASSEMBLY, REAR BRAKE
28 BOLT/SCREW, DIFFERENTIAL RING GEAR 70 SHAFT, REAR AXLE (DISC BRAKE ASSEMBLIES)
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT LOCK 71 ROTOR ASSEMBLY, REAR BRAKE
32 BEARING ASSEMBLY, DIFFERENTIAL 72 BOLT/SCREW, REAR BRAKE BACKING PLATE
33 CASE, DIFFERENTIAL . 75 SENSOR ASSEMBLY, WHEEL SPEED
34 MAGNET, REAR AXLE HOUSIN.G CHIP COLLECTING

RC0002-4B·f·RP

Figure 4 - Rear Axle Equipped With Traction Control (Acceleration Slip Regulation) - Legend

All rear axle parts of vehicles with the limited slip
rear axle assembly are interchangeable with those
equipped with the standard rear axle assembly, except for
the differential case. It is similar in all respects to the stan-
dard differential case, with the addition of cone clutches
splined to each side gear. The Auburn limited slip differ-
entia.l case is non-serviceable and must be replaced.
REAR AXLE ASSEMBLY IDENTIFICATION
Figures
The rear axle assembly identification code and
manufacturer's code must be known before attempting to
adjust or repair axle shafts or the differential assembly.
Rear axle ratio, differential type, manufacturer, and build
date information is stamped on the right axle tube on the
forward side or on a metal tag on the housing cover (43).
The service parts identification label also has RPO codes
for the rear axle assembly printed on it.
MAINTENANCE AND LUBRICATION
Figures 1 through 4
NOTICE: See "Notice" on page 4B-1 of this sec-
tion.
To check or add lubricant, hoist vehicle at suspen-
sion contact points. Refer to SECTION OA. Keep vehicle
level. Clean dirt or foreign material from around plug
opening before removing the plug (9). Maintain lubricant
level from flush with bottom of opening to no lower than
15 mm (9/16 inch) below opening. Always replace
plug (9). Tighten to 35 N•m (26 lb. ft.). Use GM
PIN 12345977 axle lubricant or SAE 80W-90 GL-5 gear
lubricant or equivalent.
Limited slip differential assemblies should have
lubricant drained and refilled at the first 12 500 km
(7,500 miles). Limited slip differential assemblies also
require 118 ml (4 fl. oz.) of GM P/N 1052358 limited slip
differential additive and GM P/N 12345977 axle lubricant
or SAE 80W-90 GL-5 gear lubricant or equivalent.
If the vehicle is used to pull a trailer, change lubri-
cant every 12 500 km (7,500 miles) in either type differ-
ential assembly.
DIAGNOSIS
Many noises reported as coming from the rear axle
assembly actually originate from other sources such as
tire and wheel assemblies, road surfaces, wheel bearing
assemblies, engine assembly, transmission assembly,
muffler or body. A thorough and careful check should be
made to determine the source of the noise before taking
apart the rear axle assembly. Noise which originates in
other places cannot be corrected by adjustment or replace-
ment of parts in the rear axle assembly. Rear axle differen-
tial gears, like any other mechanical device, are not
absolutely quiet and should be accepted as being commer-
cially quiet unless some abnormal noise is present.
48·6 REAR AXLE
A AXLE CODE
B MANUFACTURER
C DAY BUILT
D SHIFT
E LIMITED SLIP TAG
F AXLE CODE TAG
G FRONTVIEW
H REARVIEW
43 COVER, REAR AXLE HOUSING
Figure 5 - Rear Axle Assembly Identification
To make a systematic check for axle noise under
standard conditions, observe the following:
1. Check rear axle lubricant to ensure correct level,
then drive vehicle far enough to thoroughly warm up
rear axle lubricant.
2. Select a level asphalt road to reduce tire noise and
body drumming.
3. Note speed at which noise occurs. Then stop vehicle
and with the transmission assembly control lever in
"NEUTRAL," run engine slowly up and down
through engine speeds, corresponding to vehicle
speed at which noise was most pronounced, to deter-
mine if it is caused by exhaust, muffler roar or other
engine conditions.
4. Tire noise changes with different road surfaces, but
rear axle noise does not. Temporarily inflating all
tires to approximately 345 Kpa (50 psi) for test pur-
poses only, will alter noise caused by the tires, but
will not affect noise caused by the rear axle assem-
bly. Rear axle noise usually stops when coasting at
speeds under 48 km/h (30 mph). Tire noise contin-
ues, but with a lower tone as vehicle speed is
reduced. Rear axle noise usually changes when
comparing drive and coast, but tire noise remains
about the same.
• Distinguish between tire noise and rear axle
noise by noting if noise varies with various
speeds or sudden acceleration and decelera-
tion. Exhaust and axle assembly noises show
variations under these conditions while tire
noise remains constant and is more noticeable
at speeds of 32 to 48 km/h (20 to 30 mph).
Check for tire noise by driving vehicle over
smooth pavements or dirt roads (not gravel)
with tires at normal pressure. If noise is caused
by tires, it will noticeably change or disappear
and appear again with changes in the road sur-
face.
A B
H
PC0003-48-F-RP
5. Loose or rough front wheel inner or outer bearing
assemblies will cause a noise which may be con-
fused with rear axle noise. Front wheel inner or
outer bearing noise does not change when compar-
ing drive and coast. Light application of the brake
pedal assembly while holding the vehicle speed
steady will often cause front wheel inner and outer
bearing noise to diminish, as this takes some weight
off the bearing assembly. Front wheel inner and
outer bearing assemblies may be easily checked for
noise by jacking up the tire and wheel assemblies
and spinning them or by shaking the tire and wheel
assemblies to determine if bearing assemblies are
loose.
6. Rear suspension rubber bushings and spring insula-
tors dampen out rear axle assembly noise when cor-
rectly installed. Check that no metallic contact
exists between the spring and spring opening in the
underbody or between lower control arm bushings
and underbody or axle housing brackets. Metal-
to-metal contact at those points may result in tele-
graphing road noise and normal axle noise which
would not be objectionable if dampened by bush-
ings.
REAR AXLE NOISES
Gear Noise
After the noise has been determined as being in the
rear axle assembly, the type of noise should be established
to help in making repairs if necessary.
Gear noise (whine) is audible from 32 to 89 km/h
(20 to 55 mph) under four driving conditions:
1. Drive - Acceleration or heavy pull.
2. Road Load - Vehicle driving load or constant speed.
3. Float - Using enough throttle to keep the vehicle
from driving the engine assembly, the vehicle slows
down gradually but the engine assembly still pulls
slightly.

4. Coast - Throttle closed and vehicle in gear. Gear
noise most frequently has periods where noise is
more noticeable, usually 48 to 64 km/h (30 to 40
mph) and 80 to 89 km/h (50 to 55 mph).
Bearing Noise
Bad bearing assemblies generally produce more of a
rough growl or grating sound, rather than the whine typi-
cal of gear noise. Bearing noise frequently "wow-wows"
at constant bearing rpm, indicating a faulty differential
drive pinion gear or side bearing assembly. This noise
could easily be confused with rear axle shaft bearing
noise. Inspect and replace as required.
Rear Axle Shaft Bearing Noise
A rough rear axle shaft bearing assembly produces a
noise that continues with the vehicle coasting at low
speed and transmission assembly control lever in "NEU-
TRAL." Noise may diminish by gentle braking. With rear
tire and wheel assemblies jacked up, spin rear tire and
wheel assemblies by hand while listening at hub assem-
blies for evidence of rough (noisy) rear axle shaft bearing
assembly.
Knock at Low Speeds
Low speed knock can be caused by a worn universal
joint or a side gear hub counterbore in the differential case
worn oversize. Inspect and replace universal joint or the
differential case and side gear as required.
Backlash Clunk
Excessive clunk with acceleration and deceleration
is caused by worn differential drive pinion gear shaft,
worn differential case, excessive clearance between the
rear axle shaft and side gear splines, excessive clearance
between side gear hub and counterbore in case, worn dif-
ferential drive pinion gear and side gear teeth, worn dif-
ferential pinion gear thrust washers and excessive
differential ring gear-to-differential drive pinion gear
backlash. Remove worn parts and replace as required,
selecting close fitting parts when possible. Adjust differ-
ential ring gear-to-differential drive pinion gear backlash.
Refer to "Differential Ring Gear-to-Differential Drive
Pinion Gear Backlash" in this section.
LIMITED SLIP REAR AXLE ASSEMBLY
Improper operation is generally indicated by clutch
slippage or grabbing. Sometimes this produces a chatter
or whirring sound. These sounds are not always indicative
of failure as they could be produced from lack of proper
lubrication. For example, under certain conditions where
one tire and wheel assembly is on a very slippery surface
and the other on dry pavement, wheel spin can occur if
hard acceleration is attempted. Continued spinning may
cause audible noise, such as a whirring sound, due to the
cones lacking sufficient lubricant. This does not necessar-
ily indicate a failure of the unit.
During regular operation (straight ahead driving)
when both tire and wheel assemblies rotate at equal
speeds, there is an equal driving force delivered to each
tire and wheel assembly. When cornering, the inside tire
and wheel assembly requires extra driving force causing
slippage in the clutch cone. Consequently, the operational
REAR AXLE 48·7
life of the limited slip unit is dependent upon equal rota-
tion of both tire and wheel assemblies during straight
ahead operation. If wheel rotation for both rear tire and
wheel assemblies is not equal during straight ahead opera-
tion, the limited slip unit will constantly be functioning as
if the vehicle were cornering. This will impose constant
slippage on the clutch and will eventually lead to abnor-
mal wear on clutch cone.
Checking Limited Slip Operation
Figure 6
Tools Required:
J 2619-01 Slide Hammer
with 1/2 x 13 Adapter
J 21579 Axle Shaft Remover
1. Place transmission assembly control lever in
"PARK" position, or in gear if manual transmission
assembly, parking brake lever assembly released.
2. Raise both rear tire and assemblies off the floor.
3. Remove one tire and wheel assembly. Refer to
SECTION 3E.
4. Install J 21579, 1/2 x 13 adapter from J 2619-01 and
a torque wrench.
5. Measure torque required to rotate one tire and wheel
assembly. Torque should be between 169 and
305 N•m (125 and 225 lb. ft.).
6. Place transmission assembly control lever in "NEU-
TRAL" position and lower one rear tire and wheel
assembly to ground.
7. Measure torque required to rotate raised tire and
wheel assembly. Torque should be between 58 and
91 N•m (43 and 67 lb. ft.).
8. Install tire and wheel assembly. Refer to
SECTION 3E.
The differential case must be replaced as an assem-
bly if any of the above checks do not fall within specifica-
tions.
A 1/2 x 13 ADAPTER FROM J 2619-01
B TORQUE WRENCH
NC4004-4B-B-RP
Figure 6 - Measuring Limited Slip Rotating Torque
48-8 REAR AXLE

REAR AXLE STANDARD AND LIMITED SLIP DIAGNOSIS

CONDITION CAUSE
1. Noise is the same in "DRIVE" or when coasting. a. Road noise.
b. Tire noise.
c. Front wheel bearing noise.
d. Incorrect driveline angles.
2. Noise changes on a different type of road. a. Tire noise.
b. Road noise.
3. Noise tone lower as vehicle speed is lowered. a. Tire noise.
4. Noise is produced with vehicle standing and driv- a. Engine noise.
ing. b. Transmission noise.
5. Vibration. a. Rough rear axle shaft bearing assembly.
b. Unbalanced or damaged propeller shaft assembly.
c. Tire unbalance.
d. Worn universal joint in propeller shaft assembly.
e. Incorrect driveline angles.
f. Mis-indexed propeller shaft assembly at drive pinion
gear yoke.
g. Drive pinion gear yoke runout too great.
6. A knock or click approximately every two a. Rear axle shaft bearing assembly.
revolutions of rear wheel assembly.
7. Noise most pronounced on turns. a. Differential side gear and pinion gear noise.
8. Continuous low pitch whirring or scraping noise a. Drive pinion gear inner or outer bearing noise.
starting at relatively low speed.
9. Drive noise, coast noise or float noise. a. Ring and drive pinion gear noise.
10. Clunk on acceleration or deceleration. a. Worn differential pinion gear shaft in case or side
gear hub counterbore in case worn oversize.
b. Worn universal joint on propeller shaft assembly.
c. Differential drive pinion gear yoke lubrication
insufficient.
11. Groan in forward or reverse. a. Wrong lubricant in rear axle assembly.
12. Chatter on turns. a. Wrong lubricant in rear axle assembly.
b. Clutch cones worn (limited slip).
13. Clunk or knock on rough road operation. a. Excessive end play of rear axle shafts.

INSPECTION AND DIAGNOSIS
A close examination of the rear axle assembly prior
to taking it apart will often reveal valuable information as
to the extent and type of repairs or adjustments necessary.
This information and the report of the malfunction pro-
vides a basis for determining the degree of tearing down
required. Frequent causes of rear axle noise are improper
backlash, differential drive pinion gear inner or outer
bearing preload, differential side bearing preload, or a
combination of these items. A few simple adjustments
may be all that are necessary to correct the problem.
Before removing the differential case from the hous-
ing assembly, these items should be checked and the
results recorded and analyzed: (1) backlash; (2) total dif-
ferential assembly preload; and (3) tooth contact pattern.
Use care at all times to keep dirt and other foreign
matter, such as grinder dust, soot, or sand, away from the
rear axle assembly to prevent the possibility of subse-
quent failure.

Differential Ring Gear Tooth Nomenclature
Figure 7
The side of the differential ring gear tooth which
curves outward, or is convex, is referred to as the "drive"
side. The concave side is the "coast" side. The end of the
tooth nearest center of the differential ring gear is referred
to as the "toe" end. The end of the tooth farthest away
from the center is the "heel" end. The toe end of the tooth
is smaller than the heel end.
Tooth Contact Pattern Test
Figures 1 through 4, 7 and 8
Tool Required:
J 39446 ABS Exciter Ring Protector Kit
NOTICE: It is very important that tooth contact be
tested beforethe differential assembly is taken apart.
Variations in the differential assembly or differential
drive pinion gear inner bearing assembly may cause
the differential drive pinion gear to be too far away
from, or close to, the differential ring gear. Thus, the
tooth contact must be tested and corrected, if neces-
sary, or the gears may be noisy.
NOTICE: See "Notice" on page 4B-l of this sec-
tion.
!i,I Clean
I. All dirt from area of cover (43) before removing
cover (43).
2. Remove housing cover. Refer to "Rear Axle Hous-
ing Cover and Gasket" in this section.
3. Wipe oil out of the housing assembly (16)and care-
fully clean each tooth of the ring gear (20).
4. Select correct exciter ring protector from J 39446
and attach to speed sensor reluctor wheel (39) on
vehicles with standard rear axle assemblies only.
B ential bearing assemblies will also cause a change in tooth
A TOE
B HEEL
C CONVEX SIDE IDRIVE)
D CONCAVE SIDE (COAST)
E CORRECT PATTERN
NC4005·4B·B-RP
Figure 7 - Differential Ring Gear Tooth Nomenclature
REAR AXLE 46·9
5. Use gear marking compound GM PIN 1052351 or
equivalent and apply this mixture sparingly to all
ring gear teeth, using a medium stiff brush. When
properly used, the area of differential drive pinion
gear tooth contact will be visible when hand load is
applied.
l~I Tighten
• Bolts/screws (26) to 75N•m (55 lb. ft.).
6. Apply parking brake until a torque of 54 to 70 N•m
(40 to 52 lb. ft.) is required to turn drive pinion
gear (23).
A test made without loading the gears will not give a
satisfactory pattern. Turn yoke (3) with a wrench so
that ring gear (20) rotates one full revolution.
Reverse rotation so that ring gear (20) rotates one
revolution in the opposite direction.
7. Observe pattern on the ring gear teeth and compare
with Figure 8. ·
8. If pattern is acceptable, remove J 39446.
9. Install housing cover. Refer to "Rear Axle Housing
Cover and Gasket" in this section.
Effects of Increasing Load on Tooth
Contact Pattern
When the "load" on the differential ring and drive
pinion gears is increased, such as when the vehicle is
accelerated forward from standstill or from normal drive,
the tooth contact will tend to spread out and, under very
heavy load, will extend from near toe to near heel on the
drive side. The entire contact also tends to shift toward the
heel under increasingly heavier loads and will become
somewhat broader with respect to tops and bottoms of
teeth. The patterns obtained by this tooth contact pattern
test approximate a light load and, for this reason, they will
extend only about halfway.
The important thing to note is that the contact pat-
tern is centrally located up and down on the face of the
differential ring gear teeth.
Insufficiently preloaded drive pinion gear and differ-
contact pattern under load.
Adjustments Affecting Tooth Contact
Figure 9
Two adjustments can be made which will affect the
tooth contact pattern: backlash and position of drive pin-
ion gear (23) in the housing assembly. The effects of bear-
ing preloads are not readily apparent on hand-loaded
tooth contact pattern tests.
Backlash is adjusted by means of shims (24). They
move the entire differential assembly closer to or farther
from the drive pinion gear (23). Shims (24) are also used
to set differential bearing preload. If the thickness of the
right shim (24) is increased, along with decreasing the left
shim thickness, backlash will increase. The backlash will
decrease if the left shim thickness is increased, along with
a decrease in right shim thickness.
The position of the drive pinion gear (23) is adjusted
by increasing or decreasing the shim thickness between
48·10 REAR AXLE

D E B

A LOW FLANK CONTACT: DECREASE DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES SMALLER DIAME-
TER OF DIFFERENTIAL DRIVE PINION GEAR OUT TOWARD DIFFERENTIAL RING GEAR CENTER LINE
B HEEL CONTACT: DECREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD TOE
C HIGH FACE CONTACT: INCREASE DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES LARGER DIAMETER
OF DIFFERENTIAL DRIVE PINION GEAR IN TOWARD CENTER OF DIFFERENTIAL RING GEAR
D TOE CONTACT: INCREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD HEEL
E DESIRED PATTERN: IN CENTER OF DIFFERENTIAL RING GEAR TOOTH

PC8006·4B-D-RP

Figure 8 - Differential Ring Gear Tooth Contact Pattern Diagnosis Chart

 REAR AXLE 48-11

the drive pinion gear head and race of the differential

drive pinion gear inner bearing assembly. The shim (19) is
used in t~e rear axle assembly to compensate for
manufactunng tolerances. Increasing shim thickness
moves the drive pinion gear (23) closer to the centerline
of the ring gear (20). Decreasing shim thickness moves
the drive pinion gear (23) farther away from the centerline
of the ring gear (20).

Effects of Differential Drive Pinion Gear

Position on Tooth Pattern

A DIFFERENTIAL DRIVE PINION GEAR DEPTH
ADJUSTMENT
B BACKLASH ADJUSTMENT
19 SHIM, DIFFERENTIAL DRIVE PINION GEAR
20 GEAR, DIFFERENTIAL RING
23 GEAR, DIFFERENTIAL DRIVE PINION
24 SHIM, DIFFERENTIAL BEARING
Figure 9 - Tooth Contact Adjustments
Figure 10
When the differential drive pinion gear is too far
away from the centerline of the differential ring gear, the
pattern will be a high heel contact on the drive side and
high toe contact on the coast side. Moving the differential
drive pinion gear closer to the centerline of the differential
ring gear by decreasing backlash will cause the high heel
contact on the drive side to move down and toward the
toe: the high toe contact on the coast side will move down
and toward the heel.
When the differential drive pinion gear is too close
to the centerline of the differential ring gear, the pattern
will be a low toe contact on the drive side, and a low heal
PC0004-4B·F-RP contact on the coast side. Moving the differential drive
pinion gear farther away from the differential ring gear by
increasing backlash will cause low toe contact on the
drive side to move up and toward the heel: the low heel
contact on the coast side will move up and toward the toe.

G F
G
E
E

G G
A DIFFERENTIAL DRIVE PINION GEAR TOO FAR AWAY FROM DIFFERENTIAL RING GEAR E TOE
(INSUFFICIENT DIFFERENTIAL BEARING SHIM THICKNESS) F HEEL, COAST SIDE (CONCAVE)
B EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS INCREASED G HEEL, DRIVE SIDE (CONVEX)
C DIFFERENTIAL DRIVE PINION GEAR TOO CLOSE TO DIFFERENTIAL RING GEAR
I-EXCESSIVE DIFFERENTIAL BEARING SHIM THICKNESS)
D EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS DECREASED
PC6008-4B-D-RP

Figure 1O - Differential Bearing Shim Thickness Effect on Tooth Pattern

48·12 REAR AXLE
ON-VEHICLE SERVICE
Before attempting any service procedures, the tech-
nician must know what type rear axle assembly is to be
serviced. Refer to "Rear Axle Assembly Usage" in this
section to identify codes, differential ring gear size, and
ratios. Also, refer to the service parts identification label
on the vehicle.
Most rear axle assembly service repairs can be made
with the vehicle properly supported and the rear axle
housing assembly lowered to its lowest travel. On some
vehicles, it may be necessary to disconnect shock
absorber assemblies to obtain additional clearance. When
doing this, do not allow the rear brake hose assemblies to
become kinked or stretched.
Lubricant may be drained by removing all rear axle
housing bolts/screws and breaking the rear axle housing
cover loose at the bottom.
If the rear axle housing assembly is removed for any
reason, rear axle assembly service can be performed on
the bench.
When a new differential ring gear and differential
drive pinion gear are installed, the owner should be
advised not to accelerate rapidly or exceed 80 km/h
(50 mph) for the first 80 km (50 miles) of driving.
REAR AXLE LUBRICANT FILL AND CHECK
Figures 1 through 4
NOTICE: See "Notice" on 4B- l of this section.
1. Raise and suitably support vehicle. Refer to
SECTION OA.
• Keep vehicle level.
2. Clean dirt or foreign material from around plug
opening before removing plug (9).
3. Remove plug (9).
4. Maintain axle lubricant level from flush with bottom
of plug opening to no lower than 15 mm (9/16 inch)
below plug opening.
5. Add or replace axle lubricant using GM PIN
12345977 axle lubricant or SAE 80W-90 GL-5 gear
lubricant or equivalent.
6. If equipped with limited slip differential assemblies,
add 118 ml (4 fl. oz.) of GM PIN 1052358 limited
slip differential additive or equivalent.
7. Install plug (9).
l~I Tighten
• Plug (9) to 35 N•m (26 lb. ft.).
8. Lower vehicle.
REAR AXLE HOUSING COVER AND
GASKET
Figures 1 through 4
(++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to
SECTION OA.
2. Bolts/screws (41), parking brake cable guides and
pry cover (43) loose.
l~I Clean
• All dirt from area of cover (43) before remov-
ing cover (43).
3. Drain lubricant.
4. Gasket (45).
1~1 Clean
• Both gasket sealing surfaces.
l++l lnstall or Connect
NOTICE: See "Notice" on page 4B-1 of this sec-
tion.
1. New gasket (45) and cover (43).
2. Parking brake cable guides and bolts/screws (41).
l~I Tighten
• Bolts/screws (41) in a crosswise pattern to
30 N•m (22 lb. ft.).
3. Lubricant. Refer to "Rear Axle Lubricant Fill and
Check" in this section.
4. Lower vehicle.
REAR AXLE SHAFT
Figures 1 through 4, and 11
Tool Required:
J 39446 ABS Exciter Ring Protector Kit
!++I Remove or Disconnect
1. Rear tire and wheel assembly. Refer to
SECTION 3E.
2. Rear brake drum assembly and components, if
equipped. Refer to SECTION 5C2.
3. Rear brake rotor assembly, if equipped. Refer to
SECTION 5B2.
4. Rear axle housing cover. Refer to "Rear Axle Hous-
ing Cover and Gasket" in this section.
5. Install J 39446 to speed sensor reluctor wheel (39)
on vehicles equipped with standard rear axle assem-
blies.
6. Bolt/screw (29) from case (33).
7. Pinion gear shaft (35) from case (33).
8. Shaft lock (54).
• Access by pushing flanged end of axle shaft
(63 or 70) into housing assembly (16).
9. Axle shaft (63 or 70) from housing assembly (16),
being careful not to damage seal (49).
IT] Important
• If vehicle is equipped with traction control
(acceleration slip regulation), be careful not to
damage rear wheel speed sensor reluctor wheel
 REAR AXLE 48-13

located on axle shaft when removing the axle

shaft assembly. If damage has occurred to the
rear wheel speed sensor reluctor wheel on
vehicles equipped with traction control, the
rear axle shaft assembly must be replaced.

!++I Install or Connect

NOTICE: See "Notice" on page 4B-1 of this sec-
tion.
1. Axle shaft (63 or 70) into place, taking care that.
splines on end of axle shaft (63 or 70) do not damage'
seal ( 49) and that they engage with splines of side
gear (40).
2. Shaft lock (54).
• Push axle shaft (63 or 70) outward so that shaft
lock (54) seats in counterbore of side gear (40).
3. Pinion gear shaft (35) through case (33), thrust
washers (37) and pinion gears (36), aligning hole in 16 39
pinion gear shaft (35) with lock bolt/screw hole in
case (33). 16 HOUSING ASSEMBLY, REAR AXLE
22 CAP, DIFFERENTIAL CARRIER BEARING
4. Bolt/screw (29). 26 BOLT/SCREW, DIFFERENTIAL BEARING CAP
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT
[I) Important LOCK
39 WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
• Coat bolt/screw (29) with Loctite® 242 or 54 LOCK, REAR AXLE SHAFT
equivalent before installing. PC0005·4B-F-RP

I~! Tighten
Figure 11 - Internal View of Rear Axle
Housing Assembly (Typical)
• Bolt/screw (29) to 36 N•m (27 lb. ft.).
5. Remove J 39446 from speed sensor reluctor wheel
(39) if vehicle is equipped with standard rear axle
assembly. If new speed sensor reluctor wheel (39)
was installed, remove protective covering and throw
away.
6. Rear axle housing cover. Refer to "Rear Axle Hous-
ing Cover and Gasket" in this section.
7. Rear brake rotor assembly, if equipped. Refer to
SECTION 5B2.
8. Rear brake drum assembly and components, if
equipped. Refer to SECTION 5C2.
9. Rear tire and wheel assembly. Refer to
SECTION 3E.

REAR AXLE SHAFT BEARING ASSEMBLY

AND/OR BEARING SEAL

Figures 12 through 15
Tools Required:
J 2619-01 Slide Hammer with 1/2 x 13 16 HOUSING ASSEMBLY, REAR AXLE
44 BEARING ASSEMBLY, REAR AXLE SHAFT
Adapter 49 SEAL, REAR AXLE SHAFT BEARING
J 8092 Driver Handle 63 SHAFT, REAR AXLE (DRUM BRAKE ASSEMBLY)
70 SHAFT, REAR AXLE (DISC BRAKE ASSEMBLY)
J 22813-01 Axle Bearing Remover PC0006-4B·F·RP

J 23765 Axle Bearing Installer Figure 12 - Rear Axle Shaft (Typical)

J 23 771 Axle Oil Seal Installer
48·14 REAR AXLE
PC0007-48-F-RP
Figure 13 - Removing Rear Axle Shaft Bearing Assembly
l.,+I Remove or Disconnect
1. Rear axle shaft. Refer to "Rear Axle Shaft" in this
section.
2. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
3. Rear brake caliper anchor bracket and mounting
plate, if equipped. Refer to SECTION 5B2.
4. Seal (49) from housing assembly (16) with a pry bar
behind steel case of seal (49), being careful not to
damage housing assembly (16).
5. Insert J 22813-01 into bore and position it behind
shaft bearing assembly (44) so tangs on tool engage
bearing outer race.
6. Shaft bearing assembly (44), using J 2619-01.
l++l lnstall or Connect
1. Lubricate new shaft bearing assembly (44) with GM
P/N 12345977 axle lubricant or SAE 80W-90 GL-5
gear lubricant or equivalent.
2. Shaft bearing assembly (44) so that tool bottoms
against shoulder in housing assembly (16), using
J 23765 and J 8092.
J8092 /
44 BEARING ASSEMBLY, REAR AXLE SHAFT
PC0008-4B-F-RP
Figure 14 - Installing Rear Axle Shaft Bearing Assembly
PC0009-4B·F-RP
Figure 15 - Installing Rear Axle Shaft Bearing Seal
3. Lubricate sealing lips with GM P/N 12345977 axle
lubricant or SAE 80W-90 GL-5 gear lubricant or
equivalent.
4. Position seal (49) on J 23771 and direct seal (49)
into housing bore.
5. Seal (49) into place, flush with axle tube.
6. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
7. Rear brake caliper anchor bracket and mounting
plate, if equipped. Refer to SECTION 5B2.
8. Rear axle shaft. Refer to "Rear Axle Shaft" in this
section.
ll'l'l 1nspect
• Operation of rear axle assembly.
DIFFERENTIAL DRIVE PINION GEAR YOKE
AND SEAL
Figures 1 through 4 and 16 through 19
Tools Required:
J 8614-2 Pinion Flange Remover Adapter
J 8614-3 Pinion Flange Remover Screw
J 8614-10 Pinion Flange Remover
J 23911 Pinion Oil Seal Installer
l.,+I Remove or Disconnect
1. Both tire and wheel assemblies. Refer to
SECTION 3E.
2. Rear brake drum assemblies, if equipped. Refer to
SECTION 5C2.
3. Rear brake rotor assemblies, if equipped. Refer to
SECTION 5B2.
4. Propeller shaft assembly from differential drive pin-
ion gear yoke. Refer to SECTION 4A.
5. Mark position of yoke (3), drive pinion gear (23)
and nut (1) so proper drive pinion gear inner and
outer bearing assembly preload can be maintained.
6. If joint bearing assemblies are not retained by a
retainer strap, use a piece of tape to hold bearing
assemblies on their journals.
7. Check preload with a pound-inch torque wrench and
record. This will give combined drive pinion gear

A TORQUE WRENCH
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR
PC0010-48-F-RP
Figure 16 - Checking Differential Drive Pinion Gear Preload
inner and outer bearing, axle shaft bearing and dif-
ferential bearing preload.
8. Nut (1) and washer (2), using J 8614-10.
• Use a suitable container to hold any fluid that
may drain from rear axle assembly.
9. Yoke (3), using J 8614-2, J 8614-3 and J 8614-10.
10. Seal (6) by driving it out qf housing assembly (16)
with a blunt chisel. Do not damage housing
assembly (16).
!L"'I Inspect
• Differential drive pinion gear seal surface of yoke
(3) for tool marks, nicks, or damage, such as a
groove worn by seal (6). If damaged, replace
yoke (3).
• Housing assembly bore and remove any burrs that
might cause leaks around outer diameter (OD) of
seal (6).
!++I Install or Connect
NOTICE: See "Notice" on page 4B-1 of this sec-
tion.
1. New seal (6), using J 23911.
2. Apply pinion gear seal lubricant, GM P/N 1050169
or equivalent, to the OD of yoke (3) and sealing lip
ofnew seal (6).
3. Yoke (3).
4. Washer (2) and nut (1) finger tight.
5. While holding yoke (3), using J 8614-10, tighten nut
gradually and turn drive pinion gear (23) several
revolutions after each tightening to set the bearing
assemblies. Check preload of bearing assemblies
each time with a pound-inch torque wrench until
preload is 0.3 to 0.6 N•m (3 to 5 lb. in.) more than
reading obtained in removal procedure.
6. Propeller shaft assembly to differential drive pinion
gear yoke. Refer to SECTION 4A.
REAR AXLE 48·15
\
A WRENCH
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR
PC0011-4B-F-RP
Figure 17 - Removing Differential Drive Pinion Gear Nut
7. Rear brake drum assemblies, if equipped. Refer to
SECTION 5C2.
8. Rear brake rotor assemblies, if equipped. Refer to
SECTION 5B2.
9. Tire and wheel assemblies. Refer to SECTION 3E.
10. Lubricant. Refer to "Rear Axle Lubricant Fill and
Check" in this section.
11. Lower vehicle.
!L"'l Inspect
• Operation of rear axle assembly.
REAR AXLE ASSEMBLY
Figures 1 through 4
!++I Remove or Disconnect
1. Rear tire and wheel assemblies. Refer to
SECTION 3E.
2. Mark propeller shaft assembly and yoke (3).
3. Propeller shaft assembly. Refer to SECTION 4A.
4. Rear stabilizer shaft. Refer to SECTION 3D.
5. Support housing assembly (16) with adjustable lift-
ing device.
6. Shock absorber assemblies from housing assembly.
Refer to SECTION 3D.
7. Rear axle tie rod assembly. Refer to SECTION 3D.
8. Rear brake (center) hose assembly from rear brake
(center) hose assembly junction block. Refer to
SECTION 5.
9. Rear spring assemblies. Refer to SECTION 3D.
10. Parking brake cable assemblies from housing
assembly. Refer to SECTION SF.
48·16 REAR AXLE

J 8614-2

6 SEAL, DIFFERENTIAL DRIVE PINION GEAR

~ 23 GEAR, DIFFERENTIAL DRIVE PINION
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR
PC0012-411-F·RP PCOCl13-48-F-RP

Figure 18 - Removing Differential Drive Pinion Gear Yoke Figure 19 - Installing Differential Drive Pinion Gear Seal

11. Electrical connector from wheel speed sensor A

assembly (75).
12. Rear axle torque arm from housing assembly. Refer
to SECTION 3D.
13. Rear axle lower control arm assemblies from hous-
ing assembly. Refer to SECTION 3D.
14. Housing assembly (16) with aid of helper.
A REAR AXLE SHAFT FLANGE
!-++I Install or Connect 61 BOLT/SCREW, REAR WHEEL
PC0014-4B-F-RP

1. Housing assembly (16), with aid of helper. Figure 20 - Removing Rear Wheel Bolt/Screw

2. Rear axle lower control arm assemblies to housing

assembly. Refer to SECTION 3D. REAR WHEEL BOLT/SCREW
3. Rear axle torque arm to housing assembly. Refer to
SECTION 3D. Figures 20 and 21
Tool Required:
4. Electrical connector to wheel speed sensor
assembly (75). J 6627-A Wheel Stud Remover
When replacing wheel bolts (hub studs), use the fol-
5. Parking brake cable assemblies to housing assem-
lowing guide:
bly. Refer to SECTION SF.
• Stripped bolts/screws - Replace bolts/screws
6. Rear spring assemblies. Refer to SECTION 3D. involved.
7. Rear brake (center) hose assembly to rear brake • One loose bolt/screw - Replace all bolts/
(center) hose assembly junction block. Refer to screws.
SECTION 5. • One broken bolt/screw - Replace all bolts/
8. Rear axle tie rod assembly. Refer to SECTION 3D. screws.
• Wheel bolt/screw hole elongated - Replace
9. Shock absorber assemblies to housing assembly. axle shaft.
Refer to SECTION 3D.
10. Remove adjustable lifting device from housing !+-+I Remove or Disconnect
assembly (16). 1. Rear tire and wheel assembly. Refer to
11. Rear stabilizer shaft. Refer to SECTION 3D. SECTION 3E.
2. Rear brake drum assembly, if equipped. Refer to
12. Propeller shaft assembly. Refer to SECTION 4A.
SECTION 5C2.
13. Bleed hydraulic brake system. Refer to 3. Rear brake rotor assembly, if equipped. Refer to
SECTION 5El. SECTION 5B2.
14. Rear tire and wheel assemblies. Refer to 4. Wheel bolt/screw (61) from axle shaft flange using
SECTION 3E. J 6627-A.

A THE EXACT RELATIONSHIP TO EACH
B When a new differential ring gear and drive pinion
51
A REAR AXLE SHAFT FLANGE
B WASHER
51 NUT, REAR WHEEL
61 BOLT/SCREW, REAR WHEEL
PC0015-4B·f·RP
Figure 21 - Installing Rear Wheel Bolt/Screw
!++I Install or Connect
NOTICE: See "Notice" on page 4B-l of this sec-
tion.
1. Wheel bolt/screw (61), four washers and wheel nut
(51) to axle shaft flange.
2. Wheel nut (51) until wheel bolt/screw (61) is com-
pletely seated against axle shaft flange.
!~I Tighten
• Wheel nut (51) to 140 N•m (100 lb. ft.).
3. Remove wheel nut (51) and four washers.
4. Rear brake drum assembly, if equipped. Refer to
SECTION 5C2.
5. Rear brake rotor assembly, if equipped. Refer to
SECTION 5B2.
6. Rear tire and wheel assembly. Refer to
SECTION 3E.
UNIT REPAIR
. NOTICE: Any time components are removed or
replaced within the rear axle housing assembly on
vehicles with standard rear axle assemblies only, use
J 39446, ABS Exciter Ring Protector Kit, to prevent
damage to the rear wheel speed sensor reluctor
wheel.
rn Important
• The driveline components in this vehicle have been
factory system balanced. System balance provid~s.a
smoother running driveline operation. However, 1t 1s
essential that the positions of all driveline compo-
nents relative to the propeller shaft and rear axle
assembly be observed and ACCURATELY REF-
ERENCE MARKED PRIOR TO DISASSEM-
BLY. These components include the propeller shaft
assemblies, rear axle assemblies, differential drive
pinion gear yoke, output shaft, etc. ALL COM-
REAR AXLE 48-17
PONENTS MUST BE REASSEMBLED IN
OTHER AS THEY WERE WHEN REMOVED.
Additionally, the published specifications and
torque values, as well as any measurements made
prior to disassembly must be followed to maintain
the factory balance.
gear are installed, the original differential drive pinion
gear yoke should be replaced with a service differential
drive pinion gear yoke. The owner should be advised not
to accelerate rapidly or exceed 80 km/h (50 mph) for the
first 80 km (50 miles) of driving.
Any time the rear axle assembly is taken apart for
service, the following cleaning and inspecting procedures
should be followed:
• Select correct ABS exciter ring protector from
J 39446 and attach to speed sensor reluctor wheel on
vehicles with standard rear axle assemblies only.
!r,IClean
• All differential bearing assemblies thoroughly in
clean solvent.
!l1tl 1nspect
• Bearing assemblies visually and by feel. Bearing
assemblies should feel smooth when oiled and
rotated while applying as much hand pressure as
possible. Minute scratches and pits that appear on
rollers and races at low mileage are due to the initial
preload, and bearing assemblies having these marks
should not be replaced.
• Sealing surface of differential drive pinion gear yoke
for nicks, burrs, or rough tool marks which would
cause damage to the differential drive pinion gear
seal and result in an oil leak. Replace if damaged.
• Housing assembly bore and remove any burrs that
might cause leaks around the OD of the drive pinion
gear seal.
• Differential ring gear and drive pinion gear teeth for
excessive wear and scoring. If any of these condi-
tions exist, replacement of the gears as a set will be
required .
• Differential drive pinion gear shaft for unusual wear.
Also, check the differential pinion and side gears
and differential pinion gear thrust washers.
• Press fit of the differential bearing assembly inner
race on the differential case hub by prying against
the shoulder at the puller recess in the case. Differ-
ential bearing assemblies must be press fit on the
hub.
• Rear axle assembly failures such as chipped bearing
assemblies, loose (lapped-in) bearing assemblies,
chipped gears, etc. are indications that foreign mate-
rial is present. The rear axle housing assembly must
be cleaned.
• Speed sensor reluctor wheel on vehicles with stan-
dard rear axle assemblies for chipped or missing
teeth; also check for looseness or wobble. Replace
speed sensor reluctor wheel if damaged.
48-18 REAR AXLE

DIFFERENTIAL CASE 4. Bolts/screws (26).

Figures 1 through 4 and 22 through 26

Tools Required:
J 22888-20 Differential Side
Bearing Remover
J 8107-2 Differential Side
Bearing Remover Plug
J 8092 Driver Handle
J 21465-13 Driver Handle Extension
J 25299 Differential Side Bearing Installer
J 25588 Side Bearing Shim Installer
J 39446 ABS Exciter Ring Protector Kit
!+,.I Remove or Disconnect
Figures 1 through 4 and 22
rn Important
• Before removing the differential case from the
rear axle housing assembly, differential ring
gear-to-differential drive pinion gear backlash
must be checked. Refer to "Differential Ring
Gear-to-Differential Drive Pinion Gear Back-
lash" in this section. This will indicate gear or
bearing wear or an error in backlash or preload
setting which will help in determining the
cause of axle noise.
1. Rear axle shafts. Refer to "Rear Axle Shaft" in this
section.
2. Bolt/screw (73) from wheel speed sensor
assembly (75) on vehicles with standard rear axle
assemblies only.
3. Wheel speed sensor assembly (75) on vehicles with
standard rear axle assemblies only.
• Carefully place wheel speed sensor
assembly (75) along side of housing assembly
(16).
m Important
A. Bearing caps (22) should be marked "R" and
"L" to make sure they will be assembled in
their original locations.
B. Place right and left bearing outer races of bear-
ing assemblies (32) and shims (24) in sets with
marked bearing caps (22) so that they can be
reinstalled in their original positions.
5. Shims (24).
NOTICE: Exercise caution in prying on rear axle
housing assembly so gasket sealing surface is not
damaged.
6. Case (33) from housing assembly (16).
!+;+I Disassemble
Figures 1 through 4 and 23
1. Differential bearing assembly (32) from case (33),
if replacing, using J 22888-20 and J 8107-2. If
removing an Auburn type limited slip differential
case, skip step 2.
2. Pinion gears (36), thrust washers (37), side gears
(40) and thrust washers (38) from case (33).
• Mark side gears (40) and case (33) so side
gears (40) can be reinstalled in their original
position.
3. All bolts/screws (28) from case (33), if replacing
ring gear (20) or speed sensor reluctor wheel (39).
• Bolts/screws (28) are left-hand thread type.
• Discard bolts/screws (28).
4. Ring gear (20) from case (33).
• Do not pry between ring gear (20), speed
sensor reluctor wheel (39) and case (33), if ring
gear (20) is on tight.
- Drive ring gear (20) from case (33) using
brass drift and hammer.

J 39446 (]] Important

• Speed sensor reluctor wheel must be replaced
if removed from vehicles with standard rear
axle assemblies.
5. Speed sensor reluctor wheel (39) only if necessary,
using brass hammer.
• Discard speed sensor reluctor wheel (39).

!+!+I Assemble
Figures 1 through 4, 24 and 25
NOTICE: See "Notice" on page 4B-l of this
section.
A PRY BAR
16 HOUSING ASSEMBLY, REAR AXLE
33 CASE, DIFFERENTIAL
PC0018-4B-F·RP
rn Important
• Before assembling the differential assembly,
Figure 22 - Removing Differential Case lubricate all parts with GM P/N 12345977 axle
lubricant or SAE 80W-90 GL-5 gear lubricant
or equivalent.
 REAR AXLE 48·19

J 22888-20

32

20 GEAR, DIFFERENTIAL RING

28 BOLT/SCREW, DIFFERENTIAL RING GEAR (LEFT-HAND
THREAD)
32 BEARING ASSEMBLY, DIFFERENTIAL PC0017-4B·F-RP 33 CASE. DIFFERENTIAL
PC0018-4B·f·RF
Figure 23 - Removing Differential Bearing Assembly Figure 24 - Differential Ring Gear-to-Differential Case

!S:-1 Clean
• Connecting surfaces of ring gear (20) and
B. Position one pinion gear (36), without thrust
case (33), if replacing ring gear (20).
washer (37), between side gears (40) and rotate
CAUTION: Once the speed sensor side gears (40) until pinion gear (36) is directly
reluctor wheel has been removed from opposite loading opening in case (33). Place
the differential case, a new speed sen· other pinion gear (36) between side gears (40)
sor reluctor wheel must be installed. so that pinion gear shaft holes are in line: then
The press fit may be lost if the speed rotate gears; lining up holes in pinion gears
sensor reluctor wheel is used more (36) with holes in case (33).
than once. This would allow the speed
sensor reluctor wheel to rotate freely C. Rotate pinion gears (36) back toward loading
on the differential case causing a opening just enough to permit sliding in thrust
significant reduction in performance of washers (37).
the antilock brake system, which could 5. Differential bearing assemblies (32) to case (33), if
result in bodily injury. removed, using J 8092, J 25299 and J 21465-13.
1. Speed sensor reluctor wheel (39), if removed from
vehicles with standard rear axle assemblies.
• Carefully place speed sensor reluctor wheel
(39) over case (33) on ring gear side.
2. Ring gear (20), if removed.
• On vehicles with standard rear axle assem-
blies, position ring gear (20) over speed sensor
reluctor wheel (39).
3. Two bolts/screws (28) into opposite sides of ring J 21465-13
gear (20). If converting to an Auburn type limited
slip differential case, skip step 4.
J 25299
• Install remaining new bolts/screws (28) until I

just snug.

l~I Tighten
• New bolts/screws (28) alternately in pro-
gressive stages to 120 N•m (89 lb. ft.).
4. Thrust washers (38), side gears (40), pinion gears
(36) and thrust washers (37) into case (33). 32 BEARING ASSEMBLY, DIFFERENTIAL PC0019-48-F-RP
A. Position thrust washers (38) over side gear Figure 25 - Installing Differential Bearing Assembly
hubs and install side gears (40) in case (33). If
same parts are reused, install in original sides.
48-20 REAR AXLE

!++I Install or Connect

Figures 1 through 4 and 26
NOTICE: See "Notice" on page 4B-1 of this
section.
1. Case (33) into housing assembly (16). Refer to
"Differential Case" in this section.
2. Shims (24).

m Important
• Do not attempt to reinstall the production
shims as they may break when tapped
into place.
• If service shims were previously
installed, they can be reused, but whether
using new or old differential bearing
assemblies (32), adhere to the following
procedure in all cases. If differential bear-
ing assemblies (32) are used again, they
must have original outer races in place.
Refer to "Differential Bearing Assembly
Preload Adjustment" in this section.
• Keep shim packs in their respective posi-
tion, right or left side.
A. Select a shim 0.10 mm (0.004 inch) thicker
than the one removed from the left side; then
insert left side shim pack between the spacer
and the left bearing race.
B. Loosely install bearing cap (22).
C. Select a shim 0.10 mm (0.004 inch) thicker
than the one removed from the right side and
insert between the spacer (25) and the right
bearing assembly race.
D. It will be necessary to drive the right shim into
position using J 25588.
3. Bolts/screws (26).
l~I Tighten
• Bolts/screws (26) to 75 N•m (55 lb. ft.).
4. Check backlash and correct if necessary. Refer to
"Differential Ring Gear-to-Differential Drive Pin-
ion Gear Backlash" in this section.
5. Rear axle shafts (63 or 70). Refer to "Rear Axle
Shaft" in this section.
6. Wheel speed sensor assembly (75) and bolt/
screw (73), if removed.
l~J Tighten
• Bolt/screw (73) to 10 N•m (89 lb. in.).
16 HOUSING ASSEMBLY, REAR AXLE
22 CAP, DIFFERENTIAL .CARRIER BEARING
PC0020-4B·F-RP
Figure 26 - Installing Differential Bearing Shims
sor reluctor wheel is not serviceable. If the speed sensor
reluctor wheel is damaged, the rear axle drive shaft
assembly must be replaced. Refer to "Rear Axle Shaft"
in this section.
DIFFERENTIAL RING GEAR-TO·
DIFFERENTIAL DRIVE PINION GEAR
BACKLASH
Figure 27
Tool Required:
J 8001 Dial Indicator Set
!++! Remove or Disconnect
• Rear axle housing cover. Refer to "Rear Axle Hous-
ing Cover and Gasket" in this section.
I~! Measure
1. Rotate case (33) several times to seat bearing assem-
blies. Mount J 8001.
A. Use a small button on indicator stem so that
contact can be made near heel end of tooth.
B. Set J 8001 so that stem is in line with gear rota-
tion and perpendicular to tooth angle for accu-
rate backlash reading.
2. Check backlash at three or four points around ring
gear (20).
A. Lash must not vary over 0.05 mm (0.002 inch)
around ring gear (20).
B. Drive pinion gear must be held stationary
when checking backlash.

SPEED SENSOR RELUCTOR WHEEL

Refer to "Differential Case" above, for removal and
rn Important
• If variation is over 0.05 mm (0.002 inch),
installation of the speed sensor reluctor wheel on vehicles check for burrs, uneven bolting conditions or
with standard rear axle assemblies. On vehicles with trac- distorted case flange and make corrections as
tion control (acceleration slip regulation), the speed sen- necessary.
 REAR AXLE 48-21

!++! Install or Connect

• Rear axle housing cover. Refer to "Rear Axle Hous-
ing Cover and Gasket" in this section.

DIFFERENTIAL BEARING ASSEMBLY

PRELOAD ADJUSTMENT

Figures 1 through 4 and 28

The differential bearing assembly preload adjust-
16 HOUSING ASSEMBLY, REAR AXLE
20 GEAR, DIFFERENTIAL RING ment is to be made before installing the drive pinion
33 CASE, DIFFERENTIAL gear (23). If drive pinion gear (23) is installed, remove
PC0021·4B-F-RP ring gear (20). Refer to "Differential Case" in this sec-
Figure 27 - Checking Differential Ring Gear-to-Differential
tion.
Drive Pinion Gear Backlash
Differential bearing assembly preload is adjusted by
changing the thickness of both the right and left
121 Adjust shims (24) by an equal amount.

1. Backlash at the point of minimum lash should be By changing the thickness of both shims (24)
between 0.13 mm and 0.23 mm (0.005 inch and equally, the original backlash will be maintained.
0.009 inch) for all new gears.
Production shims (24) are cast iron and vary in
2. Backlash by increasing thickness of one shim and thickness from 5.33 mm to 6.91 mm (0.210 inch to
decreasing thickness of other shim the same amount. 0.272 inch) in increments of 0.05 mm (0.002 inch).
• For each 0.03 mm (0.001 inch) change in back7
lash desired, transfer 0.05 mm (0.002 inch) in Standard service spacers (25) are 4.32 mm
shim thickness. (0.170 inch) thick and steel service shims (24) are avail-
• To decrease backlash 0.03 mm (0.001 inch), able from 1.02 mm to 2.08 mm (0.040 inch to 0.082 inch)
decrease thickness of right shim 0.05 mm in increments of 0.05 mm (0.002 inch).
(0.002 inch) and increase thickness of left shim
0.05 mm (0.002 inch). To increase backlash [I) Important
0.05 mm (0.002 inch), increase thickness of • Do not attempt to reinstall the production shims (24)
right shim 0.10 mm (0.004 inch) and decrease as they may break when tapped into place.
thickness of left shim 0.10 mm (0.004 inch).
• Refer to "Differential Bearing Assembly Pre- • If service shims (24) were previously installed, they
load Adjustment" in the following procedure can be reused, but whether using new or old differ-
for further information. ential bearing assemblies (32), adhere to the follow-
ing procedure in all cases. If differential bearing
4.32 mm (0.170") SERVICE assemblies (32) are used again, they must have orig-
DIFFERENTIAL BEARING SPACER inal outer races in place.
TOTAL THICKNESS OF
BOTH PRODUCTION
DIFFERENTIAL BEARING
TOT AL THICKNESS OF
SERVICE DIFFERENTIAL
BEARING SHIMS TO BE
121 Adjust
SHIMS REMOVED USED AS A STARTING POINT 1. Determine the approximate thickness of shims (24)
10.57 mm (0.416") 1.52 mm (0.060") needed by measuring each production shim (24) or
10.92 mm (0.430") 1. 78 mm (0.070") each service spacer (25) and shim pack.
11.18mm(0.440") 2.03 mm (0.080")
11.43 mm (0.450") 2.29 mm (0.090") • In addition to the service spacer (25), service
11.68 mm (0.460") 2.54 mm (0.100")
11.94 mm (0.470") 2.79 mm (0.110") shims (24) will be needed. Select a starting
12.19 mm (0.480") 3.05 mm (0.120") point in service shim thickness. Refer to
12.45 mm (0.490") 3.30 mm (0.130") Figure 28.
12.70mm (0.500") 3.56 mm (0.140")
12.95 mm (0.510") 3.81 mm (0.150") 2. Place case (33) with differential bearing assembly
13.21 mm (0.520") 4.06 mm (0. 160")
13.46 mm (0. 530") 4.32 mm (0.170")
outer races in position in the housing assembly (16).
13.97 mm (0.550") 4.83 mm (0.190")
3. Slip the service spacer (25) between each differen-
PC6030·4B·D·RP
tial bearing assembly race and housing
Figure 28 - Differential Bearing Shim Thickness assembly (16) with chamfered edge against housing
assembly (16).
48·22 REAR AXLE
NOTICE: Install the left side differential bearing
cap loosely so the differential case may be moved
while checking adjustments. Another differential
bearing assembly cap bolt/screw can be added in the
lower right side differential bearing cap hole. This
will prevent the case from dropping while making
shim adjustments.
4. Select one or two shims (24) totalling the amount
shown in the right-hand column of Figure 28 and
position between the right side differential bearing
assembly race and service spacer (25).
• Be sure left side differential bearing assembly
race and spacer (25) are against left side of
housing assembly (16).
5. Insert progressively . larger feeler gage sizes
0.25 mm, 0.30 mm, 0.36 mm, etc. (0.010 inch,
0.012 inch, 0.014 inch, etc.) between the right
shim (24) and service spacer (25) until there is
noticeable increase in drag.
6. Push feeler gage downward until end of gage makes
contact with housing assembly bore to obtain a cor-
rect reading.
• The point just before additional drag begins is
the correct feeler gage thickness.
7. Rotate case (33) while using feeler gage to ensure an
even reading.
· • The original light drag is caused by weight of
case (33) against housing assembly (16) while
additional drag is caused by differential bear-
ing assembly preload.
• By starting with a thin feeler gage, a sense of
"feel" is obtained so the beginning of preload
can be recognized to obtain zero clearance.
• It will be necessary to work case (33) in and
out and to the left in order to insert feeler gage.
8. Remove left side differential bearing assembly
cap (22) and shim (24) from housing assembly (16).
9. The total shim pack needed, with no preload on dif-
ferential bearing assemblies (32), is the feeler gage
reading found in step 7 plus the thickness of
shims (24) installed in step 4.
10. Select two shims (24) of approximately equal size
whose total thickness is equal to the value obtained
in step 9.
• These shims (24) will be installed between
each differential bearing assembly race and
service spacer (25) when case (33) is installed
in housing assembly (16).
• The pr~load will not be added until case (33) is
installed.
11. If drive pinion gear is in position, install ring gear.
Refer to "Differential Case" in this section.
DIFFERENTIAL DRIVE PINION GEAR
Figures 1 through 4, 16, 19, 29 and 30
Tools Required:
J 22536 Pinion Driver
J 23911 Pinion Oil Seal Installer
!++I Remove or Disconnect
1. Differential case. Refer to ''.Differential Case" in
this section.
2. Check differential drive pinion gear inner and outer
bearing assembly preload. If there is no preload
reading, check for looseness of drive pinion gear
(23) by shaking. Looseness could be caused by
defective inner and outer bearing assemblies (18 and
7) or worn yoke (3). If the rear axle assembly was
operated for an extended period with very loose
inner and outer bearing assemblies ( 18 and 7), ring
gear (20) and drive pinion gear (23) will also require
replacement.
3. Differential drive pinion gear yoke. Refer to "Dif-
ferential Drive Pinion Gear Yoke and Seal" in this
section.
4. Drive pinion gear (23), using J 22536. Apply heavy
hand pressure on J 22536 toward housing assembly
(16) to keep outer bearing assembly (7) seated to
avoid damage to outer race.
!++I Install or Connect
1. If installing new ring gear and drive pinion gear,
measure differential drive pinion gear depth. Refer
to "Differential Drive Pinion Gear Depth" in this
section.
2. Drive pinion gear (23) into housing assembly (16).
3. Differential drive pinion gear yoke (3).
A. Install new seal (6) using J 23911.
B. Apply pinion gear seal lubricant GM P/N
1050169 or equivalent to yoke (3) and sealing
lip of new seal (6).
C. Yoke (3).
D. Washer (2) and nut (1) finger tight.
E. Hold yoke (3).
F. While intermittently rotating drive pinion
gear (23) to seat inner and outer bearing assem-
blies (18 and 7), tighten nut (1) until end play
begins to be taken up.
[I] Important
• When no further end play is detectable and
when holder will no longer pivot freely as
drive pinion gear (23) is rotated, preload speci-
fications are being approached.
• No further tightening should be attempted
until preload has been checked.
• After preload has been checked, final tighten-
ing should be done very carefully.
• Additional tightening of nut ( 1) can add many
additional pound inches of torque.
 REAR AXLE 48·23

16 23

23 16 HOUSING ASSEMBLY, REAR AXLE

23 GEAR, DIFFERENTIAL DRIVE PINION
A CHANNEL LOCKING PLIERS PC0023-4B-F-RP
B WRENCH
16 HOUSING ASSEMBLY, REAR AXLE
Figure 30 - Removing Differential Drive Pinion Gear
23 GEAR, DIFFERENTIAL DRIVE PINION

PC0022-48-F-RP

Figure 29 - Installing Differential Drive Pinion Gear Driver
• Nut (1) should be further tightened only
slightly and preload should be checked after
each tightening.
• Exceeding preload specifications will com"
press the collapsible spacer (15) too far and
require installation of a new collapsible spacer
(15).
4. Setpreload at 1.7 N•m to 3.4 N•m (15 lb. in. to 30
lb. in.) on new inner and outer bearing assemblies
(18 and 7) or 1.0 N•m to 1.7 N•m (10 lb. in. to 15 lb.
!++I Install or Connect
in.) on used inner and outer bearing assemblies (18
and 7).
5. Rotate drive pinion gear (23) several times to ensure
that inner and outer bearing assemblies ( 18 and 7)
have been seated.
A. Check preload again.
B. If preload has been reduced by rotating drive
pinion gear (23), reset preload to specifica-
tions.
6. Differential case. Refer to "Differential Case" in
this section.
2. Differential drive pinion gear seal from rear axle
housing assembly. Refer to "Differential Drive
Pinion Gear Yoke and Seal" in this section.
3. Outer bearing assembly (7) from housing assembly
(16).
4. Outer bearing assembly race from housing
assembly (16), if replacing outer bearing assembly
(7).
• Drive race from housing assembly (16), using
a punch in slots provided for this purpose.
1. Outer bearing assembly race into housing assembly
(16), if removed, using J 8092 and J 7817.
2. Outer bearing assembly (7) into housing assembly
(16).
3. Differential drive pinion gear seal. Refer to "Differ-
ential Drive Pinion Gear Yoke and Seal" in this
section.
4. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.

Differential Drive Pinion Gear

Outer Bearing Assembly
Figures 1 through 4 and 31
Tools Required:
J 8092 Driver Handle
J 7817 Front Pinion Bearing Cup Installer

!++I Remove or Disconnect PC0024-48-F-RP

l. Differential drive pinion gear from rear axle housing
assembly. Refer to "Differential Drive Pinion Figure 31. - Installing Differential Drive Pinion Gear Outer
Bearing Assembly Race
Gear" in this section.
48-24 REAR AXLE

Differential Drive Pinion Gear

Inner Bearing Assembly
Figures 1 through 4 and 32 through 34
Tools Required:
J 22912-01 Rear Pinion Bearing Remover
J 8092 Driver Handle
J 29609 Rear Pinion Bearing Cup Installer
J 5590 Rear Pinion Bearing Cone Installer

!+-+I Remove or Disconnect

I. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.
2. Spacer (15) from drive pinion gear (23). \ A
• Discard spacer (15). A OPENING IN TOOL MUST BE SUPPORTED PC0025-4B-f..RP
3. Drive pinion gear inner bearing assembly race from Figure 32 - Removing Differential Drive Pinion Gear Inner
housing assembly (16), if replacing inner bearing Bearing Assembly
assembly ( 18).
• Drive race from housing assembly (16) using a
punch in slots provided for this purpose.
4. Drive inner bearing assembly (18) from drive pinion
gear (23) using J 22912-01.

!-++I Install or Connect

1. Inner bearing assembly (18) onto drive pinion
gear (23) using J 5590.
2. Drive inner bearing assembly race into housing
assembly (16) using J 8092 and J 29609, if inner
bearing assembly (18) was replaced.
3. New spacer ( I 5) onto drive pinion gear (23).
4. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.
18 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION
GEAR INNER
DIFFERENTIAL DRIVE PINION GEAR DEPTH 23 GEAR, DIFFERENTIAL DRIVE PINION
PC0026-48-F·RP
Figures 1 through 4, 35 and 36
Tools Required: Figure 33 - Installing Differential Drive Pinion Gear Inner
Bearing Assembly
J 8001 Dial Indicator Set
J 23597-1 Pinion Setting Gage -Arbor
J 23597-11 Pinion Setting Gage - Gage Plate
J 21777-40 Pinion Setting Gage -
Rear Pilot Washer
J 21777-42 Pinion Setting Gage -
Front Pilot Washer
J 21 777-43 Pinion Setting Gage -
Stud Assembly - Bolt
J 21777-45 Pinion Setting Gage -
Side Bearing Discs
Differential drive pinion gear depth is measured
with a pinion setting gage. The gage provides a "nomi- A RACE, DIFFERENTIAL DRIVE PINION GEAR INNER
nal" or "zero" pinion as a gaging reference. BEARING ASSEMBLY PC0027-4B-F·RP

!+!+I Disassemble Figure 34 - Installing Differential Drive Pinion Gear Inner

Bearing Assembly Race
• Differential case. Refer to "Differential Case" in
this section.
 REAR AXLE 48·25

!+-+I Remove or Disconnect !i,I Clean

• Differential drive pinion gear inner bearing assem-
bly. Refer to "Differential Drive Pinion Gear Inner
Bearing Assembly" in this section.
J 8001
1. All parts of gage.
2. Differential bearing assembly bore.
3. Inner and outer bearing assembly cups.
4. Lubricate inner and outer bearing assemblies (18
and 7) with GM P/N 12345977 axle lubricant or
SAE 80W-90 GL-5 gear lubricant or equivalent.

!++I Install or Connect

J 23597-11 NOTICE: See "Notice" on page 4B-1 of this sec-
tion.
1. J 21777-40 through J 21777-43.
2. J 23597-11.
3. J 1777-42 and nut in housing assembly (16).
J 21777-43
l~I Tighten
• Nut to 2.3 N•m (20 lb. in.).
J 21777-42 4. Rotate J 23597-11 to seat inner and outer bearing
7 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION assemblies (18 and 7).
GEAR OUTER
18 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION 5. Mount J 8001 on J 23597-1 and preload indicator
GEAR INNER PC00211-4B-F-RP against plunger about 1.27 mm (0.050 inch).
Figure 35 - Pinion Gage Plate Installed in Rear Axle Housing 6. J 21777-45 on J 23597-1 and position unit in hous-
Assembly ing assembly (16).

A OFF GAGE BLOCK

B ON GAGE BLOCK
22 CAP, DIFFERENTIAL CARRIER BEARING
26 BOLT/SCREW, DIFFERENTIAL BEARING CAP

Figure 36 - Checking Differential Drive Pinion Gear Depth

48-26 REAR AXLE
7. Bearing caps (22) and bolts/screws (26).
l~I Tighten
• Bolts/screws (26) to 75 N•m (55 lb. ft.).
!~! Measure
• Differential drive pinion gear depth.
A. Rotate J 23597-1 slowly back and forth until
J 8001 reads the greatest deflection (the point
where the needle changes direction). At that
point, set J 8001 to zero.
B. Repeat rocking action to verify zero setting.
C. After zero setting is obtained, rotate J 23597-1
just until plunger no longer touches
J 23597-11. This provides the gaging reference
of a "zero" or "nominal" drive pinion gear
(23).
D. Record J 8001 reading at pointer position. This
indicates the proper shim to use. Example: if
pointer moved counterclockwise 1. 70 mm
(0.067 inch) to a dial reading of 0.84 mm
(0.033 inch), this indicates a shim thickness of
0.84 mm (0.033 inch).
E. Required shim thickness is EQUAL to J 8001
reading.
F. Shims are available in 0.03 mm to 0.94 mm
(0.001 inch to 0.037 inch). Shim thickness is
etched on the flat surface for easy identifica-
tion.
!++I Install or Connect
I. Loosen J 21777-43 and remove special tools and
inner and outer bearing assemblies (18 and 7) from
housing assembly (16).
2. Correct shim (19) on drive pinion gear (23).
rn Important
• Proper drive pinion gear depth setting is a two-
step procedure.
a. The set-up dimension arrived at using
J 8001 is to be considered a starting
point.
b. A ring gear tooth pattern check is neces-
sary to fine tune the drive pinion gear
depth and may indicate additional shim
changes to the drive pinion gear stem.
Refer to "Tooth Contact Pattern Test" in
this section.
• Both procedures must be performed to ensure
proper rear axle assembly performance.
3. Differential drive pinion gear inner and outer bear-
ing assemblies. Refer to "Differential Drive Pinion
Gear Inner Bearing Assembly" and "Differential
Drive Pinion Gear Outer Bearing Assembly" in this
section.
!+!+I Assemble
• Differential case. Refer to "Differential Case" in
this section.
!~I Measure
• Preload of the total assembly at the drive pinion gear
nut ( 1). With new inner and outer bearing assem-
blies (18 and 7), preload is 3.6 N•m to 6.2 N•m (32
lb. in. to 55 lb. in.) rotating torque with a new seal
(6). With used inner and outer bearing assemblies
(18 and 7), preload is 1.8 N•m to 3.1 N•m (16 lb. in.
to 28 lb. in.) rotating torque with a new seal (6).
DIFFERENTIAL CASE {LIMITED SLIP)
Figure 37
The Auburn limited slip differential assembly
case (80) is non-serviceable and must be replaced as an
assembly. Removal and replacement of the differential
case and service on the side bearings and ring gear is the
same as for the standard rear axle assembly.
REAR AXLE HOUSING REPLACEMENT
It is not necessary to remove the rear axle housing
assembly for any normal repairs. However, if the rear axle
housing assembly is damaged, it may be removed and
installed using the following procedures:
Rear Axle Housing Assembly with Drum Brakes
!++I Remove or Disconnect
1. Rear axle assembly. Refer to "Rear Axle Assem-
bly" in this section.
2. Rear brake pipe assemblies from rear wheel brake
cylinders. Refer to SECTION 5.
3. Rear brake pipe assemblies from rear brake (center)
hose assembly junction block. Refer to SECTION 5.
4. Rear brake (center) hose assembly junction block
from housing assembly. Refer to SECTION 5.
5. Rear brake pipe assemblies from housing assembly.
Refer to SECTION 5.
6. Rear axle shaft bearing assemblies and seals. Refer
to "Rear Axle Shaft Bearing Assembly and/or
Bearing Seal" in this section.
7. Rear brake backing plates. Refer to SECTION 5C2.
8. Differential case. Refer to "Differential Case" in
this section.
9. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.
!++I Install or Connect
1. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear " in this section.
2. Differential case. Refer to "Differential Case" in
this section.
3. Rear brake backing plates. Refer to SECTION 5C2.
4. Rear axle shaft bearing assemblies and seals. Refer
to "Rear Axle Shaft Bearing Assembly and/or
Bearing Seal" in this section.
 REAR AXLE 48-27

8. Rear brake pipe assemblies to rear brake (center)

hose assembly junction block. Refer to SECTION 5.
9. Rear axle assembly. Refer to "Rear Axle Assem-
bly" in this section.

REAR AXLE ASSEMBLY WITH DISC BRAKES

Figures 1 through 4 and 38
A shim (67) may be installed between the rear brake
caliper assembly mounting plate (65) and the axle shaft
tube flange on the housing assembly (16). This shim (67)
centers the rear brake caliper and pad assemblies over the
brake rotor assembly (71), ensuring even brake pad
assembly pressure during braking. This shim (67) may
have to be changed when the housing assembly (16) is
replaced.

f++I Remove or Disconnect

29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT
LOCK • Rear axle assembly. Refer to "Rear Axle Assem-
80 CASE, AUBURN DIFFERENTIAL (NON-SERVICEABLE) bly" in this section.
PC0030-4B·f·RP

Figure 37 - Limited Slip Rear Axle Assembly - Auburn-Type !+!+I Disassemble

5. Rear brake pipe assemblies to housing assembly.
Refer to SECTION 5.
6. Rear brake pipe assemblies to rear wheel brake
cylinders. Refer to SECTION 5.
7. Rear brake (center) hose assembly junction block to
housing assembly. Refer to SECTION 5.
1. Rear brake pipe assemblies from brake hose
assemblies. Refer to SECTION 5.
2. Rear brake pipe assemblies from rear brake (center)
hose assembly junction block. Refer to SECTION 5.
3. Rear brake (center) hose assembly junction block
from housing assembly. Refer to SECTION 5.
4. Rear brake pipe assemblies from housing assembly.
Refer to SECTION 5.

71

DISTANCE "A" SHIM THICKNESS REQUIRED* GM PART NUMBER

68.625-69.79 mm (2.70"-2.74") NO SHIM REQUIRED

69.800-70.955 mm (2.75"-2.79") 0.60 mm (0.024") 26034667

* ORIGINAL SHIM, IF INCLUDED, MAY BE PROPER THICKNESS TO REUSE.

A DIMENSION USED TO DETERMINE SHIM

65 PLATE, REAR BRAKE CALIPER ASSEMBLY MOUNTING
71 ROTOR ASSEMBLY, REAR BRAKE
PC0031-48-F-RP
Figure 38 - Brake Caliper Assembly Mounting Plate Shim Selection
 48~28 REAR AXLE

5. Rear brake hose assemblies from housing assembly.
Refer to SECTION 5.
6. Rear brake shaft bearing assemblies and seals. Refer
to "Rear Axle Shaft Bearing Assembly and/or
Bearing Seal" in this section.
7. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
8. Shim (67), if installed.
9. Differential case. Refer to "Differential Case" in
this section.
10. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.
j..!+I Assemble
I. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.
2. Differential case. Refer to "Differential Case" in
this section.
3. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
4. Rear axle shaft bearing assemblies and seals, but do
not tighten lock bolt/screw at this time. Leave Jock
bolt/screw finger tight. Refer to "Rear Axle Shaft
Bearing Assembly and/or Bearing Seal" in this
section.
ing surface) to front face of machined axle shaft tube
flange, using a caliper.
2. Select shim (67). Refer to Figure 38.
!+!,.I Disassemble
I. Rear axle shaft. Refer to "Rear Axle Shaft" in this
section.
2. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
l..!+I Assemble
I. Shim (67), if necessary.
2. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
3. Rear brake hose assemblies to housing assembly.
Refer to SECTION 5.
4. Rear brake pipe assemblies to housing assembly.
Refer to SECTION 5.
5. Rear brake (center) hose assembly junction block to
housing assembly. Refer to SECTION 5.
6. Rear brake pipe assemblies to rear brake (center)
brake assembly junction block. Refer to SEC-
TION 5.
7. Rear brake pipe assemblies to brake hose assem-
blies. Refer to SECTION 5.

l@I Measure l++j Install or Connect

I. Distance from rear face of rear brake caliper • Rear axle assembly. Refer to "Rear Axle Assem-
assembly mounting plate (65) (tube flange mount- bly" in this section.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

Use a reliable torque wrench to tighten the parts listed to make sure the parts are properly tightened without straining
or distorting parts. These specifications are for clean and lightly-lubricated threads only; dry or dirty threads produce
increased friction which prevents measurement of tightness.

Differential Bearing Cap Bolt/Screw .................................... 75 N•m (55 lb. ft.)

Differential Drive Pinion Gear Setting Gage Nut .......................... 2.3 N•m (20 lb. in.)
Differential Pinion Gear Shaft Lock Bolt/Screw ........................... 36 N•m (27 lb. ft.)
Differential Ring Gear (Left-Hand Thread) Bolt/Screw ..................... 120 N•m (89 lb. ft.)
Rear Axle Housing Bolt/Screw ......................................... 30 N•m (22 lb. ft.)
Rear Axle Housing Drain (Fill) Plug .................................... 35 N•m (26 lb. ft.)
Sensor Plug Mounting Bolt/Screw ...................................... 10 N•m (89 lb. in.)
Wheel Nut ....................................................... 140 N•m (100 lb. ft.)
 REAR AXLE 48-29

GENERAL SPECIFICATIONS

Rear Axle Type .................................................. Semi-Floating Hypoid

Drive and Torque ..................................................... Through 4 Arms
Ring and Drive Pinion Gear Set Type ............................................. Hypoid
Rear Axle Lubricant Capacity ........................................... 1.65 L (2.90 pt.)
Rear Axle Lubricant
Standard Differential ................................ GM P/N 12345977 Axle Lubricant or
SAE SOW-90 GL-5 Gear Lubricant or equivalent
Limited Slip Differential .......... 118 ml (4 fl. oz.) GM P/N 1052358 Limited Slip Differential
Lubricant and GM P/N 12345977 Axle Lubricant or
SAE 80W-90 GL-5 Gear Lubricant or equivalent
Pinion Gear Seal Lubricant .................................. GM P/N 1050169 or equivalent
Gear Marking Compound ................................... GM P/N 1052351 or equivalent

LIMITS FOR FITTING AND ADJUSTING

Differential Drive Pinion Gear Inner and Outer Bearing Preload
(Measured at Drive Pinion Gear Nut)
New Bearing Assemblies ........ 1.7 - 3.4 N•m (15 - 30 lb. in.) Rotating Torque with New Seal
Used Bearing Assemblies ........ 1.0- 1.7 N•m (10- 15 lb. in.) Rotating Torque with New Seal
Total Assembly Preload
(Measured at Drive Pinion Gear Nut)
New Bearing Assemblies ........ 3.6 - 6.2 N•m (32- 55 lb. in.) Rotating Torque with New Seal
Used Bearing Assemblies ........ 1.8 - 3.1 N•m (16 - 28 lb. in.) Rotating Torque with New Seal
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash ............................ 0.13 - 0.23 mm (0.005" - 0.009")

REAR AXLE ASSEMBLY USAGE

RING GEAR AXLE GEAR REAR BRAKE TEETH AXLE

DIAMETER RATIO DRUM DISC RING GEAR: PINION RATIO

2.73
- 41:15 GU2
DISC
7.62"
CAST IRON DRUM
3.23 42:13 GUS
DISC

PC0032·48-f.RP

SPECIAL TOOLS

J 6627-A

~ WHEEL STUD REMOVER

MC1001-3E-B-RP
48-30 REAR AXLE

J 8614-01 SET
0 ~=====;lldl;.._;=====~l J 8614-10

J 8614-2

J 8614-01 SET.
[2J <IHPOIIOOOOP~ J 8614-3
~ PINION FLANGE REMOVER ADAPTER

0 PINION FLANGE REMOVER SCREW

0 PINION FLANGE REMOVER

LC0027·4B-F-RP

3.
® J 21777-40

1. J 23597-1

2.
r£J J 23597-11
4.

© J 21777-42

@
5. QIIIIIIIIII 1111111111.i J 21777-43

7 1/2" AND 7 5/8" RING GEAR REAR AXLE

1. PINION SETIING GAGE-ARBOR

2. PINION SETIING GAGE - GAGE PLATE
J 21777-45
6.
3. PINION SETIING GAGE - REAR PILOT WASHER
4. PINION SETIING GAGE - FRONT PILOT WASHER
5. PINION SETIING GAGE - STUD ASM-BOLT
6. PINION SETIING GAGE - SIDE BEARING DISCS
PC0034-4B-F-RP
 REAR AXLE 48·31

1. 12.

J 22536 J 23771

2.
{(8
J 7817
8.
13.
@lo
J 23911

J 22813-01

3.'@~~
14.
~ J 25299
J 8001 9.

4.~

J 8092
J 22888-20
15.
[':\
r«:
J 25588

··@ J 8107-2
10.

J 22912-01 16.
~
J 29609

6.
11.~ 17. I)
J 21579 J 23765
J 5590 ·

7 1/2" AND 7 5/8" RING GEAR REAR AXLE

1. SLIDE HAMMER WITH 1/2 X 13 ADAPTER

2. FRONT PINION BEARING CUP INSTALLER
3. DIAL INDICATOR SET 18.
4. DRIVER HANDLE
5. DIFFERENTIAL SIDE BEARING REMOVER PLUG
6. AXLE SHAFT REMOVER
7. PINION DRIVER J 39446
8. AXLE BEARING REMOVER
9. DIFFERENTIAL SIDE BEARING REMOVER
10. REAR PINION BEARING REMOVER
11.
12.
13.
14.
AXLE BEARING INSTALLER
AXLE OIL SEAL INSTALLER
PINION OIL SEAL INSTALLER
DIFFERENTIAL SIDE BEARING INSTALLER
19. ...
(, _____ ......,_
~

J 21465-13
15. SIDE BEARING SHIM INSTALLER
16. REAR PINION BEARING CUP INSTALLER
17. REAR PINION BEARING CONE INSTALLER
18. ABS EXCITER RING PROTECTOR KIT
19. DRIVER HANDLE EXTENSION
 BRAKES 5-1

BRAKES
CONTENTS
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5
Master Cylinder ........................................................... Section 5A
Front Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5B 1
Rear Disc Brakes ...........•. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5B2
Duo-Servo Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5C2
Vacuum Booster System ................................................... Section 5Dl
Antilock Brake System .................................................... Section 5El
Antilock Brake System with Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5E2
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SF

SECTION 5
BRAKES
CAUTION: Certain components in the Antilock Brake System are not intended to be serviced
individually. Attempting to remove or disconnect certain system components may result in
personal injury and/or improper system operation. Only those components with approved
removal and installation procedures in Sections 5, 5E1 and 5E2 should be serviced.

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake lin-
ings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts con-
tain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water damp-
ened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.

CAUTION: Brake fluid rnay irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact - rinse thoroughly with water.
• Skin contact - wash.with soap and water.

NOTICE: The use of rubber hoses or parts other than those specified for the Antilock Brake System may lead to
functional problems requiring major overhaul. Replace a11 components included in repair kits used to service this
system. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on
brake parts as damage to rubber components may result. If any hydraulic component is removed or brake pipe or
hose assembly disconnected, it will be necessary to bleed the entire brake hydraulic system. The torque values
specified are for dry, unlubricated fasteners.

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

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connec-
tors. Brake fluid will damage pa'int and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.

CONTENTS
General Description .......................... 5-2 Flushing Brake Hydraulic System ........... 5-2
Brake Fluid and Fluid Handling .............. 5-2 Combination Valve Assembly ................ 5-2
Substandard or Contaminated Brake Fluid .... 5-2 Brake Pressure Differential Warning Switch ... 5-2
5·2 BRAKES
Brake Proportion Valve ................... 5-2
Warning/Indicator Lamp Operation ............ 5-4
Brake ................................. 5-4
Antilock ............................... 5-4
Diagnosis .................................. 5-4
Brake System Testing ...................... 5-4
External Conditions
That Affect Brake Performance ........... 5-4
Brake System ............................. 5-4
Brake Pedal Assembly Travel ................ 5-4
Brake Fluid Leaks ......................... 5-5
Brake Hose and Pipe Assembly
Inspection ............................ 5-5
Brake Fluid .............................. 5-5
Brake Indicator
Diagnostic Charts ........ Refer to Section 8A-41
On-Vehicle Service .......................... 5-5
Filling Master
Cylinder Reservoir . . . . . . . . . Refer to Section SA
GENERAL DESCRIPTION
BRAKE FLUID AND FLUID HANDLING
CAUTION: Brake fluid may irritate eyes
and skin. In case of contact, take the
following actions:
• Eye contact - rinse thoroughly with
water.
• Skin contact - wash with soap and
water.
NOTICE: Avoid spilling brake fluid on any of the
vehicle's painted surfaces, wiring, cables or electri-
cal connectors. Brake fluid will damage paint and
electrical connections. If any fluid is spilled on the
vehicle, flush the area with water to lessen the dam-
age.
m Important
• Do not re-use fluid accumulated during brake
hydraulic system bleeding.
• Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after use.
Do not use fluid left in an open or improperly sealed
container as it absorbs moisture or can become con-
taminated.
Substandard or Contaminated Brake Fluid
Use only hydraulic brake fluid GM PIN 1052535 or
an equivalent DOT-3 fluid. DO NOT use power steering
fluid, automatic transmission fluid or DOT-5 silicone
hydraulic brake fluid.
Use of an improper fluid or one contaminated with
mineral oil or water may cause the fluid to boil or the
rubber components in the brake hydraulic system to dete-
riorate.
Flushing Brake Hydraulic System
The system must be flushed if there is any doubt
about the condition of the fluid in the system or if fluid has
been used which contains the slightest trace of petroleum
Brake Pedal Assembly with Bracket ........... 5-5
Brake Pedal Assembly ...................... 5-8
Stoplarnp and Cruise Control Switch
Assemblies ............................. 5-9
Brake Pipe Assembly ...................... 5-11
Double Lap Flare ....................... 5-13
ISO Flare ............................. 5-19
Combination Valve Assembly ............... 5-20
Brake Hose Assembly ..................... 5-21
Front Brake Hose Assembly .............. 5-21
Rear Brake (Center) Hose Assembly ........ 5-22
Rear Brake Hose Assembly ............... 5-24
Bleeding Brake
Hydraulic System . . . . . . . . . Refer to Section 5El
Flushing Brake Hydraulic System ............ 5-24
Specifications .............................. 5-25
General Specifications ..................... 5-25
Fastener Tightening Specifications ........... 5-25
Special Tools .............................. 5-26
or mineral oil based fluids. Approximately 1.5 liters
( 1.5 quarts) of hydraulic brake fluid is required to flush
the brake hydraulic system. Refer to "Flushing Brake
Hydraulic System" under "On-Vehicle Service" in this
section for more information.
COMBINATION VALVE ASSEMBLY
The non-serviceable brake combination valve
assembly is located under the hood, mounted to the ABS
modulator assembly on the left engine compartment side
inner rail assembly. The brake combination valve assem-
bly incorporates the following functions into a single
component:
Brake Pressure Differential Warning Switch
The brake pressure differential warning switch mon-
itors the front and rear brake systems to measure any dif-
ference in hydraulic pressure between the two systems. If
a sufficient pressure differential exists between the sys-
tems, an electrical ground is made energizing the red
"BRAKE" warning lamp if the ignition is on. The brake
combination valve assembly and brake pressure differen-
tial warning switch are also designed so the warning
switch will latch in the warning position once a malfunc-
tion has occurred. The "BRAKE" warning lamp will turn
off only after the malfunction is repaired and a pedal force
sufficient to develop approximately 3 100 kPa (450 psi)
hydraulic brake pressure is applied.
Brake Proportion Valve
The brake proportion valve improves front-to-rear
brake balance under severe brake application. Severe
brake application transfers part of the vehicle's rear
weight to the front wheels. The resulting decrease in
weight at the rear wheels can cause reduced brake effi-
ciency. The brake proportion valve limits the pressure to
the rear brakes to reduce the tendency for reduced brake
efficiency. The proportion valve also has a by-pass feature
which assures full system pressure to the rear brakes in the
event of a front system brake failure. Full front system
pressure is retained in the event of rear brake system mal-
function.
 BRAKES 5·3

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Leaking Brake line or Conn. x xx x xx x 5
Leaking Piston Seal x xx x x 58
Leaking Master Cylinder (Internal) x xx x x 5A
Air in Brake System xx x x xx 5
Contaminated or Improper Brake Fluid x x x x x x x 5
Leaking Vac. or Booster Sys. xx xx x 501
Restricted Passage in Vacuum Booster x x xx x 501
Damaged Vacuum Booster x x x x x xx 501
Worn Out Brake Lining x x x x x x x x x 5B,5C
Uneven Brake lining Wear x x x x x x xx x x 5B.5C
Glazed Brake lining xx x x x x x 5B,5C
Incorrect lining Material x x x xx x x x x xx x x 5B,5C
Contaminated Brake lining x xx xx x x x x x x x SB.SC
Lining Damaged by Abusive Use x x xx x x x x x x x x x x x 58,SC
Improper Rotor Surface Finish xx x x x x x 58,SC
Scored Rotor x
x x xx x x x x SB
Improper Thickness Variation in Rotor x xx xx 58
Excessive lateral Run-out in Rotor x x x x SB
Brake Asm. Attachments Loose
(Incl. Splash Shield) x x x x x x x x 58

Restricted Brake Fluid Passage x x x x x x x x 5

·Improperly Adj. Stoplamp Switch or Cruise
Control Vacuum Dump x xx x xx 5

Brake Pedal linkage Interference or Binding x x xx xx x 5

Incorrect Vacuum Booster Push rod Length x xx x x 501
Incorrect Front Wheel Align. xx xx 3A
Incorrect Tire Pressure x x 3A
Loose Front Suspension Parts x x xx x x x 3C
Out-of-balance Wheel Assm. xx x 3E
Operator Riding Brake Pedal x x x
Sticking Caliper or Caliper Pistons x x xx x x x x x x x 58
Park. Brake Switch Ckt. Gnd. xx BA
Park. Brake Not Releasing x x x xx x SF
low Brake Fluid x x x 5
Caliper to Knuckle Clearance x x x x x x 58
Improper Rear Brake Adj. xx x x x SF
low Engine Vacuum xx x x 5
Excessive Vehicle Loading x xx x x
Improperly Torqued Wheel Nuts x x 3E
Poor Drum Surface Finish x x x SC
Parking Brake Cables Seized x x xx xx SF
Rotor Corroded x x x x xx x 5
Grease/Dirt on Rotor x xx 5
ABS Modulator RR Piston Seized x x x 5E1
XX· INDICATES MORE PROBABLE CAUSE(S) X • INDICATES OTHER CAUSE(S) RC0001·5-f.RP

Figure 1 - Brake System Diagnosis

5·4 BRAKES
WARNING/INDICATOR LAMP OPERATION
Brake
The brake system uses a single red "BRAKE"
warning lamp located in the instrument cluster assembly.
When the ignition switch is in the "START" position, the
"BRAKE" warning lamp should come on. It should go
off when the ignition switch returns to the "RUN" posi-
tion.
The following conditions will. activate the
"BRAKE" warning lamp:
1. Parking brake applied. Lamp should be on when
parking brake is applied and ignition switch is
"ON."
2. Brake pressure differential warning switch detects
failure. Refer to SECTION 8A for diagnosis.
3. During engine cranking "BRAKE" warning lamp
should remain on. This notifies driver that warning
circuit is operating properly.
Anti lock
The antilock brake system (ABS) uses three indica-
tor lamps: the red "BRAKE" warning lamp, an amber
"ABS INOP" indicator lamp and an amber "LOW
TRAC'' indicator lamp, all located in the instrument clus-
ter assembly. Under normal conditions, these lamps
should operate as follows:
1. When ignition is turned to "RUN" position, prior to
starting engine, amber "ABS INOP" indicator lamp
should go on and red "BRAKE" warning lamp
should flash.
2. As engine is cranked, both red "BRAKE" warning
lamp and amber "ABS INOP" indicator lamp
should come on and "LOW TRAC" indicator lamp
may come on and off.
3. When engine is started, amber "ABS INOP" and
red "BRAKE" lamps should go out and "LOW
TRAC" indicator lamp may come on and off.
The operation of these three indicator lamps is an
important part of the antilock brake system (ABS) diagno-
sis. If the warning/indicator lamps turn on while driving
the vehicle, this indicates a malfunction. If the warning/
indicator lamps don't turn on under normal conditions as
described above, service the lamps as soon as possible.
For further information regarding warning/indicator lamp
operation for the antilock brake system (ABS), refer to
SECTION 5El.
DIAGNOSIS
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy or
covered with loose dirt so that all tires do not grip the road
equally. Testing will also be affected if the roadway is
crowned, which would throw the weight of the vehicle
toward the wheels on one side. If the roadway is too
rough, the wheels will tend to bounce.
Test brakes at different vehicle speeds with both
light and heavy brake pedal force.
External Conditions That Affect Brake
Performance
Tires
Tires having unequal contact and grip on the road
will cause unequal braking. Tires must be equally inflated,
and the tread pattern of right and left tires must be approx-
imately equal.
Vehicle Loading
A heavily loaded vehicle requires more braking
effort. When a vehicle has unequal loading, the most
heavily loaded wheels require more braking power than
others.
Wheel Alignment
Misalignment of the wheels, particularly excessive
camber and caster, will cause the brakes to pull to one
side.
BRAKE SYSTEM
Figure 1
For diagnosis of the brake hydraulic system,. refer to
Figure 1.
BRAKE PEDAL ASSEMBLY TRAVEL
Most low brake pedal assembly problems are caused
by air in the brake system or misadjusted rear drum
brakes. Bleed the system until air is purged and check rear
brake adjustment. Refer to SECTION 5El. Other less fre-
quent causes of excessive brake pedal assembly travel are
incorrect pushrod assembly length, rear brake shoe adjust-
ers not operating, linings excessively worn, and brake
hydraulic system leakage.
High brake pedal assembly force problems are usu-
ally caused by low engine assembly vacuum, a vacuum
leak, or an improperly functioning vacuum booster
assembly. These conditions would also result in higher
than normal brake pedal assembly efforts.
!@! Measure
Tool Required:
J 28662 Brake Pedal Effort Gage
1. Install J 28662 onto pedal assembly.
2. Hook end of tape measure over top edge of pedal
assembly and measure the distance to rim of steering
wheel assembly.
3. With engine running at idle and the shift lever in
"NEUTRAL" and the wheel and tire assemblies
blocked, apply brake pedal assembly with 445 N
(100 lb.) force and remeasure. The difference be-
tween both readings is actual brake pedal assembly
travel and should be between 51 to 89 mm (2.0 to 3.5
inches).
4. If brake pedal assembly travel is more than specifi-
cations, refer to Figure 1.

BRAKE FLUID LEAKS
With engine running at idle and the shift lever in
"NEUTRAL," depress the brake pedal assembly and
hold constant foot pressure. If the pedal assembly gradu-
ally falls away with constant pressure, the brake hydraulic
system may be leaking. Perform visual check to confirm
any suspected leak.
Check the master cylinder assembly fluid levels.
While a slight drop in master cylinder reservoir level does
result from normal lining wear, an abnormally low level in
either reservoir indicates a leak in the system. The brake
hydraulic system may be leaking either internally or
externally. Refer to SECTION SA. Also, the system may
appear to pass this test but still have slight leakage.
Check for possible brake fluid leaks at the brake pipe
assembly and brake hose assembly connections. If any
signs of leakage are found, replace the brake pipe or hose
assembly. Also, inspect the connecting brake comp~nent
to determine if it is damaged and should be rebmlt or
replaced. Check the brake caliper boots and rear wheel
cylinder boots for leaks. If any brake fluid appears to be
leaking, rebuild or replace the assembly. Refer to
SECTION 5Bl, SECTION 5B2 or SECTION 5C2.
When checking the brake fluid levels, the master
cylinder rear reservoir may be as low as 25.4 mm ( 1 inch)
from the top if the linings are worn. This is not abnormal.
Brake Hose and Pipe Assembly Inspection
NOTICE: Do not allow brake components to hang
from the flexible hose assemblies as damage to the
hoses may occur. Some brake hose assemblies have
protective rings or covers t? prevent dir~ct contac! of
the hose with other chassis parts. Besides causmg
possible structural damage to the hose, excessive
tension could cause the hose rings to move out of
their proper locations.
!L•l 1nspect
1. Flexible hydraulic brake hose assemblies, which
transmit hydraulic pressure from steel brake pipe
assembly on body to steel brake pipe assemblies on
rear axle assembly and to brake caliper assemblies,
at least twice a year when vehicle is on lift for
lubrication.
2. Brake hose assemblies for road hazard damage,
cracks, and chafing of outer cover, and for leaks and
blisters.
• A light and mirror may be needed for adequate
inspection.
• If any of the above conditions are observed on
brake hose assembly, it will be necessary to
replace it.
BRAKE FLUID
NOTICE: Improper brake fluid, mineral oil or water
in the brake fluid may cause rubber components in
the brake hydraulic system to deteriorate. If brake
master cylinder primary or secondary piston seals
are swollen, the rubber parts have deteriorated. This
BRAKES 5·5
deterioration may also be seen by swollen brake
master cylinder reservoir seals, rear wheel cylinder
piston boots or brake caliper piston boots.
If rubber deterioration is evident, disassemble all
hydraulic parts and wash with alcohol. Dry parts with
compressed air before assembly to keep alcohol out of the
system. Replace all rubber parts in the system, including
brake hose assemblies, master cylinder assembly rubber
parts, and brake caliper assembly and wheel cylinder
assembly boots and seals. Also replace the combination
valve assembly and brake pressure modulator valve
assembly, since they have rubber components inside
which are not serviceable. Check for brake fluid on the
linings. If excessive brake fluid is found, replace the
linings.
The system must be flushed if there is any doubt as
to the condition of brake fluid in the system or if a fluid
has been used which contains the slightest trace of petro-
leum or mineral oil based fluids. Refer to SECTION 5El
for complete brake hydraulic system flush and bleed pro-
cedures.
ON-VEHICLE SERVICE
BRAKE PEDAL ASSEMBLY WITH BRACKET
Figures 2 through 4
!+,.I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION SC.
3. Electronic brake control module assembly. Refer to
SECTION 5El.
4. Release switch assembly, stoplamp and TCC switch
assembly, and clutch switch assembly or clutch an-
ticipate switch assembly if equipped, from pedal
assembly with bracket. Refer to "Stoplamp and
Cruise Control Switch Assemblies". in this section.
5. Clutch start switch assembly (29) from brake pedal
assembly with bracket (5) on vehicle with manual
transmission assembly.
6. Accelerator lever pedal assembly. Refer to
SECTION 6C.
7. Retainer (16), brake pedal pushrod (15) and washer
(14) from brake pedal assembly pin.
8. Retainer (20) and clutch pushrod (19) from clutch
pedal assembly pin on vehicle with manual trans-
mission assembly.
9. Nuts (3 and 7) and bolts/screws (4 and 8).
10. Nuts (11 ), on vehicle with manual transmission
assembly.
11. Brake pedal assembly with bracket (5 or 6).
!-++I Install or Connect
NOTICE: See. "Notice" on page 5-1 of this section.
5-6 BRAKES

A PANEL ASSEMBLY, DASH

B PIN, BRAKE PEDAL ASSEMBLY
C PIN, CLUTCH PEDAL ASSEMBLY
1 BOOSTER ASSEMBLY, POWER BRAKE
18 ,,~-
2 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
3 NUT, BRAKE PEDAL, 25 N•m (18 LB. FT.) 20
4 BOLT/SCREW, BRAKE PEDAL BRACKET,
25 N•m (18 LB. FT.)
5 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
7 NUT, BRAKE PEDAL BRACKET, 25 N•m (18 LB. FT.)
8 BOLT/SCREW, BRAKE PEDAL BRACKET,
25 N•m (18 LB. FT.)
9 BOLT/SCREW, BRAKE PEDAL PIVOT
10 NUT, BRAKE PEDAL PIVOT
11 NUT, CLUTCH MASTER CYLINDER,
27 N•m (20 LB. FT.)
12 BUSHING, BRAKE PEDAL PIVOT
13 PEDAL ASSEMBLY, BRAKE
14 WASHER, BRAKE PEDAL PUSHROD
15 PUSHROD, BRAKE PEDAL
16 RETAINER, BRAKE PEDAL PUSHROD PIN
17 BUSHING, CLUTCH PEDAL PIVOT
18 PEDAL ASSEMBLY, CLUTCH
19 PUSHROD, CLUTCH MASTER CYLINDER
20 RETAINER, CLUTCH PEDAL LEVER PIN
24 PEDAL ASSEMBLY, ACCELERATOR LEVER
PC0002-6-f.RP

Figure 2 - Manual Transmission Brake Pedal Assembly

 BRAKES 5·7

22 6

<

24

16

A PANEL ASSEMBLY, DASH

B PIN, BRAKE PEDAL ASSEMBLY
1 BOOSTER ASSEMBLY, POWER BRAKE
2 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
3 NUT, BRAKE PEDAL, 25 N•m (18 LB. FT.)
4 BOLT/SCREW, BRAKE PEDAL BRACKET,
25 N•m (18 LB. FT.)
6 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR
(WITH BRACKET)
7 NUT, BRAKE PEDAL BRACKET, 25 N•m (18 LB. FT.)
8 BOLT/SCREW, BRAKE PEDAL BRACKET,
25 N•m (18 LB. FT.)
12 BUSHING, BRAKE PEDAL PIVOT
13 PEDAL ASSEMBLY, BRAKE
14 WASHER, BRAKE PEDAL PUSHROD
15 PUSHROD, BRAKE PEDAL
16 RETAINER, BRAKE PEDAL PUSHROD PIN
21 BOLT/SCREW, BRAKE PEDAL PIVOT
22 NUT, BRAKE PEDAL PIVOT
23 SPACER, BRAKE PEDAL PIVOT
24 PEDAL ASSEMBLY, ACCELERATOR LEVER

PC0003-5-F·RP

Figure 3 - Automatic Transmission Brake Pedal Assembly

5·8 BRAKES
rn Important
• When installing brake pedal assembly with
bracket, make sure that dash panel insulator
material does not get pinched between brake
pedal assembly with bracket and dash panel.
I. Brake pedal assembly with bracket (5 or 6).
2. Nuts (11), on vehicle with manual transmission.
3. Nuts (3 and 7) and bolts/screws (4 and 8).
l~I Tighten
• Nuts (7) to 25 N•m (18 lb. ft.) in sequence:
inboard upper, outboard lower, outboard
upper, inboard lower.
• Nuts (3) and bolts/screws (4 and 8) to 25 N•m
(18 lb. ft.).
• Nuts (11) to 27 N•m (20 lb. ft.) on vehicle with
4.
manual transmission assembly.
Accelerator lever pedal assembly. Refer to
SECTION 6C.
5. Retainer (20) and clutch pushrod (19) to clutch pedal
assembly pin on vehicle with manual transmission
assembly.
• Lubricate clutch pedal assembly pin with chas-
sis lubricant, GM P/N 1052497 or equivalent.
6. Retainer ( 16), brake pedal pushrod ( 15) and washer
(14) to brake pedal assembly pin.
• Lubricate brake pedal assembly pin with chas-
sis lubricant, GM P/N 1052497 or equivalent.
7. Release switch assembly, stoplamp and TCC switch
assembly, and clutch switch assembly or clutch
anticipate switch assembly if equipped, to pedal
assembly with bracket. Refer to "Stop lamp and
Cruise Control Switch Assemblies" in this section.
8. Electronic brake control module assembly. Refer to
SECTION 5El.
9. Clutch start switch assembly (29) to brake pedal
assembly with bracket (5), on vehicle with manual
transmission assembly.
10. Battery negative cable assembly.
~ Adjust
• Release switch assembly, stoplamp and TCC switch
assembly, and clutch switch assembly or clutch
anticipate switch assembly on vehicle with manual
transmission assembly. Refer to "Stoplamp and
Cruise Control Switch Assemblies" in this section.
BRAKE PEDAL ASSEMBLY
Figures 2 and 3
l++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Electronic brake control module assembly. Refer to
SECTION 5El.
3. Retainer (16), brake pedal pushrod (15) and washer
(14) from brake pedal assembly pin.
4. Nut (10) and bolt/screw (9) on vehicle with manual
transmission assembly.
• Slide out bolt/screw (9) part way, giving just
enough clearance to remove brake pedal
assembly (13).
5. Nut (22) and bolt/screw (21) on vehicle with auto-
matic transmission assembly.
6. Brake pedal assembly (13).
7. Bushings (12) from brake pedal assembly (13), if
necessary.
8. Spacer (23) from brake pedal assembly (13) on
vehicle with automatic transmission assembly, if
necessary.
jr:,I Clean
• All parts with suitable solvent.
!L"'I Inspect
• All parts for wear. Repair or replace as needed.
!++I Install or Connect
1. Spacer (23) to brake pedal assembly (13), if
removed.
2. Bushings (12) to brake pedal assembly (13), if
removed.
3. Lubricate bolt/screw (9) with chassis lubricant, GM
P/N 1052497 or equivalent on vehicle with manual
transmission assembly.
4. Brake pedal assembly (13).
5. Bolt/screw (9) and nut (10) on vehicle with manual
transmission assembly.
6. Bolt/screw (21) and nut (22) on vehicle with auto-
matic transmission assembly.
l~I Tighten
• Nut (10 or 22) to 54 N•m (40 lb. ft.).
7. Retainer (16), brake pedal pushrod (15) and washer
(14) to brake pedal assembly pin.
• Lubricate brake pedal assembly pin with chas-
sis lubricant, GM P/N 1052497 or equivalent.
8. Electronic brake control module assembly. Refer to
SECTION 5El.
9. Battery negative cable assembly.
~ Adjust
• Release switch assembly, and stoplamp and TCC
switch assembly, and clutch switch assembly or
clutch anticipate switch assembly if equipped. Refer
to "Stoplamp and Cruise Control Switch Assem-
blies" in the following procedure.
 BRAKES 5·9

STOPLAMP AND CRUISE CONTROL bracket (5 or 6) until retainer on release switch

SWITCH ASSEMBLIES
Figure 4
Adjustment
The release switch assembly (27) must be adjusted
at the same time the stoplamp and torque converter clutch
(TCC) switch is adjusted. The clutch switch assembly
(25) or clutch anticipate switch assembly (28) cannot be
adjusted until after the clutch pedal assembly is installed.
NOTICE: Proper stoplamp switch assembly adjust-
ment is essential. Improper stoplamp switch assem-
bly adjustment will cause brake drag and excessive
brake lining wear.
[e) Adjust
I. To adjust, depress brake pedal assembly or clutch
pedal assembly and insert release switch assembly
(27), stoplamp and TCC switch assembly (26) and
clutch switch assembly (25) or clutch anticipate
switch assembly (28) into pedal assembly with
assembly (27), stoplamp and TCC switch assembly
(26), or clutch switch assembly (25) or clutch antici-
pate switch assembly (28) is fully seated.
NOTICE: Make sure to apply the proper amount of
force to the brake pedal assembly during adjustment.
Too much force could damage the vacuum booster
assembly. Too little could cause dragging brakes.
2. Slowly pull brake or clutch pedal assembly rearward
with a force of 222 N (50 pounds) until "click"
sounds can no longer be heard. At this point, release
switch assembly (27), stoplamp and TCC switch
assembly (26), and clutch switch assembly (25) or
clutch ar1ticipate switch assembly (28) will have
moved retainers to their adjusted position.
l~I Measure
• Release switch assembly and stoplamp and TCC
switch assembly contacts should be open at 25.4 mm
(1 inch) or less of pedal assembly travel, and occur at
the same time or before the onset of braking. The

26

29

A MANUAL TRANSMISSION
B AUTOMATIC TRANSMISSION
C CONNECTOR, ELECTRICAL
D CONNECTOR, ELECTRICAL H
E CONNECTOR, ELECTRICAL
F CONNECTOR, ELECTRICAL
G CONNECTOR, ELECTRICAL
H WITH 3.4L L32 ENGINE
J WITH 5.7L LT1 ENGINE
5 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
6 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR (WITH
BRACKET)
25 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
26 SWITCH ASSEMBLY, STOPLAMP AND TORQUE
CONVERTER CLUTCH
27 SWITCH ASSEMBLY, CRUISE CONTROL RELEASE B
28 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
ANTICIPATE
29 SWITCH ASSEMBLY, CLUTCH START
PC0004-6-f..RP

Figure 4 - Stoplamp and Cruise Control Switch Assemblies

5·10 BRAKES

31

,f~~ 36

©J
33

39

44

30

~~.,. A

' 33

31

A CROSSMEMBER ASSEMBLY, FRONT 37 CLIP, BRAKE PIPE

30 CYLINDER ASSEMBLY, BRAKE MASTER 38 CLIP, BRAKE PIPE
31 PIPE ASSEMBLY, FRONT BRAKE COMBINATION VALVE 39 CLIP, BRAKE PIPE
32 PIPE ASSEMBLY, REAR BRAKE COMBINATION VALVE 40 CLIP, BRAKE PIPE
33 VALVE ASSEMBLY, BRAKE PRESSURE MODULATOR 41 CLIP, BRAKE PIPE
34 PIPE ASSEMBLY, LEFT-HAND FRONT BRAKE 42 BOLT/SCREW, BRAKE PIPE CLIP, 6 N•m (53 LB. IN.)
35 PIPE ASSEMBLY, RIGHT-HAND FRONT BRAKE 43 BOLT/SCREW, FRONT BRAKE FRONT PIPE CLIP,
36 PIPE ASSEMBLY, REAR BRAKE FRONT, 6 N•m (53 LB. IN.)
15 N•m (11 LB. FT.) 44 CLIP, BRAKE PIPE

PCOG05·5·f·RP

Figure 5 - Routing Front Brake Pipe Assemblies (Without Traction Control System)
 BRAKES 5-11

BRAKE PIPE ASSEMBLIES-TO-BRAKE MASTER CYLINDER ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE PIPE NUT TIGHTENING

NUMBER CIRCUIT SIZE OIAMETER LINEAR LENGTH SPECIFICATION

31 PRIMARY M11 x1.5 4.76mm 411.0 mm (16.848"1 32 N"l!l (24 LB. FT.I

32 SECONOARY M11 x1.5 4.76mm 519.0 mm (20.895") 32 N"l!l (24 LB. FT.I

BRAKE PIPE ASSEMBLIES-TO-COMBINATION VALVE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROX! MATE BRAKE Pl PE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION

31 PRIMARY M10x1.0 4.76mm 411.0 mm 116.848") 18 N"l!l (13 LB. FT.)

32 SECONDARY M10x 1.0 4.76 mm 519.0 mm (20.895"1 18 N"l!l (13 LB. FT.)

BRAKE PIPE ASSEM8LIES-TO-BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE PIPE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION

34 LEFT-HAND FRONT M10x 1.0 4.76mm 2321.50 mm (91.379") 32 N"lll (24 LB. FT.)

35 RIGHT-HAND FRONT MlOx 1.0 4.76mm 1398.84 mm (55.07T) 32 N"lll (24 LB. FT.)

36 REAR M12x 1.5 6.00mm 3736.0 mm (150.155") 32 N"l!l (24 LB. FT.)

BRAKE PIPE ASSEMBLIES-TO-BRAKE HOSE ASSEMBLIES

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE PIPE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION

.34 LEFT-HAND FRONT M10x1.0 4.76mm 2321.50 mm (91.379") 15 N"l!l (11 LB. FT.)

35 RIGHT-HAND FRONT M10x 1.0 U&mm 1398.84 mm (55.07T) 15 N"lll (11 LB. FT.I

NUT COLOR CODE

SIZE COLOR
Mlo"x 1.0 OLIVE
M11x1.5 ORANGE
M12x1.0 OLIVE
M12x1.5 OLIVE
318·24 UNF VIOLET
RC0008·5-f-RP

Figure 6 - Front Brake Pipe Assemblies Specifications (Without Traction Control System)

brake pedal assembly travel can be up to 25.4 mm 2. Electrical connectors.

( 1 inch) before the cruise control system disengages. 3. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION 8C.
Replacement
[t) Adjust
!+-.I Remove or Disconnect • Release switch assembly (27), stoplamp and TCC
I. Left-hand instrument panel sound insulator assem- switch assembly (26), and clutch switch assembly
bly. Refer to SECTION 8C. (25) or clutch anticipate switch assembly (28), as
2. Electrical connectors. outlined above.
3. Release switch assembly (27), stoplamp and TCC
switch assembly (26), and clutch switch assembly
(25) or clutch anticipate switch assembly (28), if BRAKE PIPE ASSEMBLY
equipped, from pedal assembly with bracket (5 or 6). Figures 5 through 14
!++I Install or Connect CAUTION: Always use double walled
steel brake pipe when replacing brake
1. Release switch assembly (27), stoplamp and TCC pipe assemblies. The use of any other
switch assembly (26), and clutch switch assembly. pipe is not recommended and may
(25) or clutch anticipate switch assembly (28), if cause brake system failure. Carefully
equipped, to pedal assembly with bracket (5 or 6). route and retain replacement brake
5·12 BRAKES

c
53

A AXLE ASSEMBLY, REAR

B CLIP, REAR AXLE RETAINER
C RAIL ASSEMBLY, REAR COMPARTMENT PANEL
LONGITUDINAL 56
36 PIPE ASSEMBLY, REAR BRAKE FRONT,
15 N•m (11 LB. FT.)
51 BOLT/SCREW, REAR BRAKE HOSE FITIING,
21 N•m (15 LB. FT.)
52 CLIP, REAR BRAKE PIPE
53 HOSE ASSEMBLY, REAR BRAKE
54 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
55 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
56 RETAINER, REAR BRAKE HOSE
57 BRACKET, REAR BRAKE HOSE
58 BOLT/SCREW, REAR BRAKE HOSE RETAINER,
10 N•m (89 LB. IN.)
67 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
68 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
PCOOCIB-6-F·RP

Figure 7 - Routing Rear Brake Pipe and Hose Assemblies (Without Traction Control System)
 BRAKES 5·13

REAR BRAKE PIPE ASSEMBLIES • TO · REAR BRAKE HOSE ASSEMBLIES

NUT TIGHTENING
SPECIFICATIONS

NUT SIZE NUT SIZE

@CENTER @RIGHT AND APPROXIMATE @RIGHT AND
CALLOUT HOSE LEFT HOSE PIPE ASSEMBLY PIPE LINEAR @ CENTER HOSE LEFT-HOSE
NUMBER CIRCUIT ASSEMBLY ASSEMBLIES DIAMETER LENGTH ASSEMBLY ASSEMBLIES
54 RIGHT-HAND 3/8-24 UNF MlOx 1.0 4.76mm 890.49 mm (35.058") 24 N•m (18 LB. FT.) 15 N•m (11 LB. FT.)
REAR DISC
55 LEFT-HAND 3/8-24 UNF MlOx 1.0 4.76mm 541.91 mm (21.335") 24 N•m (18 LB. FT.) 15 Norn (11 LB. FT.)
REAR DISC
36 REAR M12x 1.0 - 6.00mm 3826 mm (150.629") 15 Norn (11 LB. FT.) -
REAR BRAKE PIPE ASSEMBLIES ·TO· REAR WHEEL CYLINDERS

NUT TIGHTENING
SPECIFICATIONS

NUT SIZE
@CENTER NUT SIZE APPROXIMATE @RIGHT AND
CALLOUT HOSE @WHEEL PIPE ASSEMBLY PIPE LINEAR @ CENTER HOSE LEFT WHEEL
NUMBER CIRCUIT ASSEMBLY CYLINDER DIAMETER LENGTH ASSEMBLY CYLINDERS
67 RIGHT-HAND 3/8-24 UNF 3/8-24 UNF 4.76mm 1170.05 mm (46.064") 24 N•m (18 LB. FT.) 17 N•m (13 LB. FT.)
REAR DRUM
68 LEFT-HAND 3/8-24 UNF 3/8-24 UNF 4.76mm 864.30 mm (34.027") 24 N•m (18 LB. FT.) 17 N•m (13 LB. FT.)
REAR DRUM

NUT COLOR CODE

SIZE COLOR
M10x1.0 OLIVE
M11x1.5 ORANGE
M12x1.0 YELLOW
M12x1.5 BLACK
3/8-24 UNF VIOLET
RC0002-5-F-RP

Figure 8 - Rear Brake Pipe and Hose Assemblies Specifications (Without Traction Control System)

pipe assemblies. Always use the cor· Tool Required:

rect fasteners and the original location J 23530 Brake Line Flaring Tool ( 45 Degree
for replacement brake pipe assemblies. Single and Double)
Failure to properly route and retain
brake pipe assemblies may cause dam· 1. Obtain recommended tubing and steel fitting nuts of
age to the brake pipe assemblies and correct size.
cause brake system failure. • Outside diameter of tubing is used to specify
size.
Refer to Figures 5 through 14 for brake pipe routing,
2. Cut tubing to length.
tightening specifications and replacement. For informa-
tion on the brake pressure modulator valve assembly, refer • Correct length may be determined by measur-
to SECTION 5El. For information on the traction control ing old brake pipe assembly using string and
brake pressure modulator valve assembly, refer to SEC- adding 3 mm ( 1/8 inch) for each double flare.
TION 5E2. 3. Cut end square and chamfer inside and outside
diameter of tubing with de-burring tool.
II] Important • Remove all traces of lubricant from tubing.
• Rear brake front pipe assemblies (36, 117 or 118) NOTICE: Do not use single lap flaring tools.
should not be locally fabricated. These pipe assem- Double lap flaring tools must be used to produce a
blies should be ordered through your GM Parts flare strong enough to hold system pressure. Using
Dealer. single lap flaring tools could cause system damage.
A single lap flare will split tubing while a double lap
flare produces a well-formed, unbroken, reinforced
double walled flare.
Double Lap Flare
4. Double lap flare tubing ends using J 23530.
A. Make sure fittings are installed before starting
Figures 15 through 18 flare.
Double lap flares are to be used for rear brake rear pipe B. Unscrew compression screw until swivel cone
assemblies. All other brake pipe assemblies will use ISO is at its highest point.
flare. • Swing strap to one side.
5·14 BRAKES

36

~FAT

46

46

45 _ _ __
36

36
36

~FRT
49

jv1ewo I 45

BRAKE PIPE ASSEMBLY TO BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE PIPE NUT TIGHTENING
NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION

36 REAR M12x 1.5 6.00mm 3813.95 mm (150.155") 32 N•m (24 LB. FT.)

BRAKE PIPE ASSEMBLY TO REAR BRAKE (CENTER) HOSE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE PIPE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION

36 REAR M12x 1.0 6.00mm 3813.95 mm 1150.155") 15 N•m 111 LB. FT.)

NUT COLOR
SIZE COLOR
MlOx 1.0 OLIVE
36 PIPE ASSEMBLY, REAR BRAKE FRONT, Mllxl.5 ORANGE
15 N•m (11 LB. FT.) M12x 1.0 YELLOW
45 CLIP, BRAKE PIPE M12x 1.5 BLACK
46 CLIP, FUEL LINE RETAINER 3/8-24 UNF VIOLET
47 CLIP, FUEL LINE RETAINER
48 CLIP, FUEL LINE RETAINER
49 CLIP, FUEL LINE RETAINER
PC0007-5-F-RP

Figure 9 - Routing Underbody Rear Brake Front Pipe Assembly (Without Traction Control System)
 BRAKES 5·15

32

30

104
37

~~
'~ 102
A

.~~
\.
'• 103

33

A RAIL ASSEMBLY, ENGINE COMPARTMENT INNER SIDE

30 CYLINDER ASSEMBLY, BRAKE MASTER
31 PIPE ASSEMBLY, FRONT BRAKE COMBINATION VALVE
32 PIPE ASSEMBLY, REAR BRAKE COMBINATION VALVE
33 VALVE ASSEMBLY, BRAKE PRESSURE MODULATOR
34 PIPE ASSEMBLY, LEFT-HAND FRONT BRAKE
35 PIPE ASSEMBLY, RIGHT-HAND FRONT BRAKE
37 CLIP, BRAKE PIPE
38 CLIP, BRAKE PIPE
42 BOLT/SCREW, BRAKE PIPE CLIP
100 VALVE ASSEMBLY, TRACTION CONTROL BRAKE PRESSURE
MODULATOR
101 PIPE ASSEMBLY, TRACTION CONTROL BRAKE PRESSURE
MODULATOR VALVE
102 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
103 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
104 CLIP, REAR BRAKE PIPE

RC0003-5-F-RP

Figure 1 O - Routing Front Brake Pipe Assemblies (With Traction Control System)
5-16 BRAKES

BRAKE PIPE ASSEMBLIES· TO· TRACTION CONTROL MODULATOR VALVE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION
101 REAR M12x 1.5 6.00mm 403.0 mm (15.86") 32 N•m (24 LB. FT.)
102 RIGHT-HANO Mllxl.5 4.76mm 3615.0 mm (142.32") 32 N•m (24 LB.FT.)
REAR
103 LEFT-HANO M10x1.0 4.76mm 3630.0 mm (142.91") 32 N•m (24 LB: FT.)
REAR

BRAKE PIPE ASSEMBLIES· TO· BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE NUTTIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION
34 LEFT-HANO MlOx 1.0 4.76mm 2321.50 mm (91.379") 32 N•m (24 LB. FT.)
FRONT
35 RIGHT-HANO M10x 1.0 4.76mm 1398.84 mm (55.072") 32 N•m (24 LB.FT.)
FRONT
101 REAR M12x 1.5 6.00mm 403.0 mm (15.86") 32 N•m (24 LB. FT.)

BRAKE PIPE ASSEMBLIES • TO • BRAKE HOSE ASSEMBLIES

CALLOUT NUT PIPE ASSEMBLY APPROXIMATE BRAKE NUT TIGHTENING

NUMBER CIRCUIT SIZE DIAMETER LINEAR LENGTH SPECIFICATION
34 LEFT-HANO M10x 1.0 4.76mm 2321.50 mm (91.379") 15 N•m (11 LB. FT.)
FRONT
35 RIGHT-HAND M10x 1.0 4.76mm 1398.84 mm (55.072") 15 N•m (11 LB.FT.)
FRONT

NUT COLOR CODE

SIZE COLOR
M10x 1.0 OLIVE
M10x1.5 ORANGE
M12x 1.0 OLIVE
M12x 1.5 OLIVE

RC0004-5-F-RP

Figure 11 - Front Brake Pipe Assemblies Specifications (With Traction Control System)
 BRAKES 5·17

111

~ 108

) \I

107
106

103 ~

A AXLE ASSEMBLY, REAR

B RAIL ASSEMBLY, REAR COMPARTMENT PANEL 112
LONGITUDINAL
102 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
103 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
105 CLIP, REAR BRAKE PIPE
106 CLIP, REAR BRAKE PIPE
107 BRACKET ASSEMBLY, REAR BRAKE HOSE
108 BOLT/SCREW, REAR BRACKET HOSE ASSEMBLY
109 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
110 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
111 CLIP, REAR BRAKE PIPE
112 BOLT/SCREW, REAR BRAKE HOSE BRACKET
113 BRACKET ASSEMBLY, REAR BRAKE HOSE
114 HOSE ASSEMBLY, REAR BRAKE
115 HOSE ASSEMBLY, REAR BRAKE

RCOOOS-5-F-RP

Figure 12 - Routing Rear Brake Pipe and Hose Assemblies (With Traction Control System)
5-18 BRAKES

REAR BRAKE PIPE ASSEMBLIES-TO-REAR BRAKE HOSE ASSEMBLIES

NUTTIGHTENING
SPECIFICATIONS

NUT SIZE NUT SIZE

@CENTER @RIGHT AND APPROXIMATE @RIGHT AND
CALLOUT HOSE LEFT HOSE PIPE ASSEMBLY BRAKE PIPE @CENTER HOSE LEFT-HOSE
NUMBER CIRCUIT ASSEMBLY ASSEMBLIES DIAMETER LINEAR LENGTH ASSEMBLY ASSEMBLIES
54 RIGHT-HAND MlOxl.O MlOx 1.0 4.76mm 867.0 mm (34.13") 15.0 N•m (11 LB. FT.) 15.0 N•m (11 LB. FT.)
REAR DISC
55 LEFT-HAND M12x 1.0 MlOx 1.0 4.76mm 566.0 mm (22.28") 15.0 N•m (11 LB. FT.) 15.0 N•m (11 LB. FT.)
REAR DISC
114 RIGHT-HAND M12x 1.0 - 4.76 mm 3615.0 mm (142.32") 15.0 N•m (11 LB. FT.) -
REAR
115 LEFT-HAND M10x 1.0 - 4.76 mm 3630.0 mm (142.91 ") 15.0 N•m (11 LB. FT.) -
REAR

RCOOCJ6-5-F-RP

Figure 13 - Rear Brake Pipe and Hose Assemblies Specifications (With Traction Control System)

117
!VIEWA I

48

FRTt

117~=~=\
,«~ r 118 118

116
!VIEWB I
!VIEWC I
46 CLIP, FUEL LINE RETAINER
47 CLIP, FUEL LINE RETAINER
48 CLIP, FUEL LINE RETAINER
49 CLIP, FUEL LINE RETAINER
116 CLIP, REAR BRAKE FRONT PIPE REAR
117 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE FRONT
118 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE FRONT

RC0007-5-F-RP

Figure 14 - Routing Underbody Rear Brake Front Pipe Assemblies (With Traction Control System)

A
915·
A SINGLE LAP FLARE
B DOUBLE LAP FLARE
PC6009-5-D-RP
Figure 15 - Single Lap vs. Double Lap Flares
C. Open lever handle so it is at right angle to rest
of tool and revolve hexagonal tube lights to
accommodate tubing (selection of six sizes).
D. Be sure fitting nut is properly placed on tubing.
Insert end of tube between two blocks until
level with top of gage.
A COMPRESSION SCREW
B SWIVEL CONE
J 23530
PC6010-5-D-RP
Figure 16 - Placing Tubing in Tool
E. Insert proper pin of gage into tubing and swing
strap back in closed position. Tighten compres-
sion screw until gage bottoms on tool, then un-
screw compression screw and swing strap to
one side. Remove gage.
PC6011-5-D-RP
Figure 17 - Preparing for Double Lap Flare
F. Swing strap back in closed position, then tight-
en compression screw to flare cone downward
to complete double lap flare.
BRAKES 5·19
B
Figure 18 - Completing Double Lap Flare
G. Unscrew compression screw and open smaller
lever handle to remove brake pipe assembly.
H. Inspect flared ends for splits, cracks, pits or
excessive out-of-round which may cause leaks.
I. Blow out brake pipe assembly with dry com-
pressed air to remove any foreign objects.
5. Bend new brake pipe assembly to match old pipe
assembly using a tubing bender.
m Important
• Minimum clearance of 19 mm (3/4 inch) must
be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating com-
ponents, unless brake pipe assembly is clipped
to the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe assembly and contact
surface.
ISO Flare
Figures 19 through 21
ISO flares are NOT to be used for rear brake rear
pipes.
Tool Required:
J 29803-A ISO Flaring Kit
1. Obtain recommended tubing and steel fitting nuts of
correct size.
• Outside diameter of tubing is used to specify
size.
2. Cut tubing to length.
• Correct length may be determined by measur-
ing old brake pipe assembly using string and
adding 3 mm ( 1/8 inch) for each ISO flare.
3. Cut end square and chamfer inside and outside
diameter of tubing with de-burring tool.
• Remove all traces of lubricant from tubing.
4. ISO flare tubing ends using J 29803-A.
A. Make sure fittings are installed on tubing
before starting flare.
B. Clamp flaring tool body in vise.
C. Select correct size collet and forming mandrel
for tube size used.
5-20 BRAKES
A FORMING MANDREL
B FLARING TOOL BODY
C FORCING SCREW
PC6013·5·D·RP
Figure 19 - Forming Mandrel and Forcing Screw
D. Insert proper forming mandrel into tool body.
While holding mandrel in place with your fin-
ger, thread in forcing screw until it makes con-
tact and begins to move forming mandrel.
When contact is made, turn forcing screw back
one complete turn.
E. Slide clamping nut over tubing into correct
collet. Leave approximately 19 mm (3/4 inch)
of tubing extending out coll et. Insert assembly
into tool body. Tube end must contact face of
forming mandrel.
F. Tighten clamping nut into tool body very tight
or tube may push out.
G. Wrench tighten forcing screw in until it bot-
toms. Do not tighten forcing screw further or
flare may become over-sized.
H. Back clamping nut out of tool body and disas-
semble clamping nut and collet assembly.
Flare is now ready for use.
A CLAMPING NUT
B COLLET
PC6014·5·D-RP
Figure 20 - Clamping Nut and Collet
A ISO FLARE
PC6015-5-B-RP
Figure 21 - iso Flare
5. Bend new brake pipe assembly to match old pipe
using a tube bender.
• Minimum clearance of 19 mm (3/4 inch) must
be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating com-
ponents, unless brake pipe assembly is clipped
to the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe assembly and contact
surface.
COMBINATION VALVE ASSEMBLY
Figure22
l++I Remove or Disconnect
1. Brake motor assembly from brake pressure modula-
tor assembly. Refer to SECTION 5El.
2. Bolts/screws (59) and seals (60).
• Discard seals (60).
3. Combination valve assembly (62).
4. Seals (61).
• Discard seals (61).
5. Transfer tubes (64 and 65) and seals (63 and 66)
from combination valve assembly (62).
lt:.'I Clean
• All parts in clean, denatured alcohol.
- Dry with unlubricated, compressed air.
ll"'I Inspect
• All parts for wear. Repair or replace as needed.
!++! Install or Connect
NOTICE: See "Notice" on page 5-1 of this section.
1. Transfer tubes (64 and 65) and seals (63 and 66) to
combination valve assembly (62).
• Lubricate seals (63 and 66) with clean brake
fluid.
 BRAKES 5·21

62

33 VALVE ASSEMBLY, BRAKE PRESSURE MODULATOR

59 BOLT/SCREW, BRAKE COMBINATION VALVE,
16 N•m (12 LB. FT.)
60 SEAL, BRAKE COMBINATION VALVE
61 SEAL, BRAKE COMBINATION VALVE
62 VALVE ASSEMBLY, BRAKE COMBINATION
63 SEAL, TRANSFER TUBE
64 TUBE, TRANSFER
65 TUBE, TRANSFER
66 SEAL, TRANSFER TUBE
PC0010-5·F·RP

Figure 22 - Combination Valve Assembly

2. Newseals(61).
• Lubricate seals (61) with clean brake fluid. l~I Clean
3. Combination valve assembly (62). • Dirt and foreign material from front brake hose
4. New seals (60) and bolts/screws (59). assembly (71) and front brake hose fitting (72).
2. Pipe assembly (34) from hose assembly (71).
• Lubricate seals (60) with clean brake fluid.
• Use a backup wrench on hose assembly fitting.
!~I Tighten • Be careful not to bend bracket (75) or pipe
assembly (34).
• Bolts/screws (59) to 16 N•m (12 lb. ft.).
3. Retainer (76) from hose assembly fitting at bracket
5. Brake motor assembly to brake pressure modulator (75).
valve assembly. Refer to SECTION 5El.
4. Hose assembly (71) from bracket (75).
BRAKE HOSE ASSEMBLY 5. Fitting (72), hose assembly (71), and two gaskets
(73) from caliper assembly (70).
Front Brake Hose Assembly • Discard two gaskets (73).

Figure23 !•+I Install or Connect

NOTICE: See "Notice" on page 5-1 of this section.
!+-+I Remove or Disconnect 1. Fitting (72), hose assembly (71), and two new gas-
1. Tire and wheel assembly. Refer to SECTION 3E. kets (73) to caliper assembly (70).
5·22 BRAKES

71

75

76~

341

71

34 PIPE ASSEMBLY, LEFT-HAND FRONT BRAKE

70 CALIPER ASSEMBLY, FRONT BRAKE
71 HOSE ASSEMBLY, FRONT BRAKE
72 FITTING, FRONT BRAKE HOSE, 44 N•m (32 LB. FT.)
73 GASKET, FRONT BRAKE HOSE FITTING
74 BOLT/SCREW, FRONT BRAKE HOSE CLIP
75 BRACKET, FRONT BRAKE HOSE
76 RETAINER, FRONT BRAKE HOSE
PC0011-5-f·RP

Figure 23 - Front Brake Hose Assembly (Left Side Shown, Right Side Similar)

• Lubricate hose assembly fitting threads with

brake fluid. l~I Tighten
• Hose assembly fitting flange must engage cali- • Pipe assembly (34) to hose assembly (71) to
per assembly orientation ledge. 15 N•m (11 lb. ft.).
5. Bleed brake hydraulic system. Refer to SECTION
l~I Tighten 5El.
6. Tire and wheel assembly. Refer to SECTION 3E.
• Fitting (72) to 44 N•m (32 lb. ft.).
2. Hose assembly (71) into bracket (75). Rear Brake (Center) Hose Assembly
• There should be no kinks in hose assembly Without Traction Control System
(71 ).
Figures 7, B and 9
3. Retainer (76) at bracket (75).
4. Pipe assembly (34) to hose assembly (71).
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to
• Use backup wrench on hose assembly fitting. SECTION OA.
• Make sure that hose assembly (71) does not
make contact with any part of suspension.
!t:JI Clean
Check in extreme right and extreme left turn • Dirt and foreign material from hose assembly
conditions. and pipe assembly fittings.
 BRAKES 5-23

2. Pipe assembly (36) from hose assembly (53).

• Use backup wrench on hose assembly fitting.
• Be careful not to bend bracket (57) or pipe
assembly (36).
3. Retainer (56) from bracket (57) and hose assembly
(53).
4. Hose assembly (53).
5. Left rear pipe assembly (55 or 68) and right rear pipe
assembly (54 or 67) from hose assembly (53).
• Be careful not to bend left rear pipe assembly
(55 or 68) and right rear pipe assembly (54 or
67).
6. Bolt/screw (51) and hose assembly (53) from rear
axle assembly.
• Note position of hose assembly (53) for proper
location during installation.
1.,1 Clean
• Dirt and foreign material from hose assembly
and pipe assembly fittings.
2. Pipe assembly (102) from hose assembly (115).
3. Pipe assembly (103) from hose assembly (114).
• Use backup wrench on hose assembly fittings.
• Be careful not to bend bracket assembly (113)
or pipe assemblies (102 and 103).
4. Clip (105) from bracket assembly (113) and hose as-
sembly (114).
5. Clip ( 106) from bracket assembly ( 113) and hose as-
sembly (115).
6. Pipe assembly (109) from hose assembly (115).
7. Pipe assembly (110) from hose assembly (114).
• Use backup wrench on hose assembly fittings.

!++I Install or Connect • Be careful not to bend bracket (107) or pipe

assemblies (109 and 110).
NOTICE: See "Notice" on page 5-1 of this section. 8. Clip (105) from bracket assembly (107) and hose
1. Hose assembly (53) and bolt/screw (51) to rear axle assembly (114).
assembly. 9. Clip (106) from bracket assembly (107) and hose
assembly (115).
l~I Tighten 10.
I 1.
Hose assembly (114).
Hose assembly (ll5).
• Bolt/screw (51) to 21 N•m (15 lb. ft.).
2. Left rear pipe assembly (55 or 68) and right rear pipe
assembly (54 or 67) to hose assembly (53). !++I Install or Connect
NOTICE: See "Notice" on page 5-1 of this section.
l~I Tighten 1. Hose assembly (115).
• Left rear pipe assembly (55 or 68) and right 2. Hose assembly (114).
rear pipe assembly (54 or 67) at hose assembly 3. Clip (106) to bracket assembly (107) and hose as-
(53) to 24 N•m (18 lb. ft.). sembly (115).
3. Hose assembly (53) into bracket (57). 4. Clip (105) to bracket assembly (107) and hose as-
• Be sure hose assembly (53) is seated properly sembly (114).
and not twisted. • Be sure hose assemblies (114 and 115) are
4. Retainer (56) to bracket (57) and hose assembly seated properly and not twisted.
(53). 5. Pipe assembly (110) to hose assembly (114).
5. Pipe assembly (36) to hose assembly (53). 6. Pipe assembly (109) to hose assembly (115).
• Use backup wrench on hose assembly (53). • Use backup wrench on hose assembly fittings.
• Be careful not to bend bracket (57) or pipe • Be careful not to bend bracket or pipe assem-
assembly (36). blies (109 and 110).

l~I Tighten l~I Tighfen

• Pipe assembly (36) to hose assembly (53) to • Pipe assembly (110) to hose assembly (114) to
15 N•m (11 lb. ft.). 15 N•m (11 lb. ft.).
• Pipe assembly (109) to hose assembly (115) to
6. Bleed brake hydraulic system. Refer to SECTION
15 N•m (11 lb. ft.).
5El.
7. Clip (106) to bracket assembly ( 113) and hose as-
7. Lower vehicle. sembly (115).
With Traction Control System 8. Clip (105) to bracket assembly (113) and hose as-
sembly (114).
Figures 12, 13 and 14 • Be sure hose assemblies ( 114 and 115) are
seated properly and not twisted.
!+,.I Remove or Disconnect 9. Pipe assembly (103) to hose assembly (114).
1. Raise and suitably support vehicle. Refer to SEC- 10. Pipe assembly (102) to hose assembly (115).
TION OA. • Use backup wrench on hose assembly fittings.
5-24 BRAKES
• Be careful not to bend bracket or pipe assem-
blies (102 and 103).
1~1 Tighten
• Pipe assembly (103) to hose assembly (114) to
15 N•m (11 lb. ft.).
• Pipe assembly (102) to hose assembly (115) to
15 N•m (11 lb. ft.).
11. Bleed brake hydraulic system. Refer to SECTION
5El.
12. Lower vehicle.
Rear Brake Hose Assembly
Figure 24
l~-+I Remove or Disconnect
1. Wheel and tire assembly. Refer to SECTION 3E.
IS,! Clean
• Dirt and foreign material from hose assembly
(81) and pipe assembly fitting.
2. Hose assembly (81) from pipe assembly (55).
• Use backup wrench on hose assembly fitting.
• Be careful not to bend bracket (85) and pipe
assembly (55).
3. Retainer (84) from bracket (85) and hose assembly
(81).
4. Fitting (83), two gaskets (82) and hose assembly
(81) from caliper assembly (80).
• Discard two gaskets (82).
!++I Install or Connect
NOTICE: See "Notice" on page 5-1 of this section.
I. Fitting (83), two new gaskets (82) and hose assem-
bly (81) to caliper assembly (80).
• Lubricate hose assembly fitting threads with
clean brake fluid.
• Hose assembly fitting flange must engage
caliper assembly orientation ledge.
l~I Tighten
• Fitting (83) to 44 N•m (32 lb. ft.).
2. Retainer (84) to bracket (85) and hose assembly
(81 ).
3. Hose assembly (81) to pipe assembly (55).
• Use backup wrench on hose assembly fitting.
• Be careful not to bend bracket (85) and pipe
assembly (55).
l~I Tighten
• Pipe assembly (55) to hose assembly (81)
to 15 N•m (11 lb. ft.).
4. Bleed hydraulic brake system. Refer to SECTION
5EI.
55
80
81
PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
CALIPER ASSEMBLY, REAR BRAKE
HOSE ASSEMBLY, LEFT-HAND REAR BRAKE
82 GASKET, REAR BRAKE HOSE FITIING
83 FITIING, REAR BRAKE HOSE, 44 N•m (32 LB. FT.)
84 RETAINER, REAR BRAKE HOSE
85 BRACKET, REAR BRAKE HOSE
90 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
PC0012-5-F-RP
Figure 24 - Rear Disc Brake Hose Assembly (Typical)
(Left Side Shown, Right Side Similar)
5. Wheel and tire assembly. Refer to SECTION 3E.
FLUSHING BRAKE HYDRAULIC SYSTEM
NOTICE: Use only DOT 3 brake fluid from a clean,
sealed container. Do not use any fluid from a con-
tainer which is wet with water. Do not use DOT 5
silicone brake fluid. Improper brake fluid, mineral
oil or water in the fluid may cause the brake fluid to
boil or the rubber components to deteriorate. Keep
all fluid containers capped to prevent contamination.
The system must be flushed if there is any doubt
about the condition of fluid in the system or if fluid has
been used which contains the slightest trace of petroleum
or mineral oil based fluids. Approximately 1.5 liters
(1.5 quarts) of brake fluid is required to flush the brake
hydraulic system. All rubber parts, including brake hose
assemblies, master cylinder assembly rubber parts, and
brake caliper assembly and wheel cylinder assembly
boots and seals that have been subjected to a contaminated
fluid must be replaced. Also replace the combination
valve assembly and brake pressure modulator assembly,
since they have rubber components inside that are not
serviceable. Refer to SECTION 5El for complete brake
hydraulic system flush and bleed procedures.
 BRAKES 5·25

SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal Assembly Travel .................................... 51 to 89 mm (2.0 to 3.5")
Brake pedal assembly travel maximum with 445 N (100 lb.) force applied to pedal with engine
running at idle.
Hydraulic Brake (Glycol) Fluid ................... GM P/N 1052535 or equivalent DOT-3 fluid
Brake Pipe Assembly Clearance (Minimum)
Moving Components ................................................... 19 mm (3/4")
Vibrating Components ................................................. 13 mm (1/2 ")
Armor-Wrapped Pipe Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact is permitted if
there is no relative movement
between pipe assembly
and contact.surface
FASTENER TIGHTENING SPECIFICATIONS
Brake Combination Valve Bolt/Screw ................................... 16 N•m (12 lb. ft.)
Brake Pedal Bracket Bolt/Screw ........................................ 25 N•m (18 lb. ft.)
Brake Pedal Bracket Nut .............................................. 25 N•m (18 lb. ft.)
Brake Pedal Nut .................................................... 25 N•m (18 lb. ft.)
Brake Pedal Pivot Nut ................................................ 54 N•m (40 lb. ft.)
Brake Pipe Clip Bolt/Screw ............................................ 6 N•m (53 lb. in.)
Clutch Master Cylinder Nut ........................................... 27 N•m (20 lb. ft.)
Front Brake Combination Valve Pipe Assembly-to-
Brake Combination Valve Assembly .................................. 18 N•m (13 lb. ft.)
Front Brake Combination Valve Pipe Assembly-to-
Brake Master Cylinder Assembly ..................................... 32 N•m (24 lb. ft.)
Front Brake Hose Fitting ............................................. 44 N•m (32 lb. ft.)
Front Brake Pipe Assembly-to-Brake Pressure Modulator Valve Assembly ...... 32 N•m (24 lb. ft.)
Front Brake Pipe Assembly-to-Front Brake Hose Assembly .................. 15 N•m (11 lb. ft.)
Front Brake Front Pipe Clip Bolt/Screw ................................... 6 N•m (53 lb. in.)
Rear Brake (Center) Hose Fitting Bolt/Screw ............................. 21 N•m (15 lb. ft.)
Rear Brake Combination Valve Pipe Assembly-to-
Brake Combination Valve Assembly .................................. 18 N•m (13 lb. ft.)
Rear Brake Combination Valve Pipe Assembly-to-
Brake Master Cylinder Assembly ..................................... 32 N•m (24 lb. ft.)
Rear Brake Front Pipe Assembly-to-
Brake Pressure Modulator Valve Assembly ............................. 32 N•m (24 lb. ft.)
Rear Brake Front Pipe Assembly-to-Rear Brake (Center) Hose Assembly ....... 15 N•m (11 lb. ft.)
Rear Brake Hose Fitting .............................................. 44 N•m (32 lb. ft.)
Rear Brake Hose Retainer Bolt/Screw ................................... 10 N•m (89 lb. in.)
Rear Brake Pipe Assembly-to-Rear Brake (Center) Hose Assembly ............ 24 N•m (18 lb. ft.)
Rear Brake Pipe Assembly-to-Rear Brake Hose Assembly ................... 15 N•m (11 lb. ft.)
Rear Brake Pipe Assembly-to-Rear Wheel Cylinder ........................ 17 N•m (13 lb. ft.)
Rear Brake Pipe Assembly-to-Traction Control Brake Pressure
Modulator Valve Pipe Assembly ..................................... 32 N•m (24 lb. ft.)
Traction Control Brake Pressure Modulator Valve Pipe Assembly ............. 32 N•m (24 lb. ft.)
5·26 BRAKES

SPECIAL TOOLS

2.
~ ,.§e
1.
II (! (J \o o o o o::l

J 28662 J 29803-A J 23530

1. BRAKE PEDAL EFFORT GAGE

2. ISO FLARING KIT
3. BRAKE LINE FLARING TOOL (45° SINGLE AND DOUBLE)
PC0013-5-F-RP
 MASTER CYLINDER 5A·1

SECTION SA

MASTER CYLINDER
CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact - rinse thoroughly with water.
• Skin contact- wash with soap and water.

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connec-
tors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.

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

CONTENTS
General Description ........................ SA-1 Master Cylinder Assembly . . . . . . . . . . . . . . . . SA-3
Master Cylinder Assembly ................ SA-1 Bleeding Brake
Master Cylinder Reservoir ................. SA-1 Hydraulic System . . . . . . . . . Refer to Section 5El
Brake Fluid and Fluid Handling ............ SA-1 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Substandard or Contaminated Brake Fluid .. SA-2 Master Cylinder Assembly . . . . . . . . . . . . . . . . 5A-4
Diagnosis ................................ SA-2 Master Cylinder Assembly Bench Bleeding ... 5A-4
Master Cylinder Assembly Check ........... SA-2 Master Cylinder Reservoir . . . . . . . . . . . . . . . . . 5A-5
Master Cylinder Assembly ................ SA-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6
On-Vehicle Service ........................ SA-2 General Specifications . . . . . . . . . . . . . . . . . . . . 5A-6
Filling Master Cylinder Reservoir ........... SA-2 Fastener Tightening Specifications . . . . . . . . . . 5A-6

GENERAL DESCRIPTION • Eye contact - rinse thoroughly

with water.
MASTER CYLINDER ASSEMBLY • Skin contact - wash with soap and
The brake master cylinder assembly is a composite water.
design (plastic reservoir and aluminum body) incorporat-
ing a conventional front-to-rear brake system split. The
brake master cylinder primary piston provides the fluid
pressure to the front disc brakes, while the brake master
cylinder secondary piston provides the fluid pressure to A
the rear drum or disc brakes. If pressure is lost from either
system, the remaining system will function to stop the
vehicle.
5
MASTER CYLINDER RESERVOIR
Figure 1
The reservoir (5) has a fluid level indicator mark
located inside the neck of the reservoir fill opening. The
reservoir cap must be removed to view the indicator mark.

BRAKE FLUID AND FLUID HANDLING A MAXIMUM FILL LEVEL

5 RESERVOIR, BRAKE MASTER CYLINDER
CAUTION: Brake fluid may irritate eyes PC0001-&A·F-RP
and skin. In case of contact, take the
following actions: Figure 1 - Brake Fluid Level Indicator
5A·2 MASTER CYLINDER
NOTICE: Avoid spilling brake fluid on any of the
vehicle's painted surfaces, wiring cables or elec-
trical connections. Brake fluid will damage paint
and electrical connections. If any fluid is spilled on
the vehicle, flush with water to lessen damage.
II] Important
• Do not re-use brake fluid accumulated during brake
hydraulic system bleeding.
• Always store fluid in a closed container. Reseal
containers immediately after use. Do not use fluid
left in an open or improperly sealed container as it
absorbs moisture or may be contaminated.
Substandard or Contaminated Brake Fluid
Use only brake fluid GM PIN 1052535 or an equiva- .
lent DOT-3 fluid. DO NOT use power steering fluid,
automatic transmission fluid or DOT-5 silicone hydraulic
brake fluid.
This deterioration may be seen by a swollen brake
master cylinder reservoir diaphragm or swollen brake
master cylinder primary or secondary seals. Deterioration
of the rubber components may result in costly damage to
the brake pressure modulator valve assembly, disc brake
caliper assemblies and rear wheel cylinders.
If rubber deterioration is evident, the entire brake
system must be flushed and all rubber components
replaced. Refer to SECTION 5.
MASTER CYLINDER ASSEMBLY
CONDITION POSSIBLE CAUSE
Grabby Brakes 1. Insufficient brake fluid in master
(Apparent On-Off Condition) cylinder assembly.
2. Faulty master cylinder primary or
secondary piston seals.
3. Cracked master cylinder body.
These checks will not determine all master cylinder assembly malfunctions. Refer to SECTION 5.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated shop air on brake
parts as damage to rubber components may result.
m Important
• Replace all components included in repair kits used
to service this brake master cylinder assembly.
• Lubricate rubber parts with clean brake fluid to ease
assembly.
• If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake hydraulic system.
DIAGNOSIS
MASTER CYLINDER ASSEMBLY CHECK
l. Check for cracked brake master cylinder body or
brake fluid around brake master cylinder assembly.
• Leaks are indicated only if there is at least a
drop of fluid.
• A damp condition is not abnormal.
2. Check for binding brake pedal assembly linkage and
incorrect power brake booster power piston pushrod
assembly length.
A. If both of these are satisfactory, disassemble
brake master cylinder assembly and check for
swollen or elongated primary or secondary
piston seal(s).
B. If swollen primary or secondary seals are
found, substandard or contaminated brake
fluid should be suspected.
C. If contaminated, all components should be dis-
assembled and cleaned. All rubber compo-
nents, including those in the combination valve
assembly, brake pressure modulator valve
assembly, disc brake calipers and rear wheel
cylinders, should be replaced and all brake
pipe assemblies flushed.
CORRECTION
1. Fill master cylinder reservoirs with
approved brake fluid and check for
leaks.
2. Repair or replace as necessary.
3. Replace.
• The torque values specified are for dry, unlubricated
fasteners.
• Perform service operations on a clean bench, free
from all mineral oil materials.
FILLING MASTER CYLINDER RESERVOIR
The brake master cylinder reservoir must be kept
properly filled to insure adequate reserve and to prevent
air from entering the brake hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and from the engine, the reservoir must not be
overfilled.

A drop in brake fluid level is normal as the pads and
linings wear. Filling the master cylinder reservoir before
installing new pads and linings may result in brake fluid
spillage once the new pads and linings are in place. Unless
there is a leak in the brake hydraulic system, or if the
brake hydraulic system has been serviced, topping off the
master cylinder reservoir should not be necessary.
Thoroughly clean the master cylinder reservoir cap
before removal to avoid getting dirt in reservoir. Remove
reservoir cap and reservoir diaphragm.
NOTICE: Use only DOT-3 brake fluid from a clean,
sealed container. Do not use any fluid from a con-
tainer which is contaminated with water. Do not use
DOT-5 silicone brake fluid. Improper brake fluid,
mineral oil or water in the brake fluid may cause it to
boil or the rubber components to deteriorate. Keep
all containers capped to prevent contamination.
Add brake fluid GM P/N 1052535 or equivalent as
required to bring fluid level to line located inside the neck
of the reservoir fill opening.
MASTER CYLINDER ASSEMBLY
Figure2
1++! Remove or Disconnect
1. Brake fluid from reservoir (5).
• Discard old fluid.
12
18
1 PIPE ASSEMBLY, FRONT BRAKE COMBINATION VALVE,
32 N•m (24 LB. FT.)
2 PIPE ASSEMBLY, REAR BRAKE COMBINATION VALVE,
32 N•m (24 LB. FT.)
3 BOOSTER ASSEMBLY, POWER BRAKE
Figure 2 - Brake Master Cylinder Assembly
MASTER CYLINDER 5A·3
2. Brake pipe assemblies (1 and 2).
• Plug brake pipe assemblies ( 1 and 2) to prevent
fluid loss and contamination.
3. Nuts (18).
4. Master cylinder assembly (15).
!++! Install or Connect
NOTICE: See "Notice" on page 5A-1 of this
section.
1. Bench bleed master cylinder assembly. Refer to
"Master Cylinder Assembly Bench Bleeding" in
this section. ,
2. Master cylinder assembly (15).
3. Nuts (18).
l~.J Tighten
• Nuts (18) to 32 N•m (24 lb. ft.).
4. Fill master cylinder reservoir. Refer to "Filling
Master Cylinder Reservoir" in this section.
5. Brake pipe assemblies ( 1 and 2) to master cylinder
assembly (15) one at a time.
A. Remove locally fabricated plug.
B. Install brake pipe assembly fitting finger tight.
5 RESERVOIR, BRAKE MASTER CYLINDER
8 BODY, BRAKE MASTER CYLINDER
12 CAP, BRAKE MASTER, CYLINDER RESERVOIR
15 CYLINDER ASSEMBLY, BRAKE MASTER
18 NUT, BRAKE MASTER CYLINDER, 32 N•m (24 LB. FT.)
RC0001-5A-F-RP
SA-4 MASTER CYLINDER
6. Have assistant depress brake pedal assembly to
remove air at loose brake pipe assembly fittings.
l~I Tighten
• Fittings of brake pipe assemblies ( 1 and 2) to
32 N•m (24 lb. ft.).
7. Have assistant quickly release and pump brake pedal
assembly several times.
8. If brake pedal assembly remains high and firm, start
vehicle. If brake pedal assembly still feels firm, test
drive vehicle. If brake pedal assembly feels soft or
spongy, bleed entire brake hydraulic system. Refer
to SECTION 5E 1.
UNIT REPAIR
MASTER CYLINDER ASSEMBLY
Figure 3
rn Important
• Reservoir cap (12) and reservoir diaphragm ( 13) can
be inspected and/or serviced without removing the
master cylinder assembly from the vehicle.
j++I Remove or Disconnect
• Brake master cylinder assembly. Refer to "Master
Cylinder Assembly" under "On-Vehicle Service"
in this section.
@+I Disassemble
I. Cap (12) and diaphragm (13) from reservoir (5).
• Wipe cap (12) and reservoir (5) clean before
removing.
2. Empty brake fluid from reservoir (5).
NOTICE: Take care not to damage the piston bore
or retainer groove during primary piston retainer
ring removal.
3. Ring (14) while depressing primary piston (20).
4. Primary piston (20), secondary piston (21), retainer
(6) and spring (4).
• To remove parts, apply clean, low pressure dry
compressed air into outlet port near closed end
of bore with other outlet port plugged.
5. Seals (7 and 10) and retainer (6) from secondary
piston (21 ).
IL•l 1nspect
• Cap (12) and diaphragm (13) for cuts, cracks, nicks
and deformation.
• Brake master cylinder body bore for scoring or
corrosion. If noted, replace cylinder body (8).
• Replace damaged parts.
l~I Clean
• All parts in clean denatured alcohol.
• Dry with unlubricated compressed air.
• Abrasives should not be used in brake master cylin-
der body bore.
l•!•I Assemble
1. Lubricate rubber parts with clean brake fluid to ease
assembly.
2. Seals (7 and 10) and retainer (6) to secondary piston
(21).
3. Lubricated secondary piston (21) and spring (4) into
brake master cylinder body bore.
4. Lubricated primary piston (20) into brake master
cylinder body bore.
5. Ring (14) while depressing primary piston (20).
6. Diaphragm (13) into cap (12).
7. Cap (12) onto reservoir (5).
8. Bench bleed master cylinder assembly. Refer to
"Master Cylinder Assembly Bleeding" in the
following procedure.
MASTER CYLINDER ASSEMBLY BENCH
BLEEDING
Materials necessary for master cylinder assembly
bench bleeding:
• One 11 x 1.5 mm tube fitting nut
• One 12 x 1.0 mm tube fitting nut
• Two pieces of 4.75 mm (3/16 inch) brake pipe
tube approximately 50 mm (2 inches) long
1. Locally fabricate two plugs for plugging master
cylinder assembly outlet ports.
A. Fashion ISO flares on one end of each tube.
Refer to SECTION 5.
B. Install nuts onto flared tubes.
C. One at a time, place approximately 13 mm
( 1/2 inch) of unflared tube in vise.
D. Compress tube end with vise so that tube
collapses completely.
E. With tube still in vise, bend it to a 90 degree
angle.
F. Remove tube from vise and reinstall to fold
tube end against itself to form air-tight seal.
2. Plug master cylinder assembly outlet ports with
locally fabricated plugs.
NOTICE: Do not overtighten vise or damage to the
master cylinder assembly will result.
3. Place shop towels around master cylinder assembly
to absorb bled fluid and mount master cylinder
assembly in vise with front end tilted slightly down.
 MASTER CYLINDER SA-5

23

20
14
4 SPRING, BRAKE MASTER CYLINDER SECONDARY
PISTON
5 RESERVOIR, BRAKE MASTER CYLINDER
6 RETAINER, BRAKE MASTER CYLINDER SECONDARY
PISTON SPRING
7 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
PRIMARY
8 BODY, BRAKE MASTER CYLINDER
10 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
SECONDARY
12 CAP, BRAKE MASTER CYLINDER RESERVOIR
13 DIAPHRAGM, BRAKE MASTER CYLINDER RESERVOIR
14 RING, BRAKE MASTER CYLINDER PRIMARY PISTON
RETAINER
20 PISTON, BRAKE MASTER CYLINDER PRIMARY
21 PISTON, BRAKE MASTER CYLINDER SECONDARY
22 0-RING
23 PIN, SPRING
PC0003-5A-F-RP

Figure 3 - Brake Master Cylinder Assembly Components

4. Frll master cylinder assembly with clean brake fluid.

5. Using tool with smooth rounded end, stroke primary
piston about 25 mm (1 inch) several times.
[I] Important
• As air is bled from master cylinder assembly,
with outlets plugged, resistance to primary
piston travel will not allow full 25 mm (I inch)
stroke.
[II Important
• To prevent air from being sucked back into
master cylinder assembly, tighten locally fabri-
cated plugs before allowing primary piston to
return to its original position. Repeat this step
until no air escapes past locally fabricated
plugs.
8. Install master cylinder assembly into vehicle. Refer
to "Master Cylinder Assembly" under "On-Vehicle
Service" in this section.

6. Reposition master cylinder assembly in vise with MASTER CYLINDER RESERVOIR

front end of master cylinder assembly tilted slightly
up. Again, stroke primary piston about 25 mm Figures 2 and 3
( 1 inch) several times.

7. Reposition master cylinder assembly in vise to level

!++! Remove or Disconnect
position. Loosen two locally fabricated plugs one at 1. Brake master cylinder assembly. Refer to "Master
a time and push primary piston into master cylinder Cylinder Assembly" under "On-Vehicle Service"
bore to force air out of master cylinder assembly. in this section.
5A·6 MASTER CYLINDER

NOTICE: Do not clamp housing area of master
cylinder body in vise or the part may be damaged.
2. Clamp flange of cylinder body (8) in a vise.
3. Drive out spring pins (23) using 1/8-inch punch.
4. Reservoir (5) by pulling straight up and away from
cylinder body (8).
5. 0-rings (22) from grooves in reservoir (5) and
discard.
2. Dry with unlubricated compressed air.
!+.,I Install or Connect
1. Lubricate new 0-rings (22) and grooves in reservoir
(5) with clean brake fluid.
2. 0-rings (22) into grooves in reservoir (5).
• Make sure 0-rings (22) are properly seated.

!L"'I Inspect 3. Reservoir (5) to cylinder body (8) by pressing

• Reservoir (5) for cracks or deformation.
• Replace reservoir (5), if damaged.
lt:WI Clean
1. Reservoir (5) with clean denatured alcohol.
straight down by hand into cylinder body (8).
4. Drive in spring pins (23) to retain reservoir (5).
5. Brake master cylinder assembly. Refer to "Master
Cylinder Assembly" under "On-Vehicle Service"
in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS
Brake Master Cylinder Body Bore Diameter ............................... 25.4 mm (1.00")
Hydraulic Brake (Glycol) Fluid . . . . . . . . . . . . . . . . . . . GM P/N 1052535 or equivalent DOT-3 fluid

FASTENER TIGHTENING SPECIFICATIONS

Brake Master Cylinder Nut ............................................ 32 N•m (24 lb. ft.)
Brake Pipe Fittings
Front Brake Combination Valve Pipe Assembly ......................... 32 N•m (24 lb. ft.)
Rear Brake Combination Valve Pipe Assembly .......................... 32 N•m (24 lb. ft.)
 FRONT DISC BRAKES 581·1

SECTION 581

FRONT DISC BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake lin-
ings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts con-
tain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water damp-
ened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.

CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact - rinse thoroughly with water.
• Skin contact - wash with soap and water.

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connec-
tors. Brake fluid will damage pai'nt and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.

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

CONTENTS
General Description ....................... SBl-1 Front Brake Rotor Assembly .............. SBl-7
Front Brake Rotor Assembly .............. SBI-I Unit Repair .............................. SBI-7
.Front .Brake Caliper Assembly ............ SBI-1 Refinishing Front Brake Rotor
D1agnos1s ..................... , ......... SBl-2 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-7
Front Disc Brake Inner and Outer On-Vehicle Procedure ................. SBl-7
Pad Assemblies Inspection . . . . . . . . . . . . . SB 1-2 Off-Vehicle Procedure . . . . . . . . . . . . . . . . . SB I-7
Front Brake Rotor Assembly Inspection . . . . . SB 1-2 Non-Directional Finishing .............. SBl-8
Front Brake Rotor Assembly Burnishing Front Brake Rotor
Tolerance and Surface Finish . . . . . . . . . . SB 1-2 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . SB 1-8
Thickness Variation Check ............. SBl-2 Front Brake Caliper Assembly ............ SBl-8
Lateral Runout Check . . . . . . . . . . . . . . . . . SB 1-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-10
Front Brake Caliper Assembly Inspection . . . . SB 1-4 General Specifications .................. SBl-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . SB 1-4 Rotor Refinishing Specifications . . . . . . . . . . SB 1-10
Front Brake Caliper Assembly . . . . . . . . . . . . SB 1-4 Fastener Tightening Specifications . . . . . . . . SB 1-10
Front Disc Brake Inner and Outer Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-10
Pad Assemblies ...................... SBl-S

GENERAL DESCRIPTION When the brakes are applied, fluid pressure behind
the piston increases. Pressure is exerted equally against
FRONT BRAKE ROTOR ASSEMBLY the bottom of the piston and also against the bottom of the
caliper housing bore. The pressure applied to the piston is
The rotor assembly is a highly machined, cast iron transmitted to the inner pad assembly forcing the lining
finned type. It is mounted on top of an integral hub bear- against the inner rotor surface. The pressure applied to the
ing unit. bottom of the caliper housing bore forces the caliper to
slide on the caliper bolts/screws toward the center of the
FRONT BRAKE CALIPER ASSEMBLY vehicle. This movement causes the outer section of the
The caliper assembly has a single bore and is caliper to apply pressure against the back of the outer pad
mounted to the steering knuckle assembly with two bolts/ assembly, forcing the lining against the outer rotor assem-
screws. bly surface. As line pressure builds, the inner and outer
581-2 FRONT DISC BRAKES
A (0.030 inch) of the shoe. All inner and outer pad
A INSPECTION POINTS
A the braking surfaces for flatness, thickness variation and
PC0001-5B1-F-RP
Figure 1 - Front Disc Brake Inner and Outer
Pad Assemblies Inspection
pad assemblies are pressed against the rotor assembly sur-
faces with increased force, bringing the vehicle to a stop.
When the brake pedal assembly is released, line
pressure is released and the piston seal and groove cause
the piston to be slightly retracted, resulting in less drag on
the rotor assembly by the inner and outer pad assemblies.
Outward movement of the piston and inward move-
ment of the caliper assembly automatically compensate
for lining wear. As the linings wear, the increased area
behind the piston is filled with brake fluid from the brake
master cylinder reservoir.
DIAGNOSIS
FRONT DISC BRAKE INNER AND OUTER
PAD ASSEMBLIES INSPECTION
Figure 1
jl'l'l lnspect
• Inner and outer pad assemblies at least twice a year
when the wheels are removed (tire rotation, etc.).
When inspecting front disc brakes, check both ends
of the outer pad assembly by looking in at each end
of the caliper assembly. These are the points at
which the highest rate of wear normally occurs.
Also, check the lining thickness of the inner pad
assembly to make sure that it has not worn prema-
turely. Look through the hole in the top of the caliper
assembly to view the inner pad assembly. Inner and
outer pad assemblies should be replaced when the
thickness of any lining is worn to within 0.76 mm
assemblies should be replaced in axle sets.
All front disc brakes have a wear indicator that
makes a noise when the linings wear to a degree where
replacement is required. The wear indicator is an integral
part of the outer pad assembly. When the lining is worn,
the clip indicator contacts the rotor assembly and pro-
duces a warning noise.
!~I Measure
• Flatness of inner and outer pad assembly linings.
Place inner and oµter pad assembly surfaces
together and check for gap between surfaces. If
more than 0.13 mm (0.005 inch) gap is measured
midway between attaching lugs, inner and outer pad
assemblies must be replaced.
FRONT BRAKE ROTOR ASSEMBLY
INSPECTION
Front Brake Rotor Assembly Tolerance and
Surface Finish
In manufacturing the rotor assembly, tolerances of
lateral runout are very closely held. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
In addition to these tolerances, the surface finish
must be held to a specified range of 60 Ra roughness or
less. A new rotor assembly falls into this surface range, as
will a rotor assembly that is refinished exactly as directed
in "Refinishing Front Brake Rotor Assemblies" in this
section. The control of the braking surface finish is neces-
sary to avoid problems of hard pedal-apply, excessive
brake fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor assembly surfaces not
exceeding 1.5 mm (0.06 inch) in depth, which may result
from normal use, will not affect brake operation.
Thickness Variation Check
Thickness variation can be checked by measuring
the thickness of the front brake rotor assembly at four or
more points around its circumference. All measurements
must be made at the same distance in from the edge of the
rotor assembly. A rotor assembly that varies by more than
0.013 mm (0.0005 inch) can cause brake pedal assembly
pulsation and/or front end vibration during brake ap~l~ca-
tions. A rotor assembly that does not meet these spec1f1ca-
tions should be refinished to specifications or replaced.
Lateral Runout Check
Figure 2
Tool Required:
J 8001 Dial Indicator Set
1. Clean surface of rotor assembly (1 ).
2. Install wheel nuts (13).
 FRONT DISC BRAKES 581·3

5. Move rotor assembly (1) one complete revolution,

and observe total indicated runout (TIR).
• Total indicated runout (TIR) should not be
more than 0.15 mm (0.006 inch).
• In some cases, excessive lateral runout of rotor
assembly ( 1) can be improved by indexing
rotor assembly ( 1) on hub one or two bolt posi-
tions from original position. Indexing the rotor
assembly ( 1) requires removal and installation
of the front brake caliper assembly. Refer to
"Front Brake Caliper Assembly" under "On-
Vehicle Service" in this section. If lateral run-
out cannot be corrected by indexing rotor
assembly (I), check hub and front wheel bear-
ROTOR ASSEMBLY, FRONT BRAKE ing assembly for excessive lateral runout or
13 WHEEL NUT, 140 N•m (100 LB. FT.) looseness. If hub and bearing assembly lateral
18 KNUCKLE ASSEMBLY, STEERING runout exceeds 0.040 mm (0.0015 inch) then
PC0002·581-F·RP
replace hub and bearing assembly. If lateral
Figure 2 - Lateral Runout Check runout of the hub and bearing assembly is
within specifications then refinish or replace
rotor assembly (I) as necessary.
NOTICE: Whenever the rotor assembly has been
l~I Tighten
separated from the wheel bearing flange, clean any
rust or foreign material from the mating surface of
the wheel bearing flange and front brake rotor
• Wheel nuts (13) in a star pattern to 140 N•m
(100 lb. ft.). assembly. Failure to do this may result in increased
lateral runout of the rotor assembly and brake pulsa-
3. Fasten J 8001 to steering knuckle assembly (18) so tion.
that indicator button contacts rotor assembly surface
about 13 mm (0.5 inch) from rotor edge. • A rotor assembly that does not meet the lateral
runout specification should be resurfaced or
4. Set J 8001 to zero. replaced as necessary.

20

al
y11

2 -\
3

A WEAR SENSOR
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE
CALIPER, 51 N•m (38 LB. FT.)
3 BUSHING, FRONT BRAKE CALIPER BOLT 7
5 PAD ASSEMBLY, FRONT DISC BRAKE OUTER
7 PAD ASSEMBLY, FRONT DISC BRAKE INNER
8 BOOT, FRONT BRAKE CALIPER PISTON
9 PISTON, FRONT BRAKE CALIPER
10 SEAL, FRONT BRAKE CALIPER PISTON
11 VALVE, FRONT BRAKE CALIPER BLEEDER,
13 N•m (115 LB. IN.)
12 HOUSING, FRONT BRAKE CALIPER
20 CAP, FRONT BRAKE CALIPER BLEEDER VALVE
PC0003-5B1-1:.flP

Figure 3 - Front Brake Caliper Assembly

581·4 FRONT DISC BRAKES

16

18

2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER,

51 N•m (38 LB. FT.)
12 HOUSING, FRONT BRAKE CALIPER
14 FITIING, FRONT BRAKE HOSE, 44 N•m (32 LB. FT.)
16 HOSE ASSEMBLY, FRONT BRAKE
18 KNUCKLE ASSEMBLY, STEERING PC0005-5B1-F-RP
A C-CLAMP
1 ROTOR ASSEMBLY, FRONT BRAKE Figure 5 - Front Brake Caliper Assembly Attachment
12 HOUSING, FRONT BRAKE CALIPER

4. Reinstall wheel nuts to retain rotor assembly (1).

PC0004-5B1 -F-RP
5. Push piston (9) into caliper housing bore to provide
Figure 4 - Compressing Front Brake Caliper Piston
clearance between inner and outer pad assemblies
(7 and 5) and rotor assembly (1 ).
FRONT BRAKE CALIPER ASSEMBLY A. Position C-clamp on housing (12) and against
INSPECTION outer pad assembly (5).
The front brake caliper assembly must be disas- B. Tighten clamp slowly to press piston (9) into
sembled for inspection. Refer to "Front Brake Caliper caliper housing bore.
Assembly" under "Unit Repair" in this section.

ON-VEHICLE SERVICE
rn Important
• If removing caliper assembly only to access
NOTICE: Do not use lubricated shop air on brake other brake parts, skip step 6.
parts as damage to rubber components may result. • Iffitting (14) is disconnected, caliper assembly

rn Important
• Replace all components included in repair kits used
to service this front brake caliper assembly.
• Lubricate rubber parts with clean brake fluid to ease
assembly.
• If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.
• Replace shoe and linings in axle sets only.
• The torque values specified are for dry, unlubricated
fasteners.
• Perform service operations on a clean bench free
from all mineral oil materials.
FRONT BRAKE CALIPER ASSEMBLY
!L'l'! Inspect
Figures 3 through 7
!++! Remove or Disconnect
1. Two-thirds of brake fluid from master cylinder
assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Tire and wheel assembly. Refer to SECTION 3E.
must be bled during installation.
6. Fitting (14), two copper gaskets, hose assembly (16)
from housing (12), if removing caliper assembly
entirely from vehicle.
A. Plug openings in hose assembly (16) and hous-
ing (12) to prevent brake fluid loss and con-
tamination.
B. Discard copper gaskets.
7. Front brake caliper bolts/screws with sleeves (2).
8. Caliper assembly from rotor assembly (1) and
knuckle assembly ( 18).
• If caliper assembly is not being removed from
vehicle for unit repair, suspend it from front
suspension using a locally fabricated wire
hook.
1. Bolts/screws with sleeves (2) for corrosion and
bushings (3) for cuts and nicks.
• If damage is found, use new parts, when instal-
ling caliper assembly.
• Do not attempt to polish away corrosion.
2. Fitting (14).
• If through-hole in fitting (14) is blocked,
remove blockage or replace fitting (14).
 FRONT DISC BRAKES 581·5

12
A ADD SILICONE GREASE TO INNER DIAMETER OF
BUSHING
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER,
51 N•m (38 LB. FT.}
3 BUSHING, FRONT BRAKE CALIPER BOLT
12 HOUSING, FRONT BRAKE CALIPER
PC0007·5B1·F-RP
A WIRE HOOK
12 HOUSING, FRONT BRAKE CALIPER Figure 7 - Lubricating Front Brake Caliper Bolt
18 KNUCKLE ASSEMBLY, STEERING Sleeve and Bushing

PC000&-581 -F-RP

Figure 6 - Suspending Front Brake Caliper Assembly

l~I Tighten
• Fitting (14) to 44 N•m (32 lb. ft.).
5. Wheel nuts securing rotor assembly to steering
knuckle assembly flange.
6. Tire and wheel assembly. Refer to SECTION 3E.
!++I Install or Connect 7.
8.
Lower vehicle.
Fill master cylinder to proper level. Refer to SEC-
NOTICE: See "Notice".on page 5Bl-1 of this sec-
tion. TION SA.
9. If hose assembly (16) was removed, bleed caliper
1. Lubricate inner diameters of bushings (3) with sili- assembly. Refer to SECTION 5El.
cone grease GM PIN 1052863 or equivalent.
2. Bolts/screws with sleeves (2). FRONT DISC BRAKE INNER AND OUTER
PAD ASSEMBLIES
ll1'1 Inspect Figures 3, 6 and 8 through 12
A. Bolt/screw with sleeve (2) should slide through
bushing (3) using only hand pressure.
!+-+I Remove or Disconnect
• If greater force is required or mechanical
assistance is needed, remove bolt/screw 1. Front brake caliper assembly. Refer to "Front Brake
with sleeve (2) along with bushing (3). Caliper Assembly" under "On-Vehicle Service" in
this section.
B. Mounting bores for corrosion. 2. Outer pad assembly (5). Use screwdriver to disen-
a. If mounting bores show signs of corro- gage buttons on shoe from holes in caliper housing.
sion, remove corrosion using a I -inch 3. Inner pad assembly (7).
wheel cylinder housing brush.
b. Clean mounting bores with clean dena-
tured alcohol.
!~I Clean
• Wipe outside surface of boot (8).
C. Replace bushings. Refer to "Front Brake Cali- - Use denatured alcohol.
per Assembly" under "Unit Repair" in this
section. m Important

l~I Tighten
• Bolts/screws with sleeves (2) to 51 N •m (38 lb.
ft.).
3. Caliper assembly onto rotor assembly (1) and
knuckle assembly ( 18).
4. Fitting ( 14), two new copper gaskets, and hose
assembly (16) to housing (12), if removed.
1. Bottom piston (9) into caliper housing bore.
A. Use a large C-clamp positioned on housing
(12) and inside piston well.
B. Tighten clamp slowly to press piston (9) into
caliper housing bore.
2. With piston (9) bottomed in caliper housing bore, lift
inner edge of boot (8) next to piston (9) and press out
any trapped air.
581-6 FRONT DISC BRAKES
5 PAD ASSEMBLY, FRONT DISC BRAKE OUTER
12 HOUSING, FRONT BRAKE CALIPER
PC0008·5B1·F-RP
Figure 8 - Removing Outer Pad Assembly
5 PAD ASSEMBLY, FRONT DISC BRAKE OUTER
7 PAD ASSEMBLY, FRONT DISC BRAKE INNER
12 HOUSING, FRONT BRAKE CALIPER PCOOOll-SB,-F-RP
Figure 9 - Front Disc Brake Inner and Outer Pad Assemblies
8
8 BOOT, FRONT BRAKE CALIPER PISTON
9 PISTON, FRONT BRAKE CALIPER
12 HOUSING, FRONT BRAKE CALIPER
PC0010-5B1·f·RP
Figure 1O - Lifting Front Brake Caliper Piston Boot
• Boot (8) must lay flat.
l.. +I Install or Connect
m Important
• Do not use 1993 brake pad assemblies on 1994
vehicles. They are not interchangeable. This is
A RETAINER SPRING
7 PAD ASSEMBLY, FRONT DISC BRAKE INNER
8 BOOT, FRONT BRAKE CALIPER PISTON
12 HOUSING, FRONT BRAKE CALIPER
PC0011-581-F-RP
Figure 11 - Installing Front Disc Brake Inner Pad Assembly
due to a design change that was made to the
front disc brake calipers for 1994.
1. Inner pad assembly (7).
A. Inner pad retainer spring into piston (9). The
retainer spring is staked to the inner pad assem-
bly (7).
B. Inner pad assembly (7) must lay flat against
piston (9).
C. Check that boot (8) and inner pad assembly (7)
are not touching. If there is contact, remove
inner pad assembly (7) and reseat or re-posi-
tion boot (8).
2. Outer pad assembly (5).
• Back of outer pad assembly (5) must lay flat
against housing (12).
• Wear sensor should be at trailing lower edge of
outer pad assembly (5) during forward wheel
rotation. If not, outer pad assembly (5) is on
wrong side.
3. Front brake caliper assembly. Refer to "Front Brake
Caliper Assembly" under "On-Vehicle Service" in
this section.
4. Apply approximately 778 N (175 pounds) of force to
brake pedal assembly three times to seat linings.
m Important
• GM replacement brake lining material is recom-
mended for all GM vehicles to maintain the balance
between front and rear brake performance. GM
replacement brake parts have been carefully selected
to provide the proper brake balam.:e for purposes of
both stopping distance and controllability over the
full range of operating conditions. Installation of
front or rear brake lining material with performance
different from that of the GM replacement parts
recommended for this vehicle can change the
intended brake balance of this vehicle.
 FRONT DISC BRAKES 581·7

12
attachments eliminate tool chatter and will result in better
surface finish. Make sure these adapters are clean and free
of nicks.

A On-Vehicle Procedure
Tool Required:
On-Vehicle Brake Lathe, such as Kent-Moore
J 37704 On Disc Brake Lathe
In the cases where rotors are being refinished to cor-
rect a problem with brake pulsation, it is recommended
that an on-vehicle brake lathe be used to achieve best

A WEAR SENSOR
\ results. Follow the equipment manufacturer's recom-
mended specifications and procedure.
5 PAD ASSEMBLY, FRONT DISC BRAKE OUTER Off-Vehicle Procedure
12 HOUSING, FRONT BRAKE CALIPER

PC0012-581·F-RP II) Important

Figure 12 - Installing Front Disc Brake Outer Pad Assembly • Remove rust and scale from rotor assembly and
steering knuckle spindle assembly mating surfaces.
FRONT BRAKE ROTOR ASSEMBLY Failure to do so may introduce excessive lateral run-
out when the rotor assembly is mounted on the brake
The rotor assembly is an integral part of the hub lathe, or when the rotor assembly is reinstalled on
assembly. For removal procedure, refer to SECTION 3C. the steering knuckle spindle assembly.
Following are two recommended procedures that
UNIT REPAIR achieve adequate results using two different off-vehicle
drum/disc brake lathes. (If any other lathe is used, follow
that lathe's instructions and recommendations.)
REFINISHING FRONT BRAKE ROTOR
ASSEMBLIES Ammco Brake Lathe
rn Important
• DO NOT refinish rotor assemblies when perform-
(Two-cut refinishing procedure)
ROUGH CUT FINISH CUT

ing routine brake maintenance such as replacing Spindle Speed 150 rpm 150 rpm
worn front disc brake inner and outer pad assem- Depth of Cut 0.15 mm to 0.10 mm to
blies. Refinish a rotor assembly ONLY under the (per side) 0.64mm 0.15 mm
following circumstances: (0.006 inch to (0.004 inch to
0.025 inch) 0.006 inch)
- There is a complaint of brake pulsation. Tool Cross Feed 0.25 mm 0.05 mm
- There is scoring greater than 1.5 mm (0.06 (per rev.) (0.Ql O inch) (0.002 inch)
inch). Vibration Dampener Yes Yes
Sand Front Brake No Yes
All rotor assemblies have a minimum thickness
dimension cast into them. This dimension is the minimum Rotor Assembly
(Swirl Pattern)
wear dimension and not a refinish dimension. The mini-
mum refinish dimension is greater than the discard dimen-
sion. Do not use a rotor assembly that will not meet Accuturn Brake Lathe, GM Dealer Equipment
specifications. Replace with a new rotor assembly. Refer (One-cut refinishing procedure)
to "Specifications" in this section. Locate the deepest score and tum the rotor microme-
Since accurate control of the rotor assembly toler- ter knob until the tool bit bottoms out at the deepest point
ances is necessary for proper performance of the front disc of the score. Zero the scale and back out the tool bit
brakes, the rotor assembly should be machined only with (repeat for opposite side of rotor). Advance the cutter
precision equipment. Equipment should be serviced on a handwheel until the bits have cleared the inner edges of
regular basis following the manufacturer's recommended the rotor face. Adjust the micrometer knobs for approxi-
maintenance procedure. mately 0.13 mm (0.005 inch) more than the first reading.
When refinishing rotor assemblies, the attaching This will ensure resurfacing the rotor in one cut.
adapters, tool holders, vibration dampeners and tool bits
Spindle Speed 105 rpm
must be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits recom- Depth of Cut As necessary
mended by the equipment manufacturer. Dull or worn Tool Cross Feed 0.08 mm (0.003 inch)
tools leave a poor surface finish which will affect braking (per revolution)
performance. Vibration dampening attachments should Tool Bit Nose Radius 1/64
always be used when refinishing braking surfaces. These Vibration Dampener Yes
581·8 FRONT DISC BRAKES

Non-Directional Finishing a. If mounting bores show signs of corro-

It is very important that the rotor surface be made sion, remove corrosion using a 1-inch
non-directional by dressing the rotor surfaces with a sand- wheel cylinder honing brush.
ing disc tool such as Ammco 8750 Safe Swirl Disc Rotor b. Clean mounting bores with clean dena-
Grinder, Accuturn 433179 Non-Directional Swirl Fin- tured akohol.
isher, or equivalent, using 120 grit aluminum oxide sand-
paper. Sand each rotor surface with moderate pressure for 12
a minimum of 60 seconds. If the brake lathe is not
equipped with an adequate non-directional finishing tool,
an alternate method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at the
equipment manufacturer's highest recommended cutting
speed, sand each rotor surface for a minimum of 60
seconds using moderate pressure. After the rotor has
been sanded, clean each surface with denatured alco-
hol or a suitable brake cleaner.
The finished rotor assembly surface should be as 12 HOUSING, FRONT BRAKE CALIPER
close to that of a new front brake rotor assembly as pos-
PC0013-5B1·f·RP
sible. Failure to obtain the best possible finish may affect
braking performance. Figure 13 - Removing Front Brake Caliper Piston

rn Important
• Front brake rotor assemblies should always be B
replaced if turning will result in a front brake rotor
assembly that does not meet manufacturer specifica-
tions for minimum thickness. When installing new
brake rotor assemblies, do not refinish the surfaces
of these parts. New brake rotor assemblies have the
correct level of surface finish.

Burnishing Front Brake Rotor Assemblies

After front brake pad assemblies have been
replaced, it is very important that the new braking surface
be broken in, or burnished. In addition, light corrosion on
the rotors can be removed by burnishing the new braking
surface. This can be accomplished by making 20 stops
from 48 km/h (30 mph), using medium to firm brake
pedal assembly pressure. Take care to avoid overheating 9
the brakes.

12
FRONT BRAKE CALIPER ASSEMBLY
I

Figures 13 through 17 ~11 A

I
Tool Required:
9a -20
J 26267 Dust Boot Seal Installer

!+!,+! Disassemble
NOTICE: Use clean shop towels to pad interior of
caliper housing during piston removal.
1. Remove caliper assembly from vehicle. Refer to
"Front Brake Caliper Assembly" under "On-Ve-
hicle Service" in this section.
2. Bushings (3).
!L'l'! Inspect
A GROOVE
B BEVEL END FIRST
3 BUSHING, FRONT BRAKE CALIPER BOLT
8 BOOT, FRONT BRAKE CALIPER PISTON
9 PISTON, FRONT BRAKE CALIPER
10 SEAL, FRONT BRAKE CALIPER PISTON
11 VALVE, FRONT BRAKE CALIPER BLEEDER, 13 N•m
(115 LB. IN.)
12 HOUSING, FRONT BRAKE CALIPER
20 CAP, FRONT BRAKE CALIPER BLEEDER VALVE

A. Bushings (3) for nicks or cuts. Replace if dam- PC0014-5B1·f.RP

aged. Figure 14 - Front Brake Caliper Assembly Components
B. Mounting bores for corrosion.
 FRONT DISC BRAKES 581·9

8 BOOT, FRONT BRAKE CALIPER PISTON

8 BOOT, FRONT BRAKE CALIPER PISTON
12 HOUSING, FRONT BRAKE CALIPER
9 PISTON, FRONT BRAKE CALIPER
PC0015-6111·F·RP PC0016-5B1-F-RP

Figure 15 - Removing Front Brake Caliper Piston Boot Figure 16 - Installing Front Brake Caliper Piston Boot

CAUTION: Do not place fingers in front

!~I Tighten
of the piston in an attempt to catch or
protect it when applying compressed 3.
air. This could result in serious injury.
4.
3. Piston (9) from housing (12).
• Apply compressed air to housing inlet hole.
5.
ll1'1 Inspect 6.
• Piston (9) for scoring, nicks, corrosion, and
worn or damaged chrome plating.
- Replace piston if any of above are found. 7.
4. Boot (8) from housing (12).
NOTICE: Do not use a metal tool to remove piston 8.
seal from housing bore. Using a metal tool may
damage caliper bore or seal groove.
5. Piston seal (I 0) from housing ( 12).
• Bleeder valve (11) to 13 N•m (115 lb. in.).
Replace bleeder valve cap (20).
Piston seal (10) into bore groove of housing (12).
• Make sure piston seal ( 10) is not twisted.
Boot (8) onto piston (9).
Piston (9) with assembled boot (8) into bore of
housing (12).
• Push piston (9) to bottom of housing bore.
Seat boot (8) into counterbore of housing (12) using
J 26267.
Bushings (3).
A. Lubricate beveled end of bushing (3) with GM
P/N 1052863 or equivalent.
B. Pinch bushing (3) and install bevel end first.

ll1'1 Inspect C. Push bushing (3) through housing mounting

bore.
• Caliper bore and seal groove for scoring, nicks, 9. Install caliper assembly. Refer to "Front Brake
corrosion, and wear. Caliper Assembly" under "On-Vehicle Service" in
A. Use crocus cloth to polish out light corro- this section.
sion.
B. Replace housing (12) if corrosion in and
around seal groove will not clean up with
crocus cloth.
6. Bleeder valve cap (20) and bleeder valve (11) from
housing (12).

!+!+I Assemble
NOTICE: See "Notice" on page 5Bl-1 of this 12
section.

IW::W! Clean
A. All parts in clean denatured alcohol.
B. Dry with unlubricated compressed air.
C. Blow out all passages in housing (12) and
bleeder valve (11 ). 12 HOUSING, FRONT BRAKE CALIPER
I. Lubricate all rubber parts with clean brake fluid. PC001HiB1·F·RP

2. Bleeder valve (11) into housing (12). Figure 17 - Seating Front Brake Caliper Piston Boot
581-10 FRONT DISC BRAKES

SPECIFICATIONS
GENERAL SPECIFICATIONS
Front Brake Caliper Assembly
Front Brake Caliper Housing Bore Diameter ............................ 63.50 mm (2.500")
Front Brake Rotor Assembly
Rotor Diameter (Nominal) ........................................ 278.00 mm (10.945")
Lateral Runout .................................................... 0.13 mm (0.005")
Thickness Variation ............................................... 0.013 mm (0.0005")
Rotor Thickness (Maximum) ........................................ 32.00 mm (1.260")
Minimum Thickness After Refinish ................................... 31.74 mm (1.250")
Discard Thickness ................................................. 30.70 mm (1.209")
All front brake rotor assemblies have a discard dimension cast into them. This is a wear dimension
and not a refinish dimension. Any front brake rotor assembly which does not meet the specifica-
tions should be replaced.

ROTOR REFINISHING SPECIFICATIONS

Ammco Brake Lathe
Rough Cut
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 rpm
Depth of Cut (Per Side) .......................... 0.15 mm to 0.64 mm (0.006" to 0.025")
Tool Cross Feed (Per Revolution) .................................... 0.25 mm (0.010")
Vibration Dampener ......................................................... Yes
Sand Front Brake Rotor Assembly (Swirl Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No
Finish Cut
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 rpm
Depth of Cut (Per Side) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm to 0.15 mm (0.004" to 0.006")
Tool Cross Feed (Per Revolution) .................................... 0.05 mm (0.002")
Vibration Dampener ......................................................... Yes
Sand Front Brake Rotor Assembly (Swirl Pattern) ................................. Yes
Accuturn Brake Lathe
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 rpm
Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As necessary
Tool Cross Feed (Per Revolution) ...................................... 0.08 mm (0.003")
Vibration Dampener ........................................................... Yes

FASTENER TIGHTENING SPECIFICATIONS

Front Brake Caliper Bleeder Valve ..................................... 13 N•m (115 lb. in.)
Front Brake Caliper Bolt/Screw With Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N •m (38 lb. ft.)
Front Brake Hose Fitting ............................................. 44 N•m (32 lb. ft.)
Wheel Nut ....................................................... 140 N•m (100 lb. ft.)

SPECIAL TOOLS

1.

~ J26267
J 37704

1. DUST BOOT SEAL INSTALLER

2. ON DISC BRAKE LATHE
3. DIAL INDICATOR SET
PCOOZO-&B1·F·RP
 REAR DISC BRAKES 582·1

SECTION 582

REAR DISC BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake lin·
ings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts con-
tain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water damp-
ened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.

CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact - rinse thoroughly with water.
• Skin contact - wash with soap and water.

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connec-
tors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.

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

CONTENTS
G~neral pescription . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Inner and Outer Pad
Assemblies Inspection . . . . . . . . . . . . . . . . .
Rear Brake Rotor Assembly Inspection . . . . . .
Rear Brake Rotor Assembly Tolerance
and Surface Finish . . . . . . . . . . . . . . . . . .
Thickness Variation Check . . . . . . . . . . . . .
Lateral Runout Check . . . . . . . . . . . . . . . . .
Rear Brake Caliper Assembly Inspection . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Caliper Assembly . . . . . . . . . . . . .
Rear Disc Brake Inner and Outer Pad
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Caliper Anchor Bracket
and Mounting Plate . . . . . . . . . . . . . . . . . . .
5B2- l Rear Brake Rotor Assembly .............. 582-8
582-2 Parking Brake Free-Travel Adjustment . . . . . . 5B2-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2-9
582-2 Refinishing Rear Brake Rotor Assemblies . . . 582-9
5B2-2 On-Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 5B2-10
Off-Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 582-10
582-2 Non-Directional Finishing ............. 582-11
582-2 Burnishing Rear Brake Rotor
582-2 Assemblies . . . . . . . . . . . . . . . . . . . . . . . 582-11
582-3 Rear Brake Caliper Assembly ............ 582-11
582-3 Specifications ........................... 582-14
582-3 General Specifications . . . . . . . . . . . . . . . . . . 582-14
Rotor Refinishing Specifications . . . . . . . . . . 582-14
582-6 Fastener Tightening Specifications . . . . . . . . 582-15
Special Tools ........................... 582-15
582-8

GENERAL DESCRIPTION
The rear disc brake caliper assembly has a single
piston in an aluminum housing which is suspended in the
anchor bracket on two guide pins. Hydraulic pressure,
created by applying force to the brake pedal assembly,
acts equally against the piston and the bottom of the
caliper bore to move the piston outward and to slide the
caliper inward resulting in a clamping action on the rotor.
This clamping action forces the linings against the rotor
creating friction to stop the vehicle. When the parking
brake is applied, the lever on the caliper causes the
pushrod, the actuating collar and the clamp rod assembly
to be moved outward and the caliper to slide inward,
mechanically forcing the pad assemblies against the rotor
assembly. Parking brake application is completely inde-
pendent of the hydraulic braking system.
The rear disc brake rotor assembly is a composite
cast iron type vented rotor assembly. It has a stamped
sheet metal flange which is insert cast.
582·2 REAR DISC BRAKES

DIAGNOSIS

REAR DISC BRAKE INNER AND OUTER PAD

ASSEMBLIES INSPECTION

Figure 1

IL'i"I
Inspect
• Inner and outer pad assemblies at least twice a year
when the wheels are removed (tire rotation, etc.).
When inspecting rear disc brakes, check both ends
of the outer pad assembly by looking in at each end
of the caliper assembly. These are the points at
which the highest rate of wear normally occurs.
Also, check the lining thickness of the inner pad
assembly to make sure that it has not worn prema-
turely. Look through the hole in the top of the caliper
assembly to view the inner pad assembly. Inner and
outer pad assemblies should be replaced when the
thickness of any lining is worn to within 0.76 mm
(0.030 inch) of the shoe. All inner and outer pad
assemblies should be replaced in axle sets.
All rear disc brakes have a wear indicator that makes
a noise when the pad assembly linings wear to a degree A INSPECTION POINTS
where replacement is required. The wear indicator is an
integral part of the inner pad assembly. When the pad
assembly lining is worn, the clip indicator contacts the PC0001-5B2-F-RP

rotor assembly and produces a warning noise.
1@1 Measure
• Flatness of inner and outer pad assembly linings.
Place inner and outer pad assembly surfaces
together and check for gap between surfaces. If
more than 0.13 mm (0.005 inch) gap is measured
midway between attaching lugs, inner and outer pad
assemblies must be replaced.
REAR BRAKE ROTOR ASSEMBLY
INSPECTION
Rear Brake Rotor Assembly Tolerance and
Surface Finish
In manufacturing the rotor assembly, tolerances of
the braking surfaces for flatness, thickness variation and
lateral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
In addition to these tolerances, the surface finish
must be held to a specified range of 60 Ra roughness or
less. A new rotor assembly falls into this surface range, as
will a rotor assembly that is refinished exactly as directed
in "Refinishing Rear Brake Rotor Assemblies'' in this
section. The control of the braking surface finish is neces-
sary to avoid problems of hard pedal-apply, excessive
brake fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor assembly surfaces not
exceeding 1.5 mm (0.06 inch) in depth, which may result
from normal use, will not affect brake operation.
Figure 1 - Rear Disc Brake Inner and Outer Pad Assemblies
Inspection
Thickness Variation Check
Thickness variation can be checked by measuring
the thickness of the rear brake rotor assembly at four or
more points around its circumference. All measurements
must be made at the same distance in from the edge of the
rotor assembly. A rotor assembly that varies by more than
0.013 mm (0.0005 inch) can cause brake pedal assembly
pulsation and/or rear end vibration during brake applica-
tions. A rotor assembly that does not meet these specifica-
tions should be refinished to specifications or replaced.
Lateral Runout Check
Figure 2
Tool Required:
J 8001 Dial Indicator Set
1. Fasten J 8001 to rear brake caliper housing so that
indicator button contacts rotor assembly surface
about 13 mm (0.5 inch) from rotor edge.
2. Set J 8001 to zero.
• Push in rear axle assembly while setting J 8001
to eliminate endplay.
3. Turn rotor assembly (39) one complete revolution,
and observe total indicated runout (TIR).
• Push in rear axle assembly while turning rotor
assembly to eliminate endplay.
• Total indicated runout (TIR) should not be
more than 0.15 mm (0.006 inch).
 REAR DISC BRAKES 582·3

4. In some cases, excessive lateral runout of rotor

assembly (39) can be improved by indexing rotor
assembly (39).
A. Remove tire and wheel assembly. Refer to
SECTION 3E.
B. Remove rear brake caliper assembly. Refer to
"Rear Brake Caliper Assembly" under "On-
Vehicle Service" in this section.
C. Index rotor assembly (39) on hub one or two
bolt positions from original position.
5. Check lateral runout of rotor assembly (39).
6. If lateral runout of rotor assembly (39) still exceeds
0.15 mm (0.006 inch), check rear axle shaft flange
for excessive lateral runout or looseness. A JOUNCE PAD
39 ROTOR ASSEMBLY, REAR BRAKE
A. Reposition J 8001 so button contacts surface of
axle shaft flange. PC0002-5B2-F-RP
B. Push axle shaft flange inward while turning the Figure 2 - Checking Lateral Runout
axle shaft flange one full revolution.
C. Continue pushing in axle shaft flange while
setting J 8001 to zero.
D. While maintaining inward pressure, rotate axle • If any hydraulic component is removed or discon-
shaft flange and note lateral runout. nected, it may be necessary to bleed all or part of the
E. If axle shaft flange lateral runout exceeds brake hydraulic system.
0.05 mm (0.002 inch), replace rear axle shaft. • Replace pad assemblies in axle sets only.
Refer to SECTION 4B.
F. If axle shaft flange lateral runout is within • The torque values specified are for dry, unlubricated
specifications, refinish or replace rotor assem- fasteners.
bly (39) as necessary. Refer to "Refinishing • Perform service operations on a clean bench, free
Rear Brake Rotor Assemblies" under "Unit from all mineral oil materials.
Repair" in this section.
NOTICE: Whenever the rotor assembly has been
separated from the wheel bearing flange, clean any REAR BRAKE CALIPER ASSEMBLY
rust or foreign material from the mating surface of
the wheel bearing flange and front brake rotor
Figures 3 through 6
assembly. Failure to do this may result in increased
lateral runout of the rotor assembly and brake
pulsation. !+-+! Remove or Disconnect
G. A rotor assembly that does not meet the lateral 1. Raise and suitably support vehicle. Refer to SEC-
runout specification should be resurfaced or TION OA.
replaced as necessary. 2. Parking brake cable assembly at equalizer. Refer to
SECTION SF.
REAR BRAKE CALIPER ASSEMBLY
INSPECTION 3. Tire and wheel assembly. Refer to SECTION 3E.
The rear brake caliper assembly must be disas- • Install wheel nuts to retain rotor assembly (39).
sembled for inspection. Refer to "Rear Brake Caliper 4. Brake hose fitting bolt/screw (32), brake hose fitting
Assembly" under "Unit Repair" in this section. (33) and two gaskets (34) only if caliper assembly is
being removed for overhaul.
ON-VEHICLE SERVICE A. Discard old gaskets (34 ).
NOTICE: Do not use lubricated compressed air on B. Plug hole in caliper housing (14) and brake
brake parts as damage to rubber components may hose fitting (33).
result.

m Important
• Replace all components included in repair kits used
to service this caliper assembly.
• Lubricate rubber parts with clean brake fluid to ease
assembly.
5. Actuator lever return spring (4) only if defective.
• Discard actuator lever return spring (4) if coils
are opened.
6. Parking brake cable assembly (35) from parking
brake actuator lever (5) and parking brake cable
bracket (8).
582-4 REAR DISC BRAKES
7. Vibration dampener nut (41) and vibration damp-
ener assembly (40) from parking brake cable bracket
(8), if necessary.
8. Upper caliper guide pin bolt/screw (13) and discard.
9. Lower caliper guide pin bolt/screw (9) and discard,
only if removing caliper assembly from vehicle.
10. Caliper housing (14) from rotor assembly (39) and
anchor bracket ( 17).
• If caliper overhaul or replacement is not
required, hang caliper housing ( 14) from sus-
pension to avoid damage to brake hose
assembly.
11. Inner and outer pad assemblies (29 and 30) only if
they are being replaced or if anchor bracket (17) is
being removed.
12. Shim ( 10), if inner and outer pad assemblies (29 and
30) were removed.
!L'l'l tnspect
1. Guide pins ( 15) for free movement in anchor bracket
(17). Replace guide pins (15) or guide pin boots (16)
if corroded, worn or damaged.
2. Inner and outer pad assemblies (29 and 30) for wear
and maximum taper of 0.15 mm (0.006 inch).
• Replace with new inner and outer pad assem-
blies (29 and 30) if they are tapered beyond
specification.
- Replace inner and outer pad assemblies
(29 and 30) in sets of four.
3. Brake hose fitting bolt/screw (32).
• If through-hole in brake hose fitting bolt/screw
(32) is blocked, remove blockage or replace
brake hose fitting bolt/screw (32).
!-++I Install or Connect
NOTICE: See "Notice" on page 5B2-l of this
section.
1. New shim (10), if removed.
2. Inner and outer pad assemblies (29 and 30), if
removed.
m Important
• Whenever rear disc brake inner and outer pad
assemblies are replaced, immediately check
the parking brake free-travel. Adjust as neces-
sary. Refer to "Parking Brake Free-Travel
Adjustment" in this section.
A. Outer pad assembly (30) with insulator is
installed toward caliper housing (14). Inner
pad assembly (29) with wear sensor is installed
nearest to piston ( 19).
B. Wear sensor must be in leading position with
forward whee! rotation. If not, use other inner
pad assembly (29) in replacement kit.
3. Caliper housing (14) over rotor assembly (39) and
into anchor bracket ( 17).
4. New upper caliper guide pin bolt/screw (13).
l~I Tighten
• Upper caliper guide pin bolt/screw (13) to
37 N•m (27 lb. ft.).
5. New lower caliper guide pin bolt/screw (9), if
removed.
l~I Tighten
• Lower caliper guide pin bolt/screw (9) to
37 N•m (27 lb. ft.).
6. Brake hose fitting (33), two new gaskets (34) and
brake hose fitting bolt/screw (32), if removed.
l~I Tighten
• Brake hose fitting bolt/screw (32) to 30 N•m
(22 lb. ft.).
7. Vibration dampener assembly (40) and vibration
dampener nut (41) to parking brake cable bracket
(8), if removed.
!~I Tighten
• Vibration dampener nut (41) to 50 N•m
(37 lb. ft.).
8. Parking brake cable assembly (35) to parking brake
cable bracket (8) and parking brake actuator lever
(5), and parking brake cable equalizer.
9. Actuator lever return spring (4), if removed.
10. Bleed brake hydraulic system, if brake hose fitting
was removed. Refer to SECTION 5El.
11. Lower vehicle.
12. Cycle parking brake assembly.
13. Raise and suitably support vehicle. Refer to SEC-
TION OA.
!L•l tnspect
• Parking brake actuator levers to make sure
they are against stops on caliper housing (14).
If parking brake actuator levers are not on their
stops, make sure actuator lever return spring
(4) is correctly installed, then refer to SEC-
TION 5F for parking brake linkage repairs.
14. Tire and wheel assembly. Refer to SECTION 3E.
• Remove wheel nuts securing rotor assembly
(39).
15. Lower vehicle.
16. With engine running, pump brake pedal assembly
slowly and firmly three times to seat inner and outer
pad assemblies (29 and 30).
17. Check brake hydraulic system for leaks.
 REAR DISC BRAKES 582·5

8 13

41~

30
1 SEAL, REAR PARKING BRAKE LEVER PIVOT PIN 16 BOOT, REAR BRAKE CALIPER GUIDE PIN
2 CLIP, REAR PARKING BRAKE LEVER SPRAG 17 BRACKET, REAR BRAKE CALIPER ANCHOR
3 PIN, REAR PARKING BRAKE LEVER PIVOT 18 SEAL, REAR BRAKE CALIPER PISTON
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR 19 PISTON, REAR BRAKE CALIPER
LEVER RETURN 20 BOOT, ACTUATING COLLAR
5 LEVER, REAR PARKING BRAKE ACTUATOR 21 RETAINER, ACTUATING COLLAR BOOT
6 VALVE, REAR BRAKE CALIPER BLEEPER, 22 PUSHROD
11 N•m (97 LB. IN.) 23 SPRING, PRELOAD
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE 24 COLLAR, ACTUATING
8 BRACKET, PARKING BRAKE CABLE 25 BOOT, ACTUATING COLLAR
9 BOLT/SCREW, LOWER CALIPER GUIDE PIN, 26 SPRING, REAR CALIPER PARKING BRAKE COLLAR
37 N•m (27 LB. FT.) RETURN
10 SHIM 27 BUSHING
11 SCREW, PARKING BRAKE LEVER ADJUSTER 28 ROD, CLAMP
12 NUT, REAR PARKING BRAKE LEVER PIVOT PIN, 29 PAD ASSEMBLY, REAR DISC BRAKE INNER
22 N•m (16 LB. FT.) 30 PAD ASSEMBLY, REAR DISC BRAKE OUTER
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN, 31 RETAINER, ACTUATING COLLAR. BOOT
37 N•m (27 LB. FT.) 40 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
14 HOUSING, REAR BRAKE CALIPER 41 .NUT, REAR BRAKE VIBRATION DAMPENER,
15 PIN, REAR BRAKE CALIPER GUIDE 50 N•m (37 LB. FT.)
PC0003-5B2-F-RP

Figure 3 - Rear Brake Caliper Assembly Components

582·6 REAR DISC BRAKES

A 30

40
14 HOUSING, REAR BRAKE CALIPER
32 BOLT/SCREW, REAR BRAKE HOSE FITIING, A WEAR SENSOR
30 N•m (22 LB. FT.) 8 BRACKET, PARKING BRAKE CABLE
33 FITIING, REAR BRAKE HOSE 9 BOLT/SCREW, LOWER CALIPER GUIDE PIN,
34 GASKET, REAR BRAKE HOSE FITIING 37 N•m (27 LB. FT.)
39 ROTOR ASSEMBLY, REAR BRAKE 10 SHIM
40 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION 13 BOLT/SCREW, UPPER CALIPER GUIDE PIN,
PC0004·5B2·f·RP 37 N•m (27 LB. FT.)
Figure 4 - Removing Rear Brake Hose Fitting 14 HOUSING, REAR BRAKE CALIPER
15 PIN, REAR BRAKE CALIPER GUIDE
16 BOOT, REAR BRAKE CALIPER GUIDE PIN
17 BRACKET, REAR BRAKE CALIPER ANCHOR
29 PAD ASSEMBLY, REAR DISC BRAKE INNER
30 PAD ASSEMBLY. REAR DISC BRAKE OUTER
40 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
41 NUT, REAR BRAKE VIBRATION DAMPENER,
50 N•m (37 LB. FT.)

PC000&-582-F-RP

Figure 6 - Rear Brake Caliper Assembly

REAR DISC BRAKE INNER AND OUTER PAD

ASSEMBLIES

Figures 3, 7 and 8

l++I Remove or Disconnect

8 reservoir.
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
5 LEVER, REAR PARKING BRAKE ACTUATOR
8 BRACKET, PARKING BRAKE CABLE
14 HOUSING, REAR BRAKE CALIPER
35 CABLE ASSEMBLY, PARKING BRAKE REAR
40 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
PC0005·5B2·F-RP
Figure 5 - Parking Brake Cable Assembly Attachment
1. Two-thirds of brake fluid from master cylinder
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Tire and wheel assembly. Refer to SECTION 3E.
• Install wheel nuts to retain rotor assembly.
4. Position a C-clamp and tighten until piston (19) bot-
toms in base of caliper housing (14).
• Make sure one end of C-clamp rests on brake
hose fitting bolt/screw (32) and other end
against outer pad assembly (30).

A C-CLAMP,
14 HOUSING, REAR BRAKE CALIPER
17 BRACKET, REAR BRAKE CALIPER ANCHOR
PC0007-5B2-F-RP
Figure 7 - Compressing Rear Brake Caliper Piston
[I] Important
• It is not necessary to remove the actuator lever
return spring (4) to replace the inner and outer
pad assemblies (29 and 30).
5. Upper caliper guide pin bolt/screw (13).
• Discard upper caliper guide pin bolt/screw
(13).
6. Inner and outer pad assemblies (29 and 30).
A. Rotate caliper housing (14) about lower caliper
guide pin bolt/screw (9) and guide pin (15). Be
careful not to strain hose or cable conduit.
B. Lift out inner and outer pad assemblies (29 and
30).
7. Shim (10).
• Discard shim (10).
l~I Clean
• All residue from shoe guide surfaces on anchor
bracket (17) and caliper housing (14).
ll'l'I Inspect
• Guide pins ( 15) for free movement in anchor bracket
(17).
- Replace guide pins ( 15) or guide pin boots ( 16)
if corroded or damaged. Refer to "Rear Brake
Caliper Assembly" in this section.
l++I Install or Connect
NOTICE: See "Notice" on page 5B2-1 of this
section.
1. New shim (10).
2. New inner and outer pad assemblies (29 and 30).
REAR DISC BRAKES 582·7
30
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN,
37 N•m (27 LB. FT.)
14 HOUSING, REAR BRAKE CALIPER
15 PIN, REAR BRAKE CALIPER GUIDE
17 BRACKET, REAR BRAKE CALIPER ANCHOR
29 PAD ASSEMBLY, REAR DISC BRAKE INNER
30 PAD ASSEMBLY, REAR DISC BRAKE OUTER
39 ROTOR ASSEMBLY, REAR BRAKE
PC0008-5B2·F-RP
Figure 8 - Rear Disc Brake Inner and Outer Pad Assembly
Replacement
m Important
• Whenever rear disc brake inner and outer pad
assemblies are replaced, immediately check
the parking brake free-travel. Adjust as neces-
sary. Refer to "Parking Brake Free-Travel
Adjustment" in this section.
A. Outer pad assembly (30) with insulator is
installed toward caliper housing (14). Inner
pad assembly (29) with wear sensor is installed
nearest the piston (19).
B. Wear sensor must be on leading edge of inner
pad assembly (29) with forward wheel rota-
tion. If not, use other inner pad assembly (29)
in replacement kit.
C. Replace inner and outer pad assemblies (29
and 30) in axle sets only.
3. Rotate caliper housing (14) into its operating
position.
• Springs on outer pad assembly (30) must not
stick through inspection hole in caliper hous-
ing ( 14). If springs are sticking through inspec-
tion hole in caliper housing (14), lift caliper
housing (14) and reposition outer pad assem-
bly (30).
4. New upper caliper guide pin bolt/screw (13).
582-8 REAR DISC BRAKES

38
l~I Tighten
• Upper caliper guide pin bolt/screw (13) to
37 N•m (27 lb. ft.).
5. With engine running, pump brake pedal assembly
slowly and firmly to seat inner and outer pad assem-
blies (29 and 30).

IL•l 1nspect
• Parking brake actuator levers (5) to ensure they
are against stops on caliper housing (14).
- If parking brake actuator levers are not on
their stops, refer to SECTION SF for A
parking brake linkage repairs.
6. Tire and wheel assembly. Refer to SECTION 3E.
• Remove wheel nuts securing rotor assembly
(39).
7. Lower vehicle.
8. Fill master cylinder reservoirs. Refer to SECTION
SA.

REAR BRAKE CALIPER ANCHOR BRACKET

AND MOUNTING PLATE

Figure 9

l++I Remove or Disconnect

1. Caliper assembly. Refer to "Rear Brake Caliper
Assembly" under "On-Vehicle Service" in this
section.
A CALIPER ASSEMBLY REMOVED FROM
ANCHOR BRACKET
B CALIPER ASSEMBLY AND ANCHOR BRACKET
ASSEMBLED
17 BRACKET, REAR BRAKE CALIPER ANCHOR
36 BOLT/SCREW, REAR BRAKE CALIPER MOUNTING PLATE,

m Important
• Remove anchor bracket (17) only if it is dam-
100 N•m (74 LB. FT.)
38 PLATE, REAR BRAKE CALIPER MOUNTING
39 ROTOR ASSEMBLY, REAR BRAKE PC0009-5B2-F·RP

Figure 9 - Rear Brake Rotor Assembly, Caliper Anchor

aged or if rotor assembly (39) is being removed
for refinishing or other service operations.
2. Two mounting plate bolts/screws (36).
• Discard mounting plate bolts/screws (36).
3. Anchor bracket (17) from mounting plate (38).
!++I Install or Connect
NOTICE: See "Notice" on page 5B2-1 of this
section.
1. Anchor bracket ( 17) to mounting plate (38).
2. Two new mounting plate bolts/screws (36).
l~I Tighten
• Mounting plate bolts/screws (36) to 100 N•m
(74 lb. ft.).
- Check torque on both mounting plate
bolts/screws (36) immediately.
3. Caliper assembly. Refer to "Rear Brake Caliper
Assembly" under "On-Vehicle Service" in this
section.
Bracket, and Mounting Plate
REAR BRAKE ROTOR ASSEMBLY
Figure 9
Rear brake rotor assembly can be removed without
removal of caliper assembly from anchor bracket.
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Tire and wheel assembly. Refer to SECTION 3E.
3. Two mounting plate bolts/screws (36).
• Discard mounting plate bolts/screws (36).
4. Anchor bracket (17) with assembled caliper assem-
bly from mounting plate (38) and suspend them
from rear suspension out of the way using locally
fabricated wire hook.
5. Rotor assembly (39).

l•+I Install or Connect
NOTICE: See "Notice" on page 5B2-1 of this
section.
1. Rotor assembly (39).
2. Anchor bracket ( 17) with assembled caliper assem-
bly to mounting plate (38).
3. Two new mounting plate bolts/screws (36).
l~I Tighten
• Mounting plate bolts/screws (36) to 100 N•m
(74 lb. ft.).
- Check torque on both mounting plate
bolts/screws (39) immediately.
4. Tire and wheel assembly. Refer to SECTION 3E.
5. Lower vehicle.
PARKING BRAKE FREE-TRAVEL
ADJUSTMENT
Figure 10
The adjustment process requires a second person to
apply a light brake pedal load. Parking brake lever free-
travel is set by the position of the adjuster screw (11 ).
Turning the adjuster screw (11) clockwise increases the
free-travel; turning the adjuster screw (11) counterclock-
wise decreases the free-travel.
NOTICE: Inner and outer pad assemblies must be
new or parallel to within 0.15 mm (0.006 inch).
Parking brake adjustment is not valid with heavily
tapered pad assemblies and may cause caliper/park-
ing brake binding.
m Important
• Inspect old inner and outer pad assemblies and
replace with new ones if they are tapered.
• Parking brake free-travel should only be
changed if the caliper has been taken apart, or
when the pad assemblies are replaced.
• This adjustment will not correct a condition
where parking brake actuator levers will not
return to their stops.
1. Disconnect parking brake cable assembly and
remove actuator lever return spring (4).
2. Have an assistant apply light brake pedal load,
enough to stop rotor from turning by hand.
• This takes up all clearances and ensures that
components are correctly aligned.
3. Apply light pressure to parking brake actuator lever
(5).
l@I Measure
• Free-travel between parking brake actuator
lever (5) and caliper housing (14) at point B.
- Free-travel must be 0.61 mm to 0.71 mm
(0.024 inch to 0.028 inch).
4. If free-travel is incorrect, do the following:
REAR DISC BRAKES 582·9
A. Remove adjuster screw (11).
B. Clean thread adhesive residue from threads.
C. Coat threads with adhesive.
D. Screw in adjuster screw (11) far enough to
obtain 0.61 mm to 0. 71 mm (0.024 inch to
0.028 inch) free-travel between parking brake
actuator lever (5) and caliper housing (14) at
point B.
5. Have assistant release brake pedal assembly, then
apply brake pedal assembly firmly three times.
6. Recheck free-travel as described in steps 2 and 3 and
adjust as necessary.
7. Install actuator lever return spring (4) and parking
brake cable assembly
UNIT REPAIR
REFINISHING REAR BRAKE ROTOR
ASSEMBLIES
m Important
• DO NOT refinish rotor assemblies when performing
routine brake maintenance such as replacing worn
rear disc brake inner and outer pad assemblies.
Refinish a rotor assembly ONLY under the follow-
ing circumstances:
- There is a complaint of brake pulsation.
- There is scoring greater than 1.5 mm (0.06
inch).
All rotor assemblies have a minimum thickness
dimension cast into them. This dimension is the minimum
wear dimension and not a refinish dimension. The mini-
mum refinish dimension is greater than the discard dimen-
sion. Do not use a rotor assembly that will not meet
specifications. A rotor assembly that has been refinished
too thin will not have proper heat transfer capabilities.
Replace with a new rotor assembly. Refer to "Specifica-
tions" in this section.
Since accurate control of the rotor assembly toler-
ances is necessary for proper performance of the rear disc
brakes, the rotor assembly should be machined only with
precision equipment. Equipment should be serviced on a
regular basis following the manufacturer's recommended
maintenance procedure.
When refinishing rotor assemblies, the attaching
adapters, tool holders, vibration dampeners and tool bits
must be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits recom-
mended by the equipment manufacturer. Dull or worn
tools leave a poor surface finish which will affect braking
performance. Vibration dampening attachments should
always be used when refinishing braking surfaces. These
attachments eliminate tool chatter and will result in better
surface finish. Make sure these adapters are clean and free
of nicks. ·
582-10 REAR DISC BRAKES

14

A APPLY PRESSURE HERE

B MEASURE HERE
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
5 LEVER, REAR PARKING BRAKE ACTUATOR
11 SCREW, PARKING BRAKE LEVER ADJUSTER
14 HOUSING, REAR BRAKE CALIPER

PC0010-5B2-F-RP

Figure 10 - Parking Brake Free-Travel Adjustment

On-Vehicle when the rotor assembly is reinstalled on the rear

Tool Required: axle shaft flange.
On-Vehicle Brake Lathe, such as Kent~Moore Following are two recommended procedures that
J 37704 On Disc Brake Lathe achieve adequate results using two different off-vehicle
drum/disc brake lathes. (If any other lathe is used, follow
J 37160-A Brake Rotor Mounting Adapter that lathe's instructions and recommendations.)
In the cases where rotors are being refinished to cor-
rect a problem with brake pulsation, it is recommended
Ammco Brake Lathe
that an on-vehicle brake lathe be used to achieve best (Two-cut refinishing procedure)
results. Follow the equipment manufacturer's recom- ROUGH CUT FINISH CUT
mended specifications and procedure. Spindle Speed 150 rpm 150 rpm
Depth of Cut 0.15 mm to 0.10 mm to
Off-Vehicle (per side) 0.64mm 0.15 mm
Tool Required: (0.006 inch to (0.004 inch to
0.025 inch) 0.006 inch)
J 37160-A Brake Rotor Mounting Adapter

m Important
• Remove rust and scale from rotor assembly and rear
Tool Cross Feed
(per rev.)
0.25 mm
(0.010 inch)
Vibration Dampener Yes
Sand Rear Brake No
0.05mm
(0.002 inch)
Yes
Yes
axle shaft flange mating, surfaces. Failure to do so Rotor Assembly
may introduce excessive lateral runout when the (Swirl Pattern)
rotor assembly is mounted on the brake lathe, or

Accuturn Brake Lathe, GM Dealer Equipment
(One-cut refinishing procedure)
Locate the deepest score and turn the rotor microme-
ter knob until the tool bit bottoms out at the deepest point
of the score. Zero the scale and back out the tool bit
(repeat for opposite side of rotor). Advance the cutter
handwheel until the bits have cleared the inner edges of
the rotor face. Adjust the micrometer knobs for approxi-
mately 0.13 mm (0.005 inch) more than the first reading.
This will ensure resurfacing the rotor in one cut.
Spindle Speed 105 rpm
Depth of Cut As necessary
Tool Cross Feed 0.08 mm (0.003 inch)
(per revolution)
Tool Bit Nose Radius
1/64
Vibration Dampener Yes
Non-Directional Finishing
It is very important that the rotor surface be made
non-directional by dressing the rotor surfaces with a sand-
ing disc tool such as Ammco 8750 Safe Swirl Disc Rotor
Grinder, Accuturn 433179 Non-Directional Swirl Fin-
isher, or equivalent, using 120 grit aluminum oxide sand-
paper. Sand each rotor surface with moderate pressure for
a minimum of 60 seconds. If the brake lathe is not
equipped with an adequate non-directional finishing tool,
an alternate method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at the
equipment manufacturer's highest recommended cutting
speed, sand each rotor surface for a minimum of 60
seconds using moderate pressure. After the rotor has
been sanded, clean each surface with denatured alco-
hol or a suitable brake cleaner.
The finished rotor assembly surface should be as
close to .that of a new rear brake rotor assembly as pos-
sible. Failure to obtain the best possible finish may affect
braking performance.
m Important
• Rear brake rotor assemblies should always be
replaced if turning will result in a rear brake rotor
assembly that does not meet manufacturer specifica-
tions for minimum thickness. When installing new
brake rotor assemblies, do not refinish the surfaces
of these parts. New brake rotor assemblies have the
correct level of surface finish.
Burnishing Rear Brake Rotor Assemblies
After rear brake pad assemblies have been replaced,
it is very important that the new braking surface be broken
in, or burnished. In addition, light corrosion on the rotors
can be removed by burnishing the new parking brake sur-
face. This can be accomplished by making 20 stops from
48 km/h (30 mph), using medium to firm brake pedal
assembly pressure. Allow 0.8 km (0.5 mile) to 1.6 km (1.0
mile) between stops to avoid overheating the brakes.
REAR DISC BRAKES 582·11
REAR BRAKE CALIPER ASSEMBLY
Figures 3, 11 and 12
!+!+I Disassemble
1. Remove caliper assembly. Refer to "Rear Brake
Caliper Assembly" under "On-Vehicle Service" in
this section.
2. Two collar return springs (26) from actuating collar
boot retainer (31 ).
3. Actuating collar (24) with assembled parts.
• Firmly but gently pull actuating collar (24)
with assembled parts out of caliper housing
( 14) by pulling on both ends of actuating collar
boot retainer (31).
4. Clamp rod (28) and bushing (27) from actuating col-
lar (24).
• Discard bushing (27).
5. Actuating collar boot retainers (21 and 31), actuat-
ing collar boots (20 and 25) and pushrod (22) from
actuating collar (24 ).
A. Bend back actuating collar boot retainer tabs
and take apart.
B. Remove preload spring (23) from actuating
collar boot retainer (21).
C. Remove pushrod (22) from actuating collar
boot retainer (21 ).
D. Remove and discard actuating collar boot
retainers (21 and 31) and actuating collar boots
(20 and 25).
CAUTION: Do not place fingers in front
of the piston in an attempt to catch or
protect it when applying compressed
air. The piston can fly out with force
and could result in serious injury.
rn Important
• Use clean shop towels to pad the inside of the
caliper housing (14) during rear brake caliper
piston removal.
NOTICE: To prevent damage, be careful when han-
dling rear brake caliper piston.
6. Piston ( 19) by directing dry, filtered compressed air
into brake hose port of caliper housing (14).
!L'l'I Inspect
• Piston (19) for scoring, nicks, corrosion and
wear.
- Replace piston ( 19) if necessary.
NOTICE: Do not use a metal tool to remove piston
seal. Metal tools may damage the caliper housing
bore or the piston seal groove.
7. Piston seal (18).
• Use small wood or plastic tool.
8. Bleeder valve cap (7) and bleeder valve (6).
• Discard bleeder valve cap (7).
582-12 REAR DISC BRAKES

9. Parking brake lever pivot pin seal (1), sprag clip (2),
actuator lever return spring (4) and parking brake
actuator lever (5) from parking brake lever pivot pin
ll"l'I Inspect
(3). • Caliper housing bore for scoring and corrosion.
Replace caliper housing (14) if badly s.cored or cor-
• Discard sprag clip (2). roded around seal area.

ll'l'I Inspect l•!+I Assemble

• Contact points on parking brake actuator lever NOTICE: See "Notice" on page 5B2-l of this
· (5) and parking brake lever pivot pin (3) for section.
wear and corrosion.
I. Lubricate new piston seal ( 18) and caliper housing
- Replace if necessary. bore seal groove with silicone grease or clean brake
10. Parking brake lever pivot pin (3) and pivot pin nut fluid.
(12), if worn. 2. New piston seal (18) into caliper housing seal
groove.
11. Adjuster screw ( 11) from caliper housing ( 14 ).
• Make sure piston seal ( 18) is not twisted.
• Discard if damaged or worn.
3. Lubricate bore of caliper housing (14) and piston
ll'l'I Inspect
4.
(19) with clean brake fluid.
Piston (19) into bore of caliper housing (14).
• Caliper anchor bracket (17) for wear and
• Push down by hand to bottom of bore.
damage.
- Replace if necessary. Refer to "Rear
Brake Caliper Anchor Bracket and
ll"l'I Inspect
Mounting Plate" in this section. • Actuating collar (24) and clamp rod (28) for
corrosion and excessive wear on working
faces.
- If corrosion or excessive wear is present,
replace actuating collar assembly.
5. Pushrod (22), new inner and outer actuating collar
boots (20 and 25) and new actuating collar boot
retainers (21 and 31) to actuating collar (24 ).
A. Lightly coat actuating collar (24) with liquid
lubricant provided in repair kit. Do not use any
other fluid or grease.
B. Install preload spring (23) into new actuating
collar boot retainer (21 ).
C. Install new inner and outer actuating collar
boots (20 and 25) into new actuating collar
boot retainers (21 and 31 ).
D. Install pushrod (22) to new actuating collar
A SHOPTOWEL boot retainer (21 ).
14 HOUSING, REAR BRAKE CALIPER PC0011·5B2-F-RP
E. Clamp new actuating collar boot retainers (21
Figure 11 - Removing Rear Brake Caliper Piston and 31) firmly against actuating collar (24).
F. Bend tabs on new actuating collar boot retainer
(21) to hold actuating collar assembly together.
li,I Clean 6. Clamp rod (28) to actuating collar (24) and actuating
collar boot (25).
• Pad assembly contact area on anchor bracket
(17). A. Lightly coat clamp rod (28) with liquid lubri-
cant provided in repair kit.
12. Two guide pins (15) and guide pin boots (16) from B. Slide clamp rod (28) through holes in actuating
anchor bracket (17). collar boot (25) and actuating collar (24).

!i,I Clean
I. All parts not included in repair kit in denatured alco-
hol.
2. Use dry, filtered compressed air to dry parts.
3. Blow out all passages in caliper housing (14) and
bleeder valve (6).
C. Actuating collar boot (25) must be against
reaction plate on clamp rod (28).
7. New bushing (27) to clamp rod (28).
• Lubricate outside of bushing (27) with pro-
vided lubricant.
8. Clamp rod (28) with assembled parts into connect-
ing hole in piston ( 19).
 REAR DISC BRAKES 582·13

14

17

A WEAR SENSOR
3 PIN, REAR PARKING BRAKE LEVER PIVOT
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
5 LEVER, REAR PARKING BRAKE ACTUATOR ~FRT 8
6 VALVE, REAR BRAKE CALIPER BLEEDER, 28
11 N•m (97 LB. IN.)
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE'
8 BRACKET, PARKING BRAKE CABLE
9 BOLT/SCREW, LOWER CALIPER GUIDE PIN,
37 N•m (27 LB. FT.)
10 SHIM
11 SCREW, PARKING BRAKE LEVER ADJUSTER
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN,
37 N•m (27 LB.FT.)
14 HOUSING, P.EAR BRAKE CALIPER
15 PIN, REAR BRAKE CALIPER GUIDE
17 BRACKET, REAR BRAKE CALIPER ANCHOR
18 SEAL, REAR BRAKE CALIPER PISTON
19 PISTON, REAR BRAKE CALIPER
20 BOOT, ACTUATING COLLAR
21 RETAINER, ACTUATING COLLAR BOOT
22 PUSHROD
23 SPRING, PRELOAD
24 COLLAR, ACTUATING
25 BOOT, ACTUATING COLLAR
26 SPRING, REAR CALIPER PARKING BRAKE
COLLAR RETURN
27 BUSHING
28 ROD, CLAMP
29 PAD ASSEMBLY, REAR DISC BRAKE INNER
30 PAD ASSEMBLY, REAR DISC BRAKE OUTER
31 RETAINER, ACTUATING COLLAR BOOT
PC0012-5B2-F-RP

Figure 12 - Rear Brake Caliper Assembly - Cutaway View

582-14 REAR DISC BRAKES

A. Lubricate grooved bead of actuating collar
boot (20) and boot groove in caliper housing
(14) with provided lubricant. Use remaining
liquid lubricant to coat actuating collar (24 ),
especially around center hole.
B. Push clamp rod (28) firmly to bottom of con-
necting hole in piston ( 19).
C. Pull on actuating collar (24) and seat actuating
collar boot (20) into boot groove in caliper
housing ( 14).
D. Make sure that pushrod (22) enters hole in cali-
per housing (14).
9. Two collar return springs (26) to actuating collar
boot retainer (31 ).
• Actuating collar boot retainer (31) must enter
collar return springs (26) at end of second
spring coil.
10. New bleeder valve cap (7) and bleeder valve (6) into
caliper housing (14).
12. Lubricate parking brake actuator lever (5) and park-
ing brake lever pivot pin (3) with grease provided in
repair kit.
13. Pivot pin seal (1 ), parking brake actuator lever (5),
new sprag clip (2) and actuator lever return spring
(4), in that order.
A. Teeth of sprag clip (2) must face away from
parking brake actuator lever (5).
B. Snap pivot pin seal cap over parking brake
lever pivot pin (3).
14. Adjuster screw (11) into caliper housing (14) until
actuating collar (24) is about parallel to piston bore
face of caliper housing (14).
15. New guide pin boots (16) and guide pins (15).
A. Lubricate two guide pins (15) with grease pro-
vided in repair kit.
B. Slide guide pin boots (16) on guide pins (15).

l~I Tighten C. Fill guide pin boots (16) with provided grease.
• Bleeder valve (6) to 11 N•m (97 lb. in.). D. Assemble to anchor bracket (17).
11. Parking brake lever pivot pin (3) and new pivot pin E. Make sure guide pin boots (16) fit into grooves
nut (12) to caliper housing (14), if removed. of guide pins ( 15) and anchor bracket ( 17).

l~I Tighten
16. Install caliper assembly. Refer to "Rear Brake Cali-
per Assembly" under "On-Vehicle Service" in this
• Pivot pin nut (12) to 22 N•m (16 lb. ft.). section.

SPECIFICATIONS

GENERAL SPECIFICATIONS
Rear Brake Caliper Assembly
Rear Brake Caliper Housing Bore Diameter (Nominal) ................... 40.50 mm (1.595")
Rear Brake Rotor Assembly
Rotor Diameter (Nominal) ....................................... 293.00 mm (1.1.535")
Lateral Runout
Rear Brake Rotor Assembly (On-Vehicle Condition) ................... 0.15 mm (0.006")
Rear Axle Shaft Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 ")
Thickness Variation .............................................. 0.013 mm (0.0005")
Rotor Thickness (Maximum) ....................................... 20.00 mm (0.787")
Minimum Thickness After Refinish .................................. 18.63 mm (0.733")
Discard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.40 mm (0.724")

All rear brake rotor assemblies have a discard dimension cast into them. This is a wear dimension and not a refinish
dimension. Any rear brake rotor assembly which does not meet the specifications should be replaced.

ROTOR REFINISHING SPECIFICATIONS

Ammco Brake Lathe
Rough Cut
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 rpm
Depth of Cut (Per Side) . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm to 0.64 mm (0.006" to 0.025 ")
Tool Crossfeed (Per Revolution) .................................... 0.25 mm (0.010")
Vibration Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes
Sand Front Brake Rotor Assembly (Swirl Pattern) ................................. No
 REAR DISC BRAKES 582·15

Finish Cut
Spindle Speed .......................................................... 150 rpm
Depth of Cut (Per Side)................ . . . . . . . . . 0.10 mm to 0.15 mm (0.004'' to 0.006")
Tool Crossfeed (Per Revolution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 ")
Vibration Dampener ......................................................... Yes
Sand Front Brake Rotor Assembly (Swirl Pattern) ................................. Yes
Accuturn Brake Lathe
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 rpm
Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As necessarx
Tool Crossfeed (Per Revolution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003' )
Vibration Dampener ........................................................... Yes

FASTENER TIGHTENING SPECIFICATIONS

Lower Caliper Guide Pin Bolt/Screw .................................... 37 N•m (27 lb. ft.)
Rear Brake Caliper Bleeder Valve ...................................... 11 N •m (97 lb. in.)
Rear Brake Caliper Mounting Plate Bolt/Screw ........................... 100 N•m (74 lb. ft.)
Rear Brake Hose Fitting Bolt/Screw ..................................... 30 N•m (22 lb. ft.)
Rear Brake Vibration Dampener Nut .................................... 50 N•m (37 lb. ft.)
Rear Parking Brake Lever Pivot Pin Nut ................................. 22 N•m (16 lb. ft.)
Upper Caliper Guide Pin Bolt/Screw .................................... 37 N•m (27 lb. ft.)

SPECIAL TOOLS

1. 2. 3.

~ a
o~4'
J37160-A J37704

J 8001

1. BRAKE ROTOR MOUNTING ADAPTER

2. ON DISC BRAKE LATHE
3. DIAL INDICATOR SET

PC0020·5B2-F-RP
 DUO-SERVO DRUM BRAKES 5C2·1

SECTION 5C2

DUO-SERVO DRUM BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake lin-
ings or by cleaning brake parts with a dry brush or compressed air. Many brake parts con-
tain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water damp-
ened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.

CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
• Eye contact -' rinse thoroughly with water.
• Skin contact - wash with soap and water.

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connec-
tors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.

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

CONTENTS
G~neral _Description ....................... 5C2-l Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 5C2-6
D1agnos1s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C2-1 Rear Drum Brake Adjustment . . . . . . . . . . . . . 5C2-7
Primary and Secondary Shoes Inspection . . . . 5C2- l Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C2-7
Drum Assembly Inspection . . . . . . . . . . . . . . . 5C2- l Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5C2-7
Surface Finish . . . . . . . . . . . . . . . . . . . . . . . 5C2-2 Cracked, Scored or Grooved . . . . . . . . . . . . 5C2-7
Inside Diameter Check ................. 5C2-2 Out-of-Round or Tapered ............... 5C2-7
Out-of-Round or Taper Check . . . . . . . . . . . 5C2-2 Refinishing .......... '. . . . . . . . . . . . . . . . 5C2-7
Runout Check ....................... 5C2-2 Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C2-8
Balance ............................. 5C2-2 Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 5C2-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 5C2-2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C2-9
Drum Assembly ................. i. . . . . . . 5C2-2 General Specifications . . . . . . . . . . . . . . . . . . . 5C2-9
Primary and Secondary Shoes ...... 1• • • • • • • 5C2-4 Fastener Tightening Specifications . . . . . . . . . 5C2-9
Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 5C2-5 Special Tools ............................ 5C2-9

GENERAL DESCRIPTION DIAGNOSIS

The rear drum brake assembly is a duo-servo design.
In the duo-servo brake, the force which the rear wheel
cylinder applies to the primary shoe is multiplied by the
primary lining friction to provide a very large force
applied to the secondary shoe. Adjustment for both the
primary and secondary shoe and lining assemblies is auto-
matic during reverse brake applications.
The rear brake drum assembly has a honed friction
surface that reduces shoe slap, increases lining life, and
reduces the break-in time.
PRIMARY AND SECONDARY SHOES
INSPECTION
When the thickness of any lining is worn within 0. 76
mm (0.030 inch) of the primary or secondary shoe, the
primary and secondary shoes must be replaced. Replace
shoes in axle sets only.
DRUM ASSEMBLY INSPECTION
Pulsation in the brake pedal assembly is usually cor-
rected by servicing the front brakes. Service the rear
brakes only if the problem persists.
5C2·2 DUO-SERVO DRUM BRAKES

To determine if the front or rear brakes are at fault,

drive the vehicle in an area away from people and moving
traffic (such as a large parking lot), and at a slow speed.
Lightly apply the parking brake assembly, and feel for the
pulsation. Be careful not to Jock the brakes and flat-spot
the rear tires. If the pulsation is not noticed, the fault is
probably in the front brakes.
When drum assemblies are removed, thoroughly
clean and inspect them for cracks, scores, deep grooves,
out-of-round and taper.

Surface Finish
A
Normal light scoring of the drum assembly surfaces
not exceeding 0.51 mm (0.020 inch) in depth will not
affect brake operation.

Inside Diameter Check

The nominal inside diameter of the drum assembly
is 241.30 mm (9.500 inches).

Out-of-Round or Taper Check

An out-of-round or tapered drum assembly makes
accurate primary or secondary shoe adjustment impossi-
ble and is likely to cause excessive wear of other parts of
brake mechanism due to its eccentric action. An out-of-
round drum assembly can also cause severe and irregular
tire tread wear as well as a pulsating brake pedal assem-
bly. When the drum assembly exceeds the specification A SCREWDRIVER USED ONLY WHEN BACKING OFF
limits in taper and/or out-of-round, refinish drum assem- ADJUSTMENT
bly to true up the braking surface. Out-of-round as well as B BRAKE ADJUSTING TOOL
taper and wear can be accurately measured with an inside C ST AR WHEEL ROTA TION TO RETRACT REAR BRAKE
micrometer fitted with proper extension rods. SHOES
D STAR WHEEL ROTATION TO EXPAND
When measuring a drum assembly for out-of-round, REAR BRAKE SHOES
taper, and wear, take measurements at the op~n and closed 7 ACTUATOR, REAR BRAKE SHOE ADJUST
29 PLATE, REAR BRAKE BACKING
edges of machined surface and at right angles !(90 degrees)
to each other. PC6001-5C2-D-RP

Figure 1 - Backing Off Rear Brake Shoe Adjustment

Runout Check
Runout for drum assemblies is not to exceed 0.15
mm (0.006 inch).
Balance
During manufacture, weights are used to balance
drum assemblies. These weights must not be removed.
After drum assemblies have been refinished or if dif-
ficulty is experienced in maintaining proper wheel bal-
ance, drum assemblies should be checked for balance.
Drum assemblies may be checked for balance on most
off-the-vehicle wheel balancers.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated shop air on brake
parts as damage to rubber components may result.
I]] Important
• Replace all components included in repair kits used
to service this drum brake.
• Lubricate parts as specified.
• If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake system.
• Replace shoe and lining assemblies in axle sets only.
• The torque values specified are for dry, unlubricated
fasteners.
• Perform service operations on a clean bench, free
from all mineral oil materials.
DRUM ASSEMBLY
Figure 1
I++! Remove or Disconnect
1. Raise and suitably support vehicle. Refer to
SECTION OA.
2. Tire and wheel assembly. Refer to SECTION 3E.
• Mark relationship of wheel to axle flange.
NOTICE: Be careful not to drop the brake drum
assemblies during handling. Out-of-round can occur
 DUO-SERVO DRUM BRAKES 5C2·3

~5
17
12

6 29

22

14
7

30

A SHOE PAD 17 RING, REAR PARKING BRAKE LEVER RETAINER

B ANCHOR PIN 18 NUT, REAR BRAKE SHOE ADJUST
C REAR AXLE ASSEMBLY FLANGE 19 ADJUSTER, REAR BRAKE SHOE
1 SPRING, REAR BRAKE SHOE RETURN 20 VALVE, REAR BRAKE BLEEDER, 6 N•m (53 LB. IN.)
2 SPRING, REAR BRAKE SHOE RETURN 21 BOLT/SCREW, REAR WHEEL CYLINDER,
3 SPRING, REAR BRAKE SHOE HOLD-DOWN 13 N•m (115 LB. IN.)
4 PIVOT, REAR BRAKE SHOE ADJUST ACTUATOR 22 BOOT, REAR WHEEL CYLINDER PISTON
5 PIN, REAR BRAKE SHOE 23 PISTON, REAR WHEEL CYLINDER
6 LINK, REAR BRAKE SHOE ADJUST ACTUATOR 24 SEAL, REAR WHEEL CYLINDER PISTON
7 ACTUATOR, REAR BRAKE SHOE ADJUST 25 SPRING, REAR WHEEL CYLINDER PISTON
8 SPRING, REAR BRAKE SHOE ADJUST 26 BODY, REAR WHEEL CYLINDER
ACTUATOR RETURN 28 CYLINDER, REAR WHEEL
9 STRUT, REAR PARKING BRAKE LEVER 29 PLATE, REAR BRAKE BACKING
10 SPRING, REAR PARKING BRAKE LEVER STRUT 30 SPRING, PARKING BRAKE CABLE RETURN
11 PIN, REAR PARKING BRAKE LEVER PIVOT 31 ADJUSTER ASSEMBLY, REAR BRAKE SHOE
12 LEVER ASSEMBLY, REAR PARKING BRAKE 32 GUIDE, REAR BRAKE SHOE
13 SHOE, REAR BRAKE PRIMARY 34 CAP, BLEEDER VALVE
14 SHOE, REAR BRAKE SECONDARY 35 NUT. REAR.BRAKE BACKING PLATE, 58 N•m (43 LB. FT.I
15 SPRING, REAR BRAKE SHOE ADJUST 36 BOLT/SCREW, REAR BRAKE BACKING PLATE
16 SOCKET, REAR BRAKE SHOE ADJUST

PC0002·5C2·f.RP

Figure 2 - Rear Brake Assembly Components

5C2·4 DUO-SERVO DRUM BRAKES
from even the smallest fall, resulting in brake pulsa-
tion.
NOTICE: Do not pry against the splash shield that
surrounds the backing plate in an attempt to free the
drum assembly. This will bend the splash shield.
3. Drum assembly.
A. Mark relationship of drum assembly to axle
flange.
B. If you have trouble removing rear brake drum
assembly, try the following:
a. Make sure parking brake assembly is
released.
b. Disconnect parking brake cable assem-
blies from equalizer. Refer to SECTION
5F.
c. Remove adjusting hole coyer or knock-
out plate from backing plate (29) and
back off adjusting screw, using screw-
driver and brake adjusting tool.
d. Use rubber mallet to tap geJtly on outer
rim of drum and/or around: inner drum
diameter by axle flange and/br axle pilot,
while pulling outward on drum assembly.
Take care not to deform drum assembly
by excessive use of force.
!++I Install or Connect
1£1 Adjust
• Rear drum brake assemblies. Refer to "Rear
Drum Brake Adjustment" in this section.
1. Drum assembly.
• Align locating marks on drum assembly and
axle flange.
2. Tire and wheel assembly. Refer to SECTION 3E.
• Align locating marks on wheel and axle flange.
• If knockout plate was removed, an adjusting
hole cover, GM P/N 5464803 must be
installed.
• If parking brake cable assemblies were discon-
nected from equalizer, install to equalizer.
3. Lower vehicle.
4. Cycle parking brake lever assembly three times.
PRIMARY AND SECONDARY SHOES
Figures 2 through 4
Tools Required:
J 8049 Brake Spring Remover and Installer
J 8057 Brake Spring Pliers
!++I Remove or Disconnect
I. Drum assembly. Refer to "Drum Assembly" under
"On-Vehicle Service" in this section.
CAUTION: Keep fingers away from rear
brake shoe return springs to prevent
29
A REAR PARKING BRAKE LEVER NOTCH
B REAR PARKiNG BRAKE CABLE END
12 LEVER ASSEMBLY, REAR PARKING BRAKE
13 SHOE, REAR BRAKE PRIMARY
29 PLATE, REAR BRAKE BACKING
30 SPRING, PARKING BRAKE CABLE RETURN
PC0009·5C2-F-RP
Figure 3 - Removing Parking Brake Cable Assembly
fingers from being pinched between
rear brake shoe return spring and shoe
web or return spring and backing plate.
2. Return springs (I and 2) using J 8049.
3. Hold-down springs (3) and pins (5) using suitable
pliers.
4. Actuator pivot (4).
5. Actuator link (6) while lifting up on actuator (7).
6. Actuator (7) and actuator return spring (8).
7. Shoe guide (32), strut (9) and strut spring (10).
8. Primary shoe (13) and secondary shoe (14) from
backing plate (29) and parking brake rear cable
assembly.
9. Adjuster assembly (31) and spring (15).
I 0. Parking brake cable assembly from parking brake
lever assembly (12) by pushing parking brake lever
assembly (12) into parking brake cable return spring
(30). Disengage cable end from parking brake lever
assembly ( 12).
11. Primary shoe (13) with parking brake lever assem-
bly (12) and parking brake cable return spring (30).
12. Parking brake lever assembly (12).
A. Pry open retainer ring ( 17), remove and dis-
card.
B. Push out pivot pin (11).
!~! Clean
1. Adjuster assembly (31 ).
 DUQ-SERVO DRUM BRAKES 5C2·5

B
A STARWHEEL
B PROPER SPRING INSTALLATION
13 SHOE, REAR BRAKE PRIMARY
14 SHOE, REAR BRAK£ SECONDARY
15 SPRING, REAR BRAKE SHOE ADJUST
16 SOCKET, REAR BRAKE SHOE ADJUST
18 NUT, REAR BRAKE SHOE ADJUST
19 ADJUSTER, REAR BRAKE SHOE
31 ADJUSTER ASSEMBLY, REAR BRAKE SHOE

PC0003-5C2-F-RP

Figure 4 - Rear Brake Shoe Adjuster Assembly

A. Clean adjusting screw threads with wire brush.
B. Wash all components in clean denatured
alcohol.
C. Apply brake lubricant, ·GM P/N 9985907 or
equivalent, to adjuster threads, inside diameter
of adjust socket (16) and adjust socket face.
• Adequate lubrication is achieved when a
continuous bead of lubricant is at open
end of adjust nut ( 18) and adjust socket
(16) when threads are fully engaged.
2. Backing plate (29) and lubricate contact surfaces
with brake lubricant, GM P/N 9985907 or equiva-
lent. · 9. Actuator link (6) on anchor pin.
5. Strut (9) and strut spring (10) by spreading primary
shoe (13) and secondary shoe (14) apart. For proper
positioning:
A. Strut end without strut spring (10) engages
parking brake lever assembly (12) and primary
shoe (13) or secondary shoe (14).
B. Strut end with strut spring (10) engages oppo-
site primary shoe (13) or secondary shoe (14).
6. Shoe guide (32).
7. Actuator (7) and actuator return spring (8).
8. Pins (5), actuator pivot (4) and hold-down springs
(3).

!L'l"I Inspect
1. Threads of adjuster (19) for smooth rotation over
full length.
2. All parts.
• If any parts are of doubtful strength or quality
due to discoloration from heat, overstress, or
wear, the parts should be replaced.
!++I Install or Connect
NOTICE: See "Notice" on page 5C2-1 of this sec-
tion.
1. Parking brake lever assembly (12).
A. Insert pivot pin (11) through holes in primary
shoe (13) and parking brake lever assembly
(12).
B. Install and crimp new retainer ring ( 17).
2. Parking brake cable assembly to parking brake lever
assembly ( 12) by pulling back parking brake cable
return spring (30). Engage cable end into parking
brake lever assembly (12).
3. Adjuster assembly (31) and spring (15}.
4. Primary shoe (13) and secondary shoe (14) to back-
ing plate (29) and parking brake rear cable assembly.
10. Actuator link (6) into actuator (7) while holding up
on actuator (7).
11. Return springs (1 and 2) using J 8057.
12. Drum assembly. Refer to "Drum Assembly" under
"On-Vehicle Service" in this section.
WHEEL CYLINDER
Figure 5
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to
SECTION OA.
!r,I Clean
• Dirt and foreign material around wheel cylin-
der (28) and rear brake rear pipe assembly.
2. Primary and secondary shoes. Refer to "Primary
and Secondary Shoes" in this section.
3. Brake pipe fitting and rear brake rear pipe assembly.
• Plug opening in rear brake rear pipe assembly
to prevent brake fluid loss and contamination.
4. Bolts/screws (21).
5. Wheel cylinder (28).
5C2·6 DUO-SERVO DRUM BRAKES

33 DRUM ASS EMBLY, REAR BRAKE PC8005-&C2·D-RP

Figure 6 - Setting Tool to Rear Brake Drum Assembly

2. Primary and secondary shoes. Refer to "Primary

and Secondary Shoes" in this section.
3. Rear axle shaft. Refer to SECTION 4B.
21 BOLT/SCREW, REAR WHEEL CYLINDER, 4. Parking brake cable assembly from rear brake back-
13 N•m (115 LB. IN.)
28 CYLINDER, REAR WHEEL
ing plate. Refer to SECTION 5E
5. Brake pipe assembly from wheel cylinder (28).
PC0004-5C2-F-RP 6. Wheel cylinder. Refer to "Wheel Cylinder" under
Figure 5 - Rear Wheel Cylinder
"On-Vehicle Service" in this section.
7. Backing plate bolts/screws (36) and nuts (35).
8. Backing plate (29) from axle flange.
!++I Install or Connect !++I Install or Connect
NOTICE: See "Notice" on page 5C2-l of this
section. NOTICE: See "Notice" on page 5C2-1 of this
section.
1. Wheel cylinder (28).
1. Backing plate (29) to axle flange.
• Hold in place with wooden block between
wheel cylinder (28) and axle flange. 2. Backing plate bolts/screws (36) and nuts (35).
2. Bolts/screws (21).
l~I Tighten
l~I Tighten • Backing plate nuts (35) to 58 N•m (43 lb. ft.).
3. Wheel cylinder. Refer to "Wheel Cylinder" under
• Bolts/screws (21) to 13 N•m (115 lb. in.).
"On-Vehicle Service" in this section.
3. Rear brake rear pipe assembly.
4. Rear brake rear pipe assembly to wheel cylinder
l~I Tighten
(28).

• Brake pipe fitting to 17 N•m (13 lb. ft.).

4. Primary and secondary shoes. Refer to "Primary
l~I Tighten
• Brake pipe fitting to 17 N•m (13 lb. ft.).
and Secondary Shoes" in this section.
5. Parking brake cable assembly to brnke backing
5. Lower vehicle. plate. Refer to SECTION 5F.
6. Bleed brake hydraulic system. Refer to SECTION 6. Rear axle shaft. Refer to SECTION 4B.
5El.
7. Primary and secondary shoes. Refer to "Primary
and Secondary Shoes" in this section.
BACKING PLATE
8. Bleed brake hydraulic system. Refer to SECTION
Figure 2 5El.

l++I Remove or Disconnect 12) Adjust

I. Raise and suitably support vehicle. Refer to • Rear drum brake assemblies. Refer to "Rear
SECTIONOA. Drum Brake Adjustment" in this section.

9. Lower vehicle.
10. Cycle parking brake lever assembly three times.
REAR DRUM BRAKE ADJUSTMENT
Figures 4, 6 and 7
Tool Required:
J 21177-A Drum-to-Brake Shoe Clearance
Gage
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to
SECTION OA.
2. Tire and wheel assemblies: Refer to SECTION 3E.
• Mark relationship of wheel to axle flange.
3. Drum assemblies. Refer to "Drum Assembly"
under "On-Vehicle Service" in this section.
Ce) Adjust
• Rear brake assemblies.
A. Set J 21177-A so that it contacts inside diame-
ter of drum assembly (33).
B. Position J 21177-A over primary and second-
ary shoes (13 and 14 ).
C. Turn star wheel on adjuster (19) until primary
and secondary shoes (13 and 14) contact
J 21177-A.
• Outside diameter of primary shoe (13)
and secondary shoe (14) will be approxi-
mately 1.27 mm (0.050 inch) less than
inside diameter of drum assembly (33) on
each wheel.
!++I Install or Connect
1. Drum assemblies. Refer to "Drum Assembly"
under "On-Vehicle Service" in this section.
2. Tire and wheel assemblies. Refer to SECTION 3E.
3. Lower vehicle.
4. Make several stops, applying firm force to brake
pedal assembly.
• Repeat until ample pedal reserve is built up.
UNIT REPAIR
DRUM ASSEMBLY
Cracked, Scored or Grooved
A cracked drum assembly is unsafe for further ser-
vice and must be replaced. Do not attempt to weld a
cracked drum assembly.
Smooth up any slight scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it may
be necessary to refinish the drum braking surface.
If the brake linings are slightly worn, but still reus-
able, and the drum assembly is grooved, polish the drum
assembly with fine emery cloth but do not refinish. Elimi-
nating all grooves in the drum assembly and smoothing
DUO-SERVO DRUM BRAKES 5C2·7
19 A
A STARWHEEL
13 SHOE, REAR BRAKE PRIMARY
14 SHOE, REAR BRAKE SECONDARY
19 ADJUSTER, REAR BRAKE SHOE
PC6008-5C2·D·RP
Figure 7 - Setting Rear Brake Primary
and Secondary Shoes to Tool
the ridges on the shoe linings would require removing too
much metal and lining, while if left alone, the grooves and
ridges match and satisfactory service can be obtained.
If brake linings are to be replaced, refinish a grooved
drum assembly. A grooved drum assembly, if used with
new lining, will not only wear the lining, but will make it
difficult, if not impossible, to obtain proper brake perfor-
mance.
Out-of-Round or Tapered
An out-of-round or tapered drum assembly prevents
accurate rear brake shoe adjustment and is likely to cause
excessive wear of other brake parts due to its eccentric
action. An out-of-round drum assembly can also cause
severe and irregular tire tread wear as well as a pulsating
brake pedal assembly. When the drum assembly exceeds
the specification limits in taper and/or out-of-round, refin-
ish drum assembly to true up the braking surface. Out-of-
round as well as taper and wear can be accurately
measured with an inside micrometer and extension rods.
When measuring a drum assembly for out-of-round,
taper, and wear, take measurements at the open and closed
edges of the machined surface and at right angles (90 de-
grees) to each other. ·
Refinishing
All drum assemblies have a maximum diameter cast
into them. This diameter is the maximum wear diameter
and not a refinish diameter. Do not refinish a drum assem-
bly that will not meet the specifications. Refer to "Speci-
fications" at the end of this section.
5C2·8 DUO-SERVO DRUM BRAKES

Any drum assembly that does not 1neet specifica-

tions shown should be replaced.
When refinishing a drum assembly, resurface the
drum assembly to no more than a dimension of 0.76 mm
(0.030 inch) less than the discard diameter. The refinish
diameter is the maximum diameter the drum assembly
should be refinished to, and still allow safe braking action.
If this dimension is exceeded, the drum assembly will
wear beyond the discard diameter during normal brake
wear.
If a drum assembly must be refinished, remove only
enough metal to obtain a true, smooth braking surface. If a
drum assembly does not clean-up when refinished to a
maximum rebore diameter as shown at the end of this sec-
tion, replace it. Removal of more metal will affect heat
dissipation and may cause rear brake drum assembly
distortion.
When refinishing drum assemblies, always use
sharp cutting tools or bits. Dull or worn tools leave a poor 20 VALVE, REAR BRAKE BLEEDER, 6 N•m (53 LB. IN.)
surface finish which will affect initial braking perfor- 22 BOOT, REAR WHEEL CYLINDER PISTON
mance. Vibration dampening attachments should always 23 PISTON, REAR WHEEL CYLINDER
be used when refinishing braking surfaces. These attach- 24 SEAL, REAR WHEEL CYLINDER PISTON
25 SPRING, REAR WHEEL CYLINDER PISTON
ments eliminate tool chatter and will result in better
26 BODY, REAR WHEEL CYLINDER
surface finish. 34 CAP, BLEEDER VALVE

The optimum spindle speed for refinishing braking PCOOOB-5C2-F-RP

surfaces is 200 rpm. Crossfeed for rough cutting should
range from 0.15-0.25 mm (0.006-0.010 inch) per revolu- Figure 8 - Rear Wheel Cylinder Components
tion. Finish cuts should be made at crossfeeds no greater
than 0.05 mm (0.002 inch) per revolution.
WHEEL CYLINDER
After making the finish cuts, sand the brake drum
friction surface for at least 60 seconds. Use 150 grit alumi- Figure 8
num oxide sandpaper on a curved sanding block. Make
smooth in-and-out motions with the block while sanding. !+:+! Disassemble
This procedure will simulate the original factory surface
1. Wheel cylinder completely from vehicle. Refer to
finish.
"Wheel Cylinder" under "On-Vehicle Service" in
this section.
2. Boots (22).
Replacing Drum Assemblies 3. Pistons (23) and seals (24 ).
When installing new drum assemblies, do not refin- 4. Piston spring (25).
ish the braking surface. New drum assemblies have the 5. Bleeder valve cap (34).
correct level of surface finish. 6. Bleeder valve (20) from wheel cylinder body (26).

!l'l"! Inspect
Balance • Wheel cylinder bore for scoring, nicks, con-osion
and wear.
During manufacture, weights are used to balance
drum assemblies. Do not remove these weights.
!t:.W! Clean
After drum assemblies have been refinished, or 1. All parts in clean denatured alcohol.
when maintaining proper wheel balance is difficult, check 2. Dry with unlubricated compressed air.
the drum assemblies for balance. They can be checked on
most off-the-vehicle balancers. If found to be out of bal- 3. Lubricate new seals (24) with clean brake fluid.
ance, replace drum assembly.
NOTICE: Be careful not to drop the brake drum as-
l+!+! Assemble
semblies during handling. Out-of-round can occur NOTICE: See "Notice" on page 5C2-1 of this
from even the smallest fall, resulting in brake section.
pulsation. 1. Bleeder valve (20).
 DUO-SERVO DRUM BRAKES 5C2·9

3. Piston spring (25).

I~! Tighten 4. Seals (24), pistons (23) and boots (22).
• Bleeder valve (20) to 6 N•m (53 lb. in.). 5. Wheel cylinder. Refer to "Wheel Cylinder" under
2. Bleeder valve cap (34). "On-Vehicle Service" in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Rear Wheel Cylinder Bore Diameter ..................................... 20.6 mm (0.81 ")

Brake Lubricant ..................................................... GM PIN 9985907
Rear Brake Drum Assembly
Inside Diameter (Nominal) ........................................ 241.30 mm (9.500")
Runout .......................................................... 0.15 mm (0.006")
Maximum Refinish Diameter ...................................... 242.82 mm (9.560")
Discard Diameter ............................................... 243.59 mm (9.590")
All rear brake drum assemblies have a discard dimension cast into them. This is a wear dimension
and not a refinish dimension. Any rear brake drum assembly which does not meet the specification
should be replaced.

FASTENER TIGHTENING SPECIFICATIONS

Rear Brake Backing Plate Nut ......................................... 58 N•m (43 lb. ft.)
Rear Brake Bleeder Valve .............................................. 6 N•m (53 lb. in.)
Rear Brake Rear Pipe Fitting .......................................... 17 N•m (13 lb. ft.)
Rear Wheel Cylinder Bolt/Screw ...................................... 13 N•m (115 lb. in.)

SPECIAL TOOLS

1. 3. J 21177-A

2. ~ J8057 1. BRAKE SPRING REMOVER AND INST ALLER

2. BRAKE SPRING PLIERS
3. DRUM-TO-BRAKE SHOE CLEARANCE GAGE
PC8008-SC2-D-RP
 VACUUM BOOSTER SYSTEM 501-1

SECTION 501

VACUUM BOOSTER SYSTEM

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 501-1 Vacuum Check Valve .................... 501-4
Power Brake Booster Assembly ........... 501-1 Pushrod Gaging Procedure . . . . . . . . . . . . . . . 501-4
Diagnosis ...................... Refer to Section 5 Specifications ............................ 5Dl-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 501-2 Fastener Tightening Specifications ......... 501-5
Power Brake Booster Assembly ........... 501-2 Special Tools ............................ 501-5
Power Brake Booster
Vacuum Hose and Routing . . . . . . . . . . . . . 501-4

GENERAL DESCRIPTION
POWER BRAKE BOOSTER ASSEMBLY
The power brake booster assembly is a tandem vac-
uum suspended unit. In a normal operating mode, with the
service brakes in the released position, the tandem vac-
uum suspended booster assembly operates with vacuum
on both sides of its diaphragms. When the brakes are
applied, air at atmospheric pressure is admitted to one side
of each diaphragm. The air is then drawn from the booster
through the vacuum check valve to the vacuum source.

A FIPE, AIR INJECTION REACTION

B MANIFOLD, EXHAUST
.C FITTING, EXHAUST MANIFOLD
D FITTING, ENGINE
2 CYLINDER ASSEMBLY, BRAKE MASTER
3 BOOSTER ASSEMBLY, POWER BRAKE
4 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
32 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
33 BODY, BRAKE MASTER CYLINDER
34 RESERVOIR, BRAKE MASTER CYLINDER
PC0001-5D1·f..RP

Figure 1 - Vacuum Booster Hose Routing (5.7L LT1 Engine)

501-2 VACUUM BOOSTER SYSTEM
NOTICE: Internal components of this booster are
not serviceable. The housing must not be unstaked
and separated. Separating the housing will cause
permanent deformation, preventing the booster
assembly from holding proper volume.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated shop air on brake
parts as damage to rubber parts may result.
rn Important
• Replace all components included in repair kits used
to service this booster assembly.
• Lubricate rubber parts with silicone grease to ease
assembly.
• If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of the
brake hydraulic system.
• The torque values specified are for dry, unlubricated
fasteners.
POWER BRAKE BOOSTER ASSEMBLY
Figures 1 through 3
1++1-Remove or Disconnect
1. Secondary air injection system (AIR) pipe from fit-
ting on exhaust manifold, if necessary.
• Move AIR pipe out of the way.
2. Clamp (31) and vacuum hose (30) from check valve
(4).
A FITTING, ENGINE
2 CYLINDER ASSEMBLY, BRAKE MASTER
3 BOOSTER ASSEMBLY, POWER BRAKE
4 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
32 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
33 BODY, MASTER CYLINDER
34 RESERVOIR, BRAKE MASTER CYLINDER
Figure 2 -Vacuum Booster Hose Routing (3.4L L32 Engine)
3. Nuts (1) attaching master cylinder assembly (2) to
booster assembly (3).
4. Master cylinder assembly (2).
• Move .master cylinder assembly (2) forward
and toward driver's side to provide clearance
for booster assembly (3). This will flex brake
pipe assemblies slightly. Take care not to bend
or distort brake pipe assemblies.
5. Lower sound insulator assembly. Refer to SEC-
TION SC.
6. Nuts (5) attaching booster assembly (3) to brake
pedal assembly (20).
7. Loosen nut (40).
8. On vehicle with manual transmission assembly,
loosen nuts (41).
9. Pull back on brake pedal assembly (20) to access
nuts (35).
10. Nuts (35) attaching booster assembly (3) to dash
panel assembly.
• Discard nuts (35) needed for production pur-
poses only.
11. Pushrod (6) from brake pedal pin.
A. From inside vehicle, remove retainer (16) and
washer (15).
B. Tilt entire booster assembly (3) slightly to
work pushrod (6) off brake pedal pin without
putting undue side pressure on pushrod (6).
12. Booster assembly (3) from vehicle.
 VACUUM BOOSTER SYSTEM 501·3

40 5 B

~
<.
j_
"'--
.

10 6

16

A POWER BRAKE BOOSTER PUSHROD INSTALLED TO 15 WASHER, BRAKE PEDAL PUSHROD

BRAKE PEDAL LEVER PIN 16 RETAINER, BRAKE PEDAL PUSHROD
B PANEL ASSEMBLY, DASH 20 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
C PIN, BRAKE PEDAL LEVER CLUTCH (WITH BRACKET)
1 NUT, BRAKE MASTER CYLINDER, 43 N•m (32 LB. FT.) 30 HOSE, POWER BRAKE BOOSTER VACUUM
2 CYLINDER ASSEMBLY, BRAKE MASTER 31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
3 BOOSTER ASSEMBLY, POWER BRAKE 33 BODY, BRAKE MASTER CYLINDER
4 VALVE, POWER BRAKE BOOSTER VACUUM CHECK 34 RESERVOIR, BRAKE MASTER CYLINDER (PUSH-ON)
5 NUT, BRAKE PEDAL BRACKET, 25 N•m (18 LB. FT.) 35 NUT, POWER BRAKE BOOSTER ASSEMBLY
6 PUSHROD, POWER BRAKE BOOSTER 40 NUT, BRAKE PEDAL, 25 N•m (18 LB. FT.)
10 BOLT/SCREW, POWER BRAKE BOOSTER MOUNTING 41 NUT, CLUTCH MASTER CYLINDER, 27 N•m (20 LB. FT.)
PCCICJ03.501 ·f.RP
Fig~re 3 - Removing and Installing Power Brake Booster Assembly
(Manual Transmission Shown - Automatic Transmission Similar)

• Nut (40) to 25 N•m (18 lb. ft.).

l++I Install or Connect • Nuts (41) to 27 N•m (20 lb. ft.) on vehicle with
NOTICE: See "Notice" on page 501-1 of this manual transmission assembly.
section. 4. Master cylinder assembly (2) to booster assembly
1. Booster assembly (3) onto vehicle. (3) and nuts (1).
2. Pushrod (6) to brake pedal pin.
A. Tilt entire booster assembly (3) slightly to l~I Tighten
work pushrod (6) onto brake pedal pin without • Nuts (1) to 43 N•m (32 lb. ft.).
putting undue side pressure on pushrod (6).
5. Vacuum hose (30) and clamp (31) to check valve (4).
B. From inside vehicle, install washer (15) and
retainer (16). 6. Lower sound insulator assembly. Refer to SEC-
TION 8C.
3. Nuts (5).
7. AIR pipe to fitting on exhaust manifold, if removed.
l~I Tighten
l~I Tighten
• Nuts (5) to 25 N•m (18 lb. ft.) in sequence:
inboard upper, outboard lower, outboard • AIR pipe-to-exhaust manifold fitting to
upper, inboard lower. 34 N•m (25 lb. ft.).
501-4 VACUUM BOOSTER SYSTEM

POWER BRAKE BOOSTER VACUUM HOSE

AND ROUTING
Figures 1 and 2
Refer to Figures 1 and 2 for routing of the vacuum
hose (30).

VACUUM CHECK VALVE

Figure4
Vacuum check valve and grommet can be inspected
and/or serviced without removing booster assembly from
vehicle.

l++I Remove or Disconnect

1. Clamp (31) and vacuum hose (30) from check valve
(4).
2. Check valve (4) and grommet (9).

IL•l 1nspect
• Grommet (9) and vacuum hose (30) for cuts, nicks
and excessive wear. 6
- Replace grommet (9) or vacuum hose (30) if
damaged.

~ Clean 3 BOOSTER ASSEMBLY, POWER BRAKE

1. All parts in denatured alcohol.
2. Dry with unlubricated compressed air.
l++I Install or Connect
1. Lubricate inner and outer diameters of grommet (9)
with thin layer of silicone grease GM P/N 12345579
or equivalent.
2. Grommet (9) and check valve (4).
3. Vacuum hose (30) and clamp (31) to vacuum check
valve (4).
4 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
6 PUSH ROD, POWER BRAKE BOOSTER
9 GROMMET, POWER BRAKE BOOSTER VACUUM CHECK .
VALVE
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
PC0005·5D1 ·F·RP
Figure 4 - Vacuum Check Valve and Grommet

PUSHROD GAGING PROCEDURE

Figures
Tool Required:
J 37839 Pushrod Height Gage

lt!lll Measure
1. Gage booster assembly with 85.0 kPa (25 in. Hg.)
vacuum or maximum engine vacuum available.
• Booster assembly can be gaged without being
installed on vehicle, if a suitable vacuum
source is available.
2. Position J 37839 over pushrod (6). 6 PUSHROD, POWER BRAKE BOOSTER
• Check both maximum and minimum rod PC000&-501·1'-RP
length. Figure 5 - Gaging Power Brake Booster Pushrod
3. If pushrod (6) length does not fall between maxi-
mum and minimum dimensions, use a service-
adjustable pushrod to obtain correct length.
 VACUUM BOOSTER SYSTEM 501-5

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Brake Master Cylinder Nut ............................................ 43 N•m (32 lb. ft.)
Brake Pedal Bracket Nut .............................................. 25 N•m (18 lb. ft.)
Brake Pedal Nut .................................................... 25 N•m (18 lb. ft.)
Clutch Master Cylinder Nut ........................................... 27 N•m (20 lb. ft.)
Secondary Air Injection System (AIR) Pipe-to-Exhaust Manifold Fitting ....... 34 N•m (25 lb. ft.)

SPECIAL TOOLS

1.
J37839

0
1. PUSHROD HEIGHT GAGE
PC0010-5D1-f.RP
 ANTILOCK BRAKE SYSTEM 5E1-1

SECTION SE1
ANTILOCK BRAKE SYSTEM
CAUTION: To help avoid personal injury due to poor braking, DO NOT tap into the
vehicle's brake system to operate a trailer brake system.

NOTICE: When fasteners are removed, always install them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reusable, and those requiring thread-locking compound will be called out.
The correct fastener tightening specification must be used when installing fasteners. If the above
conditions are not followed, system damage could result.

NOTICE: The use ofrubber hoses or parts other than those specified for the Antilock Brake System (ABS)
may lead to functional problems requiring replacement of the hydraulic parts. Replace all components
included in repair kits used to service this system. Lubricate rubber parts with clean, fresh brake fluid to
ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result.
If any hydraulic component is removed or brake line disconnected, it is necessary to bleed the entire brake
system. The fastener tightening specifications specified are for dry, unlubricated fasteners.

NOTICE: Use only Supreme 11 (GM 1052542) or equivalent DOT 3 brake fluid. The use of DOT 5
(silicone) brake fluid is not recommended. Reduced braking performance or durability may result.

NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or electrical
connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle,
flush the area with water to lessen the damage.

DELCO CHASSIS ABS VI TECHNICAL ASSISTANCE

For 1994 model year, Delco Chassis Division has an ABS VI field service plan in place. This plan has
been developed to improve customer satisfaction. The plan is set up to help Delco Chassis understand each
field malfunction and to allow us to obtain all of the failed components back for detailed analysis. With
this direct field contact, we are able to continuously improve our ABS system components.

The plan consists of a Technical Assistance Hotline, staffed by Delco Chassis personnel, that you must
phone to create a technical assistance case or to order parts for some ABS VI malfunctions. Please be
prepared to provide specific diagnostic trouble code information, VIN and dealer code when phoning for a
part or for assistance. The phone number is 1-800-523-0203.

CONTENTS
General Description • • • • • • • • • • • • • • • SE 1-3 Spare Tire 5E1-6
Abbreviations/Definitions • • • • • • • • • SE1-3 Replacement Tires ••••••••••• 5E1-6
Basic Knowledge Required • • • • • • • • • SE1-3 System Components ••••••••••••• 5E1-6
System Operation • ••• • •• • • • • • • • SE1-3 Hydraulic Modulator/Motor Pack
Base Braking Mode • • • • • • • • • • • • 5E1-3 Assembly •••••••••••••••• 5E1-7
Antilock Braking Mode ••• • • • • • • 5E1-4 Electronic Brake Control Module
ESB Operation • • • • • • • • • • • • • • • SE 1-5 (EBCM) •••••••••••••••••• 5E1-7
System-SelfTest (Initialization) • • • • 5E1-6 Front Wheel Speed Sensors ••••••• SE1-7
Warning Lamp Operation • • •• • • • SE1-6 Front Wheel Speed Sensor Rings •••• SE1-8
Normal Lamp Operation • • • • • • • 5E1-6 Rear Wheel Speed Sensor and
Tires and ABS • • • • • • • • • • • • • • • • SE 1-6 Rings ••••••••••••••••••• 5E1-8
ABS Enable Relay ••••••••••••• SE1-8
5E1-2 ANTILOCK BRAKE SYSTEM

Brake Combination Valve ••••••• SE1-8 Checking and Adding Fluid •••••••• SE1-168
Wiring Harness ••••••••••••• SE1-8 Flushing Procedure ••••••••••••• SE1-168
Wheel Speed Sensor Pressure Flush •••••••••••••• SE1-170
Jumper Harness •••••••••• SE1-8 Bleeding Procedure •••••••••••• SE1-171
Warning Lamps ••••••••••••• SE1-8 With Tech 1 (Preferred Method) ••• SE1-172
Fuses and Fusible Links ••••••••• SE1-9 Without Tech 1 ••••••••••••• SE1-172
Diagnosis-Electrical •••••••••••••• SE1-9 Rehome Procedure ••••••••••••• SE1-172
Diagnostic Process ••••••••••••• SE1-9 Pressure Bleeding •••••••••••• SE1-172
Self-Diagnostics ••••••••••••••• SE1-9 Hydraulic Modulator •••••••• SE1-172
Displaying Diagnostic Trouble Codes Brake Pipe Connections •••••• SE1-173
(DTCs) ••••••••••••••••••• SE1-9 Wheel Brakes ••••••••••••• SE1-173
Clearing Diagnostic Trouble Codes Manual Bleeding •••••••••••• SE1-176
(DTCs) ••••••••••••••••••• SE1-9 Hydraulic Modulator •••••••• SE1-176
Tech 1 Method •••••••••••••• SE 1-10 Hydraulic Modulator Bleeder Valves •• SE1-176
Ignition Cycle Default ••••••••• SE 1-10 Hydraulic Modulator Solenoid •••••• SE1-176
lntermittents and Poor Connections SE1-10 Hydraulic Modulator/Motor Pack
Tech 1 Diagnostics ••••••••••••• SE1-10 Assembly ••••••••••••••••• SE1-176
Enhanced Diagnostics ••••••••• SE 1-10 Electronic Brake Control
Diagnostic Process (1 of 3) •••••••• SE 1-12 Module (EBCM) ••••••••••••• SE1-177
Diagnostic System Check (1 of 4) SE1-16 Front Wheel Bearing and Speed Sensor
Diagnostic Trouble Code and Assembly ••••••••••••••••• SE1-178
Symptom Table ••••••••••••• SE1-24 Front Wheel Speed
Wiring Diagram (1 of 2) •••••••••• SE1-26 Sensor Jumper Harness ••••••••• SE1-178
EBCM Connector Face View (1 of 2) ••• SE1-28 Rear Wheel Speed Sensor ••••••••• SE1-179
Diagnosis/Misc. Test (F4) ••••••••••• SE1-166 Rear Wheel Speed Sensor
Manual Control (FO) •••••••••••• SE1-166 Toothed Ring •••••••••••••• SE 1-179
Motor Test (Apply/Release) •••••• SE1-166 Rear Wheel Speed Sensor
Solenoid Test ("ON/OFF") ••••••• SE1-166 Jumper Harness ••••••••••••• SE1-179
Hydraulic Control Test (F2) •••••••• SE1-166 Enable Relay ••••••••••••••••• SE1-180
Motor Test (F4) ••••••••••••••• SE1-167 Brake combination valve ••••••••• SE1-180
No Gear Movement •••••••••••• SE1-167 Warning/Indicator Lamps ••••••••• SE1-180
Gear Tension Relief (FS) •••••••••• SE1-167 Electrical Connectors ••••••••••• SE 1-180
Relay Test (F6) •••••••••••••••• SE1-167 Fuse and Fusible Links ••••••••••• SE1-180
Voltage Load Test (F7) ••••••••••• SE1-167 Unit Repair ••••••••••••••••••• SE1-180
Lamp Test (F8) •••••••••••••••• SE1-167 Gear Cover •••••••••••••••••• SE1-180
System Id (F9) •••••••••••••••• SE1-168 Motor Pack •••••••••••••••••• SE1-180
Motor Rehome (FS) •••••••••••• SE1-168 Gear Replacement ••••••••••••• SE1-182
On-Vehicle Service ••••••••••••••• SE1-168 Hydraulic Modulator ••••••••••• SE1-183
Service Precautions ••••••••••••• SE1-168 Master Cylinder ••••••••••••••• SE1-184
Specifications •••••••••••••••••• SE1-184
Fastener Tightening Specifications ••• SE1-184
Special Tools •••••••••••••••••• SE1-184
 ANTILOCK BRAKE SYSTEM 5E1-3

GENERAL DESCRIPTION
ABBREVIATIONS/DEFINITIONS

Several abbreviations are commonly used

throughout this section. They are presented here for
reference.
ABS • • • • • • •
• • • • • Anti lock Brake System
B+ • • • • • •
• • •• • •• ••• Battery Voltage
CKT • • • • • • •
• • • • • • • • • • • • • • • Circuit
CPA • • • • • • •
Connector Position Assurance
DLC • • • • •
• •• •• • • •Data Link Connector
DTC • • • • • • •
• • • Diagnostic Trouble Codes
DVM • • • • • •
• • •• •• • • Digital Multimeter
EBCM • • • • •
Electronic Brake Control Module
ESB • • • •
• •• • •• • Expansion Spring Brake
8
Infinite • • •Open Circuit/Unmeasurably High
• •
Resistance
MSC •••• •• • • •• • Mass Storage Cartridge

BASIC KNOWLEDGE REQUIRED

Before using this section, it is important that you
have a basic knowledge of the following items.
Without this basic knowledge, it will be difficult to use
the diagnostic procedures contained in this section.
If you need a review of basic electrical
troubleshooting knowledge, SECTION SA contains
helpful information in the introduction. Basic use of
circuit testing tools is also covered in SECTION SA.
Additionally, electrical/electronic courses are offered
through General Motors Service Training.
• Basic Electrical Circuits - You should understand
the basic theory of electricity and know the
meaning of voltage, current (amps) and resistance
(ohms). You should understand what happens in a
circuit with an open or shorted wire. You should
be able to read and understand a wiring diagram.
• Use of Circuit Testing Tools - You should know
how to use a test light and how to use jumper wires
to bypass components to test circuits. You should
be familiar with the High Impedance Multimeter
(DVM) J 39200. You should be able to measure
voltage, resistance and current and be familiar
with the meter controls and how to use them
correctly.
[I] Important
• When measuring the resistance to ground of a
circuit or component, make sure to use a solid,
unpainted chassis ground or the negative battery
terminal.
CHECK VALVE OPEN
2 BRAKE PRESSURE FROM COMBINATION VALVE
3 OPEN SOLENOID
4 PISTON
5 BALL SCREW NUT
6 BALL SCREW SPINDLE
7 ABS MOTOR PACK
8 EXPANSION SPRING BRAKE (ESB)
9 BRAKE PRESSURE TO FRONT BRAKE
NS 16301
Figure 1 • Front Base Braking Mode
SYSTEM OPERATION
Base Braking Mode
Under normal operating conditions, the brake
systems will operate using conventional braking by
means of brake pedal force, the vacuum booster, and
the compact master cylinder. Each front channel
consists of a motor, solenoid, ESB, ball screw, piston,
and check valve. As illustrated in Figure 1, under
normal operating conditions (base brakes), the piston
is held in the upmost (or "home") position and the
solenoid is open (not energized). This is accomplished
by turning the ball screw via the motor to drive the nut
upwards. Once at the upmost position, the piston is
held by an Expansion Spring Brake (ESB). Two paths
are available to transfer braking pressure to the
wheel: (1) through the modulator, around the check
valve, and out to the wheel, (2) through the modulator,
past the normally open solenoid, and out to the wheel.
5E1-4 ANTILOCK BRAKE SYSTEM
MOTOR DRIVES
CLOCKWISE
4
MOTOR DRIVES
COUNTERCLOCKWISE
9
5
8
Figure 2 - Expansion Spring Brake
The solenoid in the front circuits provides an alternate
brake pressure path to the wheel. With this
arrangement, if the ABS were to lose power or
malfunction with the piston not in its home position, a
redundant brake fluid path is available. Refer to
Figure 1.
The rear channels operate in a similar manner
except no solenoid exists.
Antilock Braking Mode
ABS VI has been designed to improve the
controllability and steerability of a vehicle during
brak,ing. ABS VI accomplishes this objective by
controlling the hydraulic pressure applied to each
wheel brake. Antilock braking occurs only when the
brake switch is closed and a microprocessor, located in
the EBCM, determines one or more wheels is about to
lose traction during braking. The EBCM will then
allow the hydraulic modulator to change the brake
pressures several times each second to keep the
wheel(s) from locking and provide the driver with
maximum vehicle controllability. ABS VI CANNOT
INCREASE THE BRAKE PRESSURE ABOVE THE
MASTER CYLINDER PRESSURE APPLIED BY
THE DRIVER, AND CANNOT APPLY THE
BRAKES BY ITSELF.
The result is greatly improved braking, enabling
the driver to more easily maintain steerability and to
bring the vehicle to a controlled stop. ABS VI provides
MOTOR DRIVE DOG RELEASES
SPRING BRAKE AND DRIVES PINION
2 CIRCLIP
3 MOTOR PINION
4 PINION DRIVE DOG
5 EXPANSION SPRING BRAKE (ESB)
6 MOTOR DRIVE DOG
7 MOTOR SHAFT
8 STEEL SLEEVE
MOTOR DRIVE DOG RELEASES SPRING BRAKE
9 (SPRING LEG BENE A TH PINION DOG)
AND DRIVES PINION
PINION DOG EXPANDS SPRING AND
10 LOCKS AGAINST SLEEVE
MS 12381
effective braking and directional control over a wide
range ofroad surfaces and driving conditions.
If any wheel(s) begins to approach lock-up, the
EBCM will control the three (3) motors and two (2)
solenoids, appropriately, to control brake pressure to
the affected wheel(s). During front wheel ABS
operation, the solenoids are turned "ON" to isolate
that brake pressure path to the wheel (see Figure 3).
The EBCM then provides controlled current to the
motors to regulate the speed and amount of movement.
As the motors move backwards, the piston follows the
nut downward, allowing the check valve to seat. The
brake pressure to the wheel is now a function of the
controlled volume within the piston chamber. To
reduce brake pressure, the motor drives the nut
further downward. To reapply or increase brake
pressure, the motor drives the nut and piston upward.
If ABS was entered during low brake pressure, such as
on ice, and dry pavement is then encountered during
reapply, the piston is driven all the way to the top.
This results in the unseating of the check valve, and a
return to base brakes until sufficient brake pressure
exists to cause the wheel to approach lock-up again.
At this point, the ABS cycle would start again. This
process can occur in less than one second if the driver
is pressing firmly on the brake pedal.

1 CHECK VALVE CLOSED 6 BALL SCREW NUT IN
"MODULATION" POSITION
SOLENOID VALVE EXPANSION SPRING . 3
2 CLOSED 7 BRAKE {ESB)
3 BRAKE PRESSURE FROM B ABS MOTOR PACK
COMBO VALVE
9 BRAKE PRESSURE
4 MODULATION
CHAMBER TO FRONT BRAKE
PISTON IN
5 "MODULATION"
POSITION NS 16299
Figure 3 • Front ABS Braking Mode
Total brake pressure dui;ing ABS is limited to the
brake pressure present when ABS was entered. Also,
anytime wheel brake pressure exceeds the brake
pressure at the master cylinder (caused by reduced
force on the brake pedal), the check valve unseats and
a small volume of brake fluid is returned to the master
cylinder. In this manner, ABS VI CANNOT
INC,REASE BRi\KE P,RESSURE ABOVE MASTER
CYLINDER PRESSURE APPLIED BY THE DRIVER
AND CANNOT APPLY THE BRAKES BY ITSELF.
· When ABS is no longer required, the pistons are
returned to their upmost (or "home") position and .are
held by the ESBs (refer to "ESB Operation," found in
this section). The solenoids on the front channels are
simultaneously opened to again provide a redundant
base braking path.
The rear channel operates in a similar manner
except no solenoid is used (refer to Figure 4). Both rear
brake pressures are controlled by the same motor and
both rear brake pressures are controlled together. If
ANTILOCK BRAKE SYSTEM SE1-5
INLET FROM COMBO VALVE
• •
RHR LHR
CHECK VALVES CLOSED
2 MODULATED PRESSURE TO REAR BRAKES
PISTON LOWERED
4 EXPANSION SPRING BRAKE (ESB) LOCATION
5 MOTOR PINION
YOKE ON BALL SCREW DRIVES BOTH REAR
6 CIRCUIT PISTONS
7 MODULATION CHAMBER
NS 16300
Figure 4 • Rear ABS Braking Mode
either rear wheel begins to lock, brake pressure to both
.rear wheels is reduced to maximize vehicle stability.
There is no rear solenoid due to the nature of the
braking system. The vast majority of braking is
accomplished with the front brakes. If an ABS failure
were to occur that affected the operation of the rear
base brakes, a diagnostic trouble code would be stored
and the EBCM would turn "ON" both the "ABS !NOP"
lamp and the "BRAKE" warning lamp.
ESB OPERATION
The Expansion Spring Brake (ESB) is used to hold
the piston in the upmost (or "home") position. An ESB
is a spring that is retained in a housing at a close
tolerance. One end of the spring is in contact with the
motor drive dog and the other end is in contact with
the pinion di;ive dog (refer to Figure 2). In normal
braking, brake pressure is present on the top of the
piston, applying a down~ard force.
SE1-6 ANTILOCK BRAKE SYSTEM
The force applies a counterclockwise torque to the
motor pinion which tries to rotate the spring
counterclockwise. The counterclockwise torque
expands the spring outward within the housing and
prevents gear rotation.
When the motor is turned "ON" and tries to drive
the ball screw nut, the end of the ESB in contact with
the motor drive dog rotates inward causing the spring
to contract in its housing allowing the motor to rotate
the modulator gear (refer to Figure 2). The most
common application of this principle is in window
crank mechanisms, where a small amount of force on
the crank handle allows the window to be lowered or
raised, but the weight of the window or force on the
window will not allow the window to move downward.
For the ESB, brake pressure on the top of the pistons
corresponds to the weight of the window and the motor
corresponds to the window crank handle.
SYSTEM - SELF TEST (INITIALIZATION)
During initialization, the EBCM will not only
perform self-diagnostics, but will also verify motor,
modulator, solenoid, relay, and lamp operation to
ensure all components are functioning properly. The
EBCM also checks the wheel speed sensor circuitry for
open circuits and shorts to ground or voltage at this
time. If the EBCM detects a malfunction in either
itself or other ABS VI components, it will store a
Diagnostic Trouble Code (DTC) and turn "ON" the
ABS warning lamp ("ABS INOP") if applicable. The
"ABS INOP" warning lamp will be "ON" for about 3
seconds with the key in the "RUN" position. During
cranking the ABS warning lamp will be "ON" and
then remain "ON" for about 3 seconds after the engine
starts. A slight mechanical noise may be heard during
the system initialization, which is normal. The entire
initialization is run about 2-3 seconds after the engine
starts. If your foot is on the brake pedal when the
engine is started, the system will not initialize until
your foot is removed or 5 km/h (3 mph) is reached. If
foot pressure on the pedal interrupts the system
initialization, a slight movement in the pedal may be
felt.
Warning Lamp Operation
Normal Lamp Operation
The standard brake system uses a single red
"BRAKE" warning lamp located in the instrument
panel cluster.
The antilock brake system uses the same red
"BRAKE" warning lamp, an amber ABS warning
lamp ("ABS INOP"), and an amber ABS active lamp
("LOW TRAC").
1. When the ignition is turned to the "RUN" position,
the "ABS INOP", "LOW TRAC", and "BRAKE"
lamps all turn "ON" for approximately three
seconds, then turn "OFF."
2. As the engine is cranked, both the "ABS INOP"
lamp and the "BRAKE" lamp will turn "ON" and
remain "ON."
3. After the engine is started, the "ABS INOP",
"LOW TRAC", and "BRAKE" lamps will be "ON"
for approximately three seconds then turn "OFF."
4. Anytime the EBCM determines that the vehicle
has entered a braking event where ABS is
required, the "LOW TRAC" lamp will turn "ON" to
indicate that ABS is active. The "LOW TRAC"
lamp will remain "ON" for approximately 3 to 4
seconds after the ABS event is completed.
For further information regarding "ABS INOP",
"LOW TRAC", and "BRAKE" lamp operation, refer to
"Warning Lamps" in this section.
Tires and ABS
Spare Tire
Using the compact spare supplied with the vehicle
will not affect the operation of ABS. The EBCM
software can compensate for this smaller tire.
However, increased stopping distances may occur due
to reduced tire tread depth on compact spare tires.
Replacement Tires
Tire size is important for proper performance of the
ABS. Replacement tires should be the same size load
range and construction as the original tires. Replace
tires in axle sets and only with tires of the same TPC
(Tire Performance Criteria) specification number. Use
of any other tire size or type may seriously affect the
ABS operation. For more information on original
equipment and replacement tires, refer to SECTION
3E.
SYSTEM COMPONENTS
The ABS VI Antilock Braking System (ABS)
consists of a conventional hydraulic brake system plus
antilock components. The conventional brake system
includes a vacuum power booster, master cylinder,
front disc brakes, rear disc or drum brakes,
interconnecting hydraulic brake lines, low fluid
sensor, and a red "BRAKE" warning lamp.
The ABS components include a hydraulic
modulator/motor pack assembly, an Electronic Brake
Control Module (EBCM), a system enable relay, three
wheel speed sensors, interconnecting wiring, an amber
ABS warning lamp, and an amber ABS active lamp
(refer to Figure 5).

MODULATOR ASSEMBLY
(REMOTE MOUNTED AT LEFT
FRONT UNDERHOOD)
LAMP DRIVER MODULE
(INTEGRATED INTO I.P. CLUSTER)
ENABLERELAV ~
(IN A RELAY CENTER MOUNTED
TO THE LEFT FRONT FENDER
UNDER HOOD)
Figure 5 - ABS-VI Component Location View
Hydraulic Modulator/Motor Pack Assembly
The hydraulic modulator/motor pack assembly
controls hydraulic pressure to the front calipers and
rear wheel cylinders or calipers by modulating
hydraulic pressure to prevent wheel lock-up. The
basic hydraulic modulator configuration consists of
gear subassemblies, ball screws, nuts, pistons, and
hydraulic check valves. The motor pack consists of
three motors, three drive gears, and three ESBs. For
more information, refer to "Base Braking Mode" and
"Antilock Braking Mode" in this section.
Electronic Brake Control Module {EBCM)
The controlling element of ABS VI is a
microprocessor based Electronic Brake Control
Module, or EBCM. Inputs to the system include three
wheel speed sensors, the brake switch, ignition switch,
and unswitched battery voltage. Outputs include
three bidirectional motor controls, three lamp controls,
two solenoid controls, and the system enable relay. A
bidirectional serial data line, located in pin "M" of the
Data Link Connector (DLC), is provided for service
diagnostic tools and assembly plant testing.
The EBCM monitors the speed of each wheel. If
any wheel begins to approach lock-up and the brake
switch is "ON," the EBCM controls the motors and
solenoids to reduce brake pressure to the wheel
approaching lock-up. Once the wheel regains traction,
ANTILOCK BRAKE SYSTEM SE1-7
EBCM
(ABOVE DRIVER'S SIDE KICK PANEL)
NS 16302
brake pressure is increased until the wheel again
begins to approach lock-up. This cycle repeats until
either the vehicle comes to a stop, the brake is
released, or no wheels approach lock-up. Additionally,
the EBCM monitors itself, each input (except the
serial data link) and each output for proper operation.
If any system malfunction is detected, the EBCM will
store a OTC in nonvolatile memory (DTCs will not
disappear if the battery is disconnected). Refer to
"Self-Diagnostics" in this section for more detailed
information.
NOTICE: There is no serviceable or removable
PROM. The EBCM must be replaced as an
assembly.
Front Wheel Speed Sensors
The front wheel speed sensors consist of a variable
reluctance sensor. The sensor and toothed ring are
pa.rt of the hub and bearing assembly. As teeth pass by
the sensor, an AC voltage with a frequency
proportional to the speed of the wheel is generated.
The magnitude of the voltage increases with
increasing speed. The sensor is not repairable, nor is
the air gap adjustable. The entire front bearing
assembly must be replaced.
SE1-8 ANTILOCK BRAKE SYSTEM
Front Wheel Speed Sensor Rings
The front wheel speed sensor toothed rings are an
integral part of the hub and bearing assembly. Like
the front wheel speed sensors themselves, they are not
serviceable. If a malfunction is detected in either the
sensor or the toothed ring, the entire hub and bearing
assembly must be replaced.
Rear Wheel Speed Sensor and Ring
A single rear wheel speed sensor is used for this
ABS application and is located on the rear differential.
It operates in the same manner as the front wheel
speed sensors, refer to ."Front Wheel Speed Sensors."
However, the toothed ring is located within the rear
differential and contains 106 equally spaced teeth.
The sensor and toothed ring are not repairable and no
provision for air gap adjustment exists.
ABS Enable Relay
The ABS enable relay is a normally-open contact
type, and has special contact material to handle the
high currents required for ABS VI operation. The
relay allows battery voltage and current to be supplied
to the EBCM, which supplies power to the motors and
solenoids.
Brake Combination Valve
Refer to "Brake Combination Valve" in SECTION
5A.
Wiring Harness
The wiring harness is the mechanism by which the
EBCM is electrically connected to power and ground,
wheel speed sensors, motors, solenoids, fuses, switches,
lamps, the enable relay and the serial communications
port. The components, considered part of the wiring
harness, are the wires that provide electrical
interconnection and connectors/terminals that provide
an electrical/mechanical interface from the wire to a
system component.
Wheel Speed Sensor Jumper Harness
Between each wheel speed sensor and the main
wiring harness is a jumper harness made up of highly
flexible twisted pair wiring. This wiring exists
because the main harness must connect to the
suspension of the vehicle, thus the wiring in this area
is subjected to the same motion as a spring or shock
absorber.
Consequently, any repair to this section of wiring will
result in stiffening and therefore, eventual failure due
to wire fatigue. For this reason, THE WHEEL SPEED
SENSOR JUMPER HARNESSES ARE NOT
REPAIRABLE AND MUST BE REPLACED. DO
NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP
THESE HARNESSES AS EVENTUAL FAILURE
WILL LIKELY RESULT. Refer to "On-Vehicle
Service" in this section.
Warning Lamps
The Electronic Brake Control Module (EBCM)
continuously monitors itself and the other ABS
components. If the EBCM detects a problem with the
system, the "ABS INOP" lamp will either flash or light
continuously (solid lamp) to alert the driver of the
problem. The "ABS INOP" lamp will flash if the
EBCM attempts to turn "ON" the red "BRAKE"
warning lamp in conjunction with the "ABS INOP"
lamp and is unable to do so. The lamp is flashed to
warn the driver that an ABS malfunction exists which
may have degraded base brake performance. The
vehicle must be serviced immediately to regain full
base and ABS braking ability.
CAUTION: The braking system may not
be working properly if the "ABS INOP"
lamp is flashing. Driving with a flashing
"ABS INOP" lamp can lead to an accident.
If the "ABS INOP" lamp is flashing, pull
safely off the road and have the vehicle
towed for service.
A solid "ABS INOP" lamp indicates that a problem
has been detected that affects the operation of ABS.
No antilock braking will be available. Normal, non-
antilock brake performance will remain. In order to
regain ABS braking ability, the ABS must be serviced.
The red "BRAKE" warning lamp will be
illuminated when a low brake fluid level in the master
cylinder is sensed, the parking brake switch is closed,
the bulb test switch section of the ignition switch is
closed, or under control of the EBCM when certain
ABS DTCs are set. This lamp indicates to the driver a
base brake problem may exist.
The "LOW TRAC" indicator lamp is used to alert
the driver when ABS is active. Anytime the EBCM
determines that the vehicle has entered a braking
event where ABS is required, the "LOW TRAC" lamp
will turn "ON" to indicate that ABS is active. The
"LOW TRAC" lamp will remain "ON" for
approximately 3 to 4 seconds after the ABS event is
completed.

Fuses and Fusible Links
The vehicle's power distribution system consists of
fuses, fusible links, circuit breakers, and the ignition
switch. Fusible links are short pieces of wire several
sizes smaller than the circuit wire to which they
supply power. They are covered with special high
temperature insulation. When conducting an
improperly high current flow, they will melt and stop
current flow. They are designed to protect the
vehicle's electrical system from electrical shorts in
circuits that are not protected by circuit breakers or
fuses. For fuse and fusible link locations, refer to
SECTIONS SA-10 and 8A-ll.
DIAGNOSIS-ELECTRICAL
DIAGNOSTIC PROCESS
When servicing the ABS, the following steps
should be followed in order. Failure to follow these
~teps may result in the loss of important diagnostic
data and may lead to difficult and time-consuming
diagnosis procedures:
1. Perform a vehicle preliminary diagnosis
inspection. This should include:
• Inspection of the master cylinder fluid
reservoir for proper brake fluid level and
signs of contamination.
• Inspection of the hydraulic modulator for
any leaks or wiring damage.
• Inspection of brake components at all four
wheels. Verify no drag exists. Also, verify
proper brake apply operation.
• Inspection for worn or damaged wheel
bearings that may allow a wheel to
"wobble."
• Inspection of the wheel speed sensors and
their wiring. Verify proper solid sensor
attachment, undamaged sensor toothed
ring, and undamaged wiring, especially at
vehicle attachment points.
• Verify proper outer CV joint alignment
and operation.
• Verify tires meet legal tread depth
requirements.
2. Perform "Diagnostic System Check" found in
this section. If any DTCs are displayed, select
"Fl: DTC History" to note the last
malfunction that occurred. Diagnose and
repair this malfunction first.
3. If no DTCs are present, or mechanical
component malfunctions are present, or if the
failure is intermittent and not reproduceable,
test drive the vehicle while using the
automatic snapshot feature of the Tech 1.
Perform normal acceleration, stopping, and
turning maneuvers. If this does not reproduce
ANTILOCK BRAKE SYSTEM 5E1-9
the malfunction, perform an ABS stop, on a
low coefficient surface such as gravel, from
approximately 48-80 km/h (30-50 mph) while
triggering the snapshot mode on any ABS
DTC. If the failure is still not reproduceable,
use the enhanced diagnostic information found
in DTC HISTORY to determine whether or not
this malfunction should be diagnosed further
based on frequency of failure. Refer to
"Enhanced Diagnostics" found.in this section.
4. Once all system malfunctions have been
corrected, clear the ABS DTCs.
SELF-DIAGNOSTICS
The EBCM contains sophisticated on-board
diagnostics that, when accessed with a Tech 1 or T-100
(this service manual is written for the use of Tech 1),
are designed to identify the source of any system
malfunction as specifically as possible, including
whether or not the malfunction is intermittent. There
are 53 diagnostic trouble codes to assist with
diagnosis.
When using the Tech 1 with ABS VI, the last
diagnostic trouble code is specifically identified, and
specific ABS data is stored at the time of this
malfunction. Also, in addition to the last DTC set,
there is information about the first five DTCs set.
Using the Tech 1, each input and output can be
monitored, thus enabling malfunction confirmation
and repair verification. Manual control of components
and automated functional tests are also available
when using the Tech 1. Details of many of these
functions are contained in the following sections.
DISPLAYING DIAGNOSTIC TROUBLE CODES
(DTCs)
Diagnostic trouble codes can be read through the
use of the Tech 1 scan tool. There are no provisions for
"Flash Code" diagnostics.
CLEARING DIAGNOSTIC TROUBLE CODES
(DTCs)
The DTCs in EBCM memory are erased in one of
two ways:
1. Tech 1.
2. Ignition cycle default.
These two methods are detailed below. Be sure to
verify proper system operation and absence of DTCs
when the clearing procedure is completed.
The EBCM will not permit DTC clearing until all
DTCs have been displayed. Also, DTCs cannot be
cleared by unplugging the EBCM, disconnecting the
battery cables, or turning the ignition "OFF" (except
on an ignition cycle default).
SE1-10 ANTILOCK BRAKE SYSTEM
Tech 1 Method
Select "F2: DTC(s)" for diagnostic trouble codes.
After DTCs have been viewed completely, Tech 1 will
ask, "CLEAR DTCs"?; answer "YES." Tech 1 will
then read, "HISTORY DATA WILL BE LOST.
CLEAR DTCs"? Answer "YES" and DTCs will be
cleared.
Ignition Cycle Default
If no diagnostic trouble codes occur for 100 drive
cycles [a drive cycle occurs when the ignition is turned
"ON" and the vehicle is driven faster than 16 km/h (10
mph)], any existing DTCs are automatically cleared
from the EBCM memory.
INTERMITTENTS AND POOR CONNECTIONS
As with most electronic systems, intermittent
malfunctions may be difficult to accurately diagnose.
The following is a method to try to isolate an
intermittent malfunction, especially wheel speed
circuitry.
If an ABS malfunction occurs, the ABS warning
lamp will be "ON" during the ignition cycle in which
the malfunction was detected. If it is an intermittent
problem which seems to have corrected itself (ABS
warning lamp "OFF"), a diagnostic trouble code will be
stored. Also stored will be the history data of the DTC
at the time the malfunction occurred. The Tech 1 must
be used to read DTC history data.
Most intermittents are caused by faulty electrical
connections or wiring. Refer to "Intermittents and
Poor Connections" in SECTION SA-4 for a very
detailed explanation of how to locate and repair
intermittent conditions.
TECH 1 DIAGNOSTICS
The Tech 1, when plugged into the DLC, becomes
part of the vehicle's electronic system. The Tech 1 can
perform the following functions:
• Display ABS data.
• Display and clear ABS diagnostic trouble
codes.
• Control ABS components.
• Perform extensive ABS diagnosis.
• Provide diagnostic testing for intermittent
ABS conditions.
Each test mode has specific diagnosis capabilities
which depend upon various keystrokes. In general,
five keys control sequencing: "YES," "NO," "EXIT,"
up arrow and down arrow. The FO through F9 keys
select operating modes, perform functions within an
operating mode, or enter DTC or model year
designations.
In general, the Tech 1 has six test modes for
diagnosing the ABS. The six test modes are as follows:
• MODE FO: DATA LIST - In this test mode, the
Tech 1 continuously monitors wheel speed
data, brake switch status and other inputs and
outputs.
• MODE F1: OTC HISTORY - In this mode, DTC
history data is displayed. This data includes
how many ignition cycles since the DTC
occurred, along with other information for the
last DTC set. The first five and last DTC set
are included in the DTC history data.
• MODE F2: DIAGNOSTIC TROUBLE CODES - In
this test mode, diagnostic trouble codes stored
by the EBCM, both current ignition cycle and
history, may be displayed or cleared.
• MODE F3: SNAPSHOT - In this test mode, the
Tech 1 captures data before and after a system
malfunction (auto trigger) from a forced
manual key press, or from a DTC setting.
• MODE F4: MISC. TESTS - In this test mode, the
Tech 1 performs various ABS functional tests
to assist in problem isolation during
troubleshooting.
• MODE FS: MOTOR REHOME - In this mode,
the Tech 1 commands the EBCM to rehome the
motors on the hydraulic modulator/master
cylinder assembly. This mode should ALWAYS
be used prior to bleeding the brake system.
Enhanced Diagnostics
Enhanced diagnostic information, found in the
DTC HISTORY function of the Tech 1, is designed to
provide the service technician with specific
malfunction occurrence information. For each of the
first five and the very last diagnostic trouble code
stored, data is stored to identify the specific OTC, the
number of occurrences, and the number of drive cycles
since the malfunction first and last occurred [a drive
cycle occurs when the ignition is turned "ON" and the
vehicle is driven faster than 16 km/h (10 mph)].
However, if a malfunction is present, the drive cycle
counter will increment by turning the ignition "ON"
and "OFF." These first five diagnostic trouble codes
are also stored in the order of occurrence. The order in
which the first five DTCs occurred can be useful in
determining if a previous malfunction is linked to the
most recent malfunction, such as an intermittent
wheel speed sensor which later becomes completely
open.
During difficult diagnosis situations, this
information can be used to identify malfunction
occurrence trends. Did the malfunction only occur
once over a large number of drive cycles, indicating an
unusual condition present when it occurred?

Does the malfunction occur infrequently over a large
number of drive cycles, indicating that special
diagnosis techniques may be required to identify the
source of the malfunction?
If, for example, a malfunction occurred 1 out of 50
drive cycles, the malfunction is intermittent and has
not recurred for 49 drive cycles. This malfunction may
be difficult or impossible to duplicate and may have
been caused by a severe vehicle impact (large pot hole,
speed bump at high speed, etc.) that momentarily
opened an electrical connector or caused unusual
vehicle suspension movement. Problem resolution is
unlikely, and the problem may never recur (check
diagnostic aids provided for that DTC). If, for example,
the malfunction occurred 3 out of 15 drive cycles, the
odds of finding the cause are still not good, but you
know how often it occurs.
ANTILOCK BRAKE SYSTEM SE1-11
If the malfunction occurred 10 out of 20 drive cycles,
the odds of finding the cause are very good, as the
malfunction may be easily reproduced.
By using the additional malfunction data, you can
also determine if a malfunction is randomly
intermittent or if it has not recurred for long periods of
time due to weather changes or a repair prior to this
visit. Say a DTC occurred 10 of 20 drive cycles but has
not recurred for 10 drive cycles. This means the
malfunction occurred 10 of 10 drive cycles but has not
reoccurred since. A significant environmental change
or a repair may have occurred 10 drive cycles ago. A
repair may not be necessary if customer information
can confirm a recent repair. If no repair was made, the
service technician can focus on diagnosis techniques
used to locate difficult-to-recreate problems, such as
those suggested in "Diagnostic Aids" for the DTC in
question.
SE1-12 ANTILOCK BRAKE SYSTEM

DIAGNOSTIC PROCESS
(Page 1 of 3)

MSC CHASSIS APPLICATION SELECTION TECH 1 SCREEN DISPLAY

STEP 1 SELECT VEHICLE MODEL YEAR MODEL YEAR: 19??

STEP 2 SELECT VEHICLE TYPE "FO: PASSENGER CAR"

STEP 3 SELECT BODY TYPE

STEP 4 SELECT MODE (FIRST SCREEN)

--. FRONT WHL SPEEDS
REAR WHL SPEEDS
FO: DATA LIST
VEHICLE SPEED
ABS WARNING LAMP
INFORMATION ABOUT LF ABS MOTOR CMD
F1: OTC HISTORY
PREVIOUS DTCs STORED LF ABS MTR FDBK
RF ABS MOTOR CMD
RF ABS MTR FDBK
F2: DTC(s) DTCs STORED AND CLEAR DTCs
REAR ABS MTR CMD
REAR ABS MTR FBK
LF SOLENOID CMD
F3: SNAPSHOT SNAPSHOT OPTIONS
RF SOLENOID CMD
FO: REPLAY DATA
BRAKE SWITCH
F1: MANUAL TRIG.
ABS RELAY CMD
F4: MISC•. TESTS F2: AUTO TRIG.
BRK WARN LP CMD
F3: ANYDTC
BRAKE WARN LAMP
F4: SINGLE OTC
EBCM BAT VOLTAGE
FS: MOTORREHOME F9: TRIG.POINT
EBCM IGN VOLTAGE
•
FO: BEGINNING
F1: CENTER
F2: END OF DATA

~
I
CONTINUED ON FOLLOWING 1
I
CHART I
I
(PAGE 2 OF 3)
~---------------------~
1 1

REHOMES MOTORS PRIOR TO

BLEEDING THE BRAKE SYSTEM.

6-11-93
MS 12563
 ANTILOCK BRAKE SYSTEM 5E1-13

DIAGNOSTIC PROCESS
(Page 2 of 3)

r-----------------------,
: CONTINUED FROM PREVIOUS CHART :
~
1---------------------- J
(PAGE 1 OF 3)

MISC. TESTS I
I
r- --- --------------------------,
FO: MANUAL CNTRL CONTINUED ON FOLLOWING CHART (PAGE 3 OF 3) '
L--------------------------------J
I MANUAL TEST OF MODULA TOR
F2: HYDRL. CNTRL
I HYDRAULICS-APPLY/HOLD/RELEASE FUNCTIONS I
F4: MOTOR TEST :. ABS MOTOR PACK DIAGNOSIS
I
I PREPARE ABS MODULATOR FOR OFF VEHICLE
FS: GEAR TEN REL
I SERVICE I
I
F6: RELAY TEST I TEST OF ENABLE RELAY I
F7: VOLTAGE LOAD I TEST FOR ADE QUA TE BATTERY CAPACITY FOR ABS
I OPERATION
I
I MANUAL CONTROL OF THE "ABS INOP," "LOW
FS: LAMP TEST
I TRAC,.. AND RED "BRAKE" LAMPS I
I
F9: SYSTEM ID I SYSTEM NUMBER
I

7-6-93
NS 15761
5E1-14 ANTILOCK BRAKE SYSTEM

DIAGNOSTIC PROCESS
(Page 3 of 3)

I
CONTINUED FROM I
PREVIOUS CHART I
I
(PAGE 2 OF 3) I
--,-------------- J

MANUAL CONTROL
OF SOLENOIDS
AND MOTORS.
I

t = TURN ON
i = TURNOFF
YES TO CONTINUE
I
SELECT FUNCTION
FO: LFAPPLY
F1: LF RELEASE
F2: LFSOLENOID
F4: RF APPLY
F5: RF RELEASE
F6: RF SOLENOID
FS: REAR APPLY
F9: REAR RELEASE
I
MOTOR APPLY
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
•
MOTOR RELEASE
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
I
SOLENOID
COMMAND: ON/OFF
ABS RELAY: ON/OFF

6-11-93
MS 12565
 ANTILOCK BRAKE SYSTEM 5E1-15

BLANK
SE1-16 ANTILOCK BRAKE SYSTEM

REFER TO EBCM
DATA LINK CONNECTOR SECTION SA-50
(DLC)

~
C1

B+
(REFER TO
11 r I IMrcJ---soOTAN---S-2.. t---=~A!2~-sooTAN
C200A
SERIAL DATA LINE

SECTION C200D
SA-10) UNDERHOOD ELECTRICAL CENTER
r-----------------------,
FUSIBLE ABS BAT
LINK "K" FUSE 1
502RED---+-----~-----+-------4400RN BATTERY FEED
~NIT~N 5AMP
(REFER TO

L
SECtlON SA-10-3) ABS IGN
FUSES
300 ORN----t--fT ~~---------t----------541 BRN SWITCHED
IGNITION

-------1632PNK- ABS ENABLE

RELAY CONTROL

302RED~ 1633 RED SWITCHED

C1
302RED :
:
\

5175 ABS ENABLE RELAY

t
5180
1633 RED BATTERY INPUT

L-----------------------J ABS SOLENOIDS

r.------1-651 BLKJWHT GROUND

-L 5111
C2
G101 6-29-93
PS18838

DIAGNOSTIC SYSTEM CHECK

(Page 1 of 4)
System Description:
The diagnostic system check is an organized approach to identifying a problem created by an Antilock Brake
System (ABS) malfunction. It must be the starting point for any ABS complaint diagnosis because it directs the
service technician to the next logical step in diagnosing the complaint.
Serial data is transmitted by the EBCM through terminal "All". The EBCM is supplied switched ignition
voltage through terminal "811", battery voltage through terminal "810" and switched battery voltage through
terminal "D". The EBCM ground is provided through terminal "E".

Chart Test Description: Number(s) below refer to Diagnostic Aids: Excessive resistance in the
circled number(s) on the diagnostic chart. ground or power supply circuits will not allow
1. Indicates if EBCM is transmitting data. communication with the EBCM. If communication
2. Checks for a serial data line malfunction. with the EBCM is not possible, ensure the ABS ground
3. Checks for proper Tech 1 connection to DLC. connection is good and that there is no excessive
4. Checks for open ABS BAT 5 amp Fuse 1. resistance in any of the power supply circuits.
5. Checks for open ABS ION 5 amp Fuse 5.
6. Checks for high resistance in the EBCM ground
circuit.
7. Checks for current DTCs.
8. Checks for proper ABS warning lamp operation.
9. Checks for history DTCs.
 ANTILOCK BRAKE SYSTEM 5E1-17

DIAGNOSTIC SYSTEM
0 • •
VERIFY ALL EBCM CONNECTORS ARE CONNECTED PROPERLY.
INSTALL TECH 1. CHECK
• IGNITION "ON."
• WITHIN ABS PORTION OF MASS STORAGE CARTRIDGE CHASSIS (Page 1 of 4)
APPLICATION, SELECT "FO: DATA LIST."
IS DATA BEING RECEIVED FROM THE EBCM?

NOTICE: ENSURE MASS STORAGE CARTRIDGE IS

UPDATED TO INCLUDE THE LATEST AVAILABLE
VERSION OF THE CHASSIS APPLICATION.
DOES TECH 1 SELECT "F2: OTC(s)."
DISPLAY "NO ARE ANY CURRENT DTCs DISPLA YEO?
COMMUNICATIO
N WITH VEHICLE.
CHECKOLC
r ------,
CONNECTOR"?
: REFERTO : IGNITION "OFF" FOR 10 SECONDS.
I APPLICABLE I TURN IGNITION "ON" AND OBSERVE "ABS INOP" LAMP.
: OTC CHART. : DID LAMP ILLUMINATE FOR 3 SECONDS AND THEN GO "OFF"?
L--------J

0 • SELECT "F1: DTC HISTORY."

ARE ANY HISTORY DTCs PRESENT?

r ---------,r ----------~
ENSURE TECH 1
DLC CONNECTOR
: REFER TO :
: SECTION :
TO FURTHER
DIAGNOSE
REVIEW
"ENHANCED : :gRT'?A~~~=~:.. ! :gRT'~~~~=~:..
IS CONNECTED I BA-50. 1 CUSTOMER DIAGNOSTICS" : LAMP "ON" OR I LAMP "ON"
PROPERLY TO L-------.1 COMPLAINT, INFORMATION : "OFF" : INTERMITTENTLY
DLC. REFER TO INTHIS I CONSTANTLY, I , NO DTCs
IS CONNECTION "DIAGNOSTIC SECTION. : NO OTCs : STORED.
GOOD? PRO.CE SS," STORED.
IL___________ J '------------
STEP 3, IN THIS
SECTION.

IGNITION "OFF." RECONNECT TECH 1 DLC CONNECTOR.

REMOVE ANO INSPECT ABS/BAT FUSE 1, 5 AMP. RETURN TO FIRST STEP IN THIS CHART.
IS FUSE BLOWN?

INSTALL ABS/BAT FUSE 1,:; AMP. : GO TO PAGE 2 OF 4 :

REMOVE AND INSPECT ABS/IGN FUSE 5, 5 AMP. : OF THIS DIAGNOSTIC :
IS FUSE BLOWN? I SYSTEM CHECK. I
L---------------'
©• •
DISCONNECT NEGATIVE BATTERY CABLE.
INSTALL ABS/IGN FUSE 5, 5 AMP.
: GOTOPAGE30F4 :
: OF THIS DIAGNOSTIC :
• DISCONNECT 8-WAY EBCM CONNECTOR. I SYSTEM CHECK. 1
• USING J 39200, MEASURE RESISTANCE BETWEEN THE NEGATIVE BATTERY L--------------J
TERMINAL AND 8-WA Y EBCM HARNESS CONNECTOR TERMINAL "E ".
IS RESISTANCE 20 OR LESS?

r ----------------------------------,
: GO TO PAGE 4 OF 4 OF THIS DIAGNOSTIC SYSTEM CHECK. : REPAIR OPEN OR HIGH RESISTANCE
~------------------------------------~ IN CKT 651. RETURN TO FIRST STEP
IN THIS CHART. 7-14-93
NS 15700
SE1-18 ANTILOCK BRAKE SYSTEM

REFER TO EBCM
DATA LINK CONNECTOR SECTION SA-50
{DLC)

I I IM@J---soo
C1

S+
{REFER TO
@1 11 T A N - - --)•- - - ~A12
5 25
C200A
~-soo TAN SERIAL DATA LINE

SECTION C200D
SA-10) UNDERHOOD ELECTRICAL CENTER
r--------------- -------,
FUSIBLE ABS BAT :
LINK "K" FUSE 1
502RED---;,-----~~------;--------4400RN BATTERY FEED
IGNITION 5 AMP
(REFER TO

L
SECtlON SA-10-3) ABS IGN
FUSES
3000RN~-+--, ~.....- - - - - - - - - ; - - - - - - - ~ 6 4 1 B R N SWITCHED
IGNITION

ABS ENABLE
1632PNK- 83 RELAY CONTROL
FUSIBLE
LINK " B e " 302 RED 1633 RED SWITCHED
t--\
302 RED --'-1 - - - - ' - C1
t 1633 RED BATTERY INPUT

'
: SHS ABS ENABLE RELAY 5180
I
L----------------------- ABS SOLENOIDS

_I_ t
5111
651 BLKJWHT GROUND

C2
G101 6-29-93
PS18838

DIAGNOSTIC SYSTEM CHECK

(Page 2 of 4)
System Description:
The diagnostic system check is an organized approach to identifying a problem created by an Antilock Brake
System (ABS) malfunction. It must be the starting point for any ABS complaint diagnosis because it directs the
service technician to the next logical step in diagnosing the complaint.
Serial data is transmitted by the EBCM through terminal "All". The EBCM is supplied switched ignition
voltage through terminal "Bll", battery voltage through terminal "BlO" and switched battery voltage through
terminal "D". The EBCM ground is provided through terminal "E" .

Chart Test Description: Number(s) below refer to
circled number(s) on the diagnostic chart.
10. Checks for possible short to ground in the battery
feed circuitry.
11. Checks for possible short to ground in the EBCM.
12. Ensures short to ground is not due to physical
damage of the circuitry.
.Diagnostic Aids: Excessive resistance in the
ground or power supply circuits will not allow
communication with the EBCM. If communication
with the EBCM is not possible, ensure the ABS ground
connection is good and that there is no excessive
resistance in any of the power supply circuits.

r--------------------------,
: CONTINUED FROM DIAGNOSTIC SYSTEM :
I CHECK (PAGE 1 OF 4) 1
L -------------------------~
@ • REPLACE ABS BAT 5 AMP FUSE 1.
• WAIT 10 SECONDS.
• REMOVE AND INSPECT ABS BAT 5 AMP FUSE 1.
IS FUSE BLOWN?
@ • DISCONNECT 32-WAY EBCM CONNECTOR.
• REPLACE ABS BAT 5 AMP FUSE 1.
• WAIT 10 SECONDS.
• REMOVE AND INSPECT ABS BAT 5 AMP FUSE 1.
IS FUSE BLOWN?
: REFER TO SECTION SA TO DIAGNOSE :
: FOR A SHORT TO GROUND IN THE I
I BATTERY FEED CIRCUITRY. :
L-----------------------~
ANTILOCK BRAKE SYSTEM 5E1-19
DIAGNOSTIC SYSTEM CHECK
(Page 2 of 4)
NO
• INSTALL FUSE.
• REFER TO SECTION SA TO DIAGNOSE
FOR A POSSIBLE SHORT TO GROUND IN
BATTERY FEED CIRCUITRY. RETURN TO
FIRST STEP IN THIS CHART.
@ • INSPECT CKT 440 AND 32-WA Y EBCM HARNE SS
CONNECTOR FOR PHYSICAL DAMAGE WHICH MAY
RESULT IN A SHORT TO GROUND WITH THE
32-WAY EBCM HARNESS CONNECTOR CONNECTED
TO THE EBCM. CORRECT DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS
• WAIT 10 SECONDS.
• REMOVE AND INSPECT ABS BAT 5 AMP FUSE 1.
IS FUSE BLOWN?
• REPLACE EBCM.
• REPLACE ABS BAT 5
AMP FUSE 1. RETURN
TO FIRST STEP IN THIS
CHART.
7.3.93
PS 18924
SE1-20 ANTILOCK BRAKE SYSTEM

REFER TO EBCM
DATA LINK CONNECTOR SECTION 8A-50
{DLC)
C1

B+
{REFER TO
[i 11 r I IM'31---800TAN---S-2.. t-s--~A.!.2 ~-800TAN
C200A
SERIAL DATA LINE

SECTION C200D
8A-10) UNDERHOOD ELECTRICAL CENTER
r-----------------------,
FUSIBLE ABS BAT
LINK "K" FUSE 1
502 R E D - - - + - - - - - f l ' " ' v , - - - - - - + - - - - - - - 4 4 0 ORN BATTERY FEED
IGNITION 5 AMP
(REFER TO

L
SECTION BA-10-3) ABS IGN
FUSES
300 O R N - - - + - ~ ' - ~ . - - - - - - - - - - i - - - - - - - - 5 4 1 BRN SWITCHED
IGNITION

ABS ENABLE
1632 PNK- Bl RELAY CONTROL
FUSIBLE
L I N K " B ~ 3 0 2 R E D ~ C1 1633 RED SWITCHED
'--302RED~\
: 5175 ABS ENABLE RELAY
t
5180
1633 RED BATTERY INPUT

I I
L-----------------------J ABS SOLENOIDS

__[_ t
5111'
651 BLKJWHT GROUND

C2
G101 6-29-93
PS 18838

DIAGNOSTIC SYSTEM CHECK

(Page 3 of 4)
System Description:
The diagnostic system check is an organized approach to identifying a problem created by an Antilock Brake
System (ABS) malfunction. It must be the starting point for any ABS complaint diagnosis because it directs the
service technician to the next logical step in diagnosing the complaint.
Serial data is transmitted by the EBCM through terminal "Al 1". The EBCM is supplied switched ignition
voltage through terminal "Bll", battery voltage through terminal "BlO" and switched battery voltage through
terminal "D". The EBCM ground is provided through terminal "E".

Chart Test Description: Number(s) below refer to
circled number(s) on the diagnostic chart.
13. Checks for possible short to ground in the switched
ignition circuitry.
14. Isolates the short to ground to either the circuitry
ortheEBCM.
15. Ensures short to ground is not due to physical
damage of the circuitry.
Diagnostic Aids: Excessive resistance in the
ground or power supply circuits will not allow
communication with the EBCM. If communication
with the EBCM is not possible, ensure the ABS ground
connection is good and that there is no excessive
resistance in any of the power supply circuits.
 ANTILOCK BRAKE SYSTEM SE1-21

DIAGNOSTIC SYSTEM CHECK

(Page 3 of 4)

r------------------,
: CONTINUED FROM :
• DIAGNOSTIC SYSTEM CHECK I
: (PAGE 1 OF 4) :
~ ----------------~

'13' • REPLACE 5 AMP ABS IGN FUSE 5.

~ • IGNITION "ON."
• WAIT 10 SECONDS THEN TURN IGNITION "OFF."
• REMOVE AND INSPECT 5 AMP ABS IGN FUSE ~·
IS FUSE BLOWN?

@• DISCONNECT32-WAY EBCMCONNECTOR. INSTALL 5 AMP ABS IGN FUSE 5.

• REPLACE 5 AMP ABS IGN FUSE 5.
• IGNITION "ON."
• WAIT 10 SECONDS THEN TURN IGNITION "OFF."
• REMOVE AND INSPECT 5 AMP ABS IGN FUSE 5.
IS FUSE BLOWN?
REFER TO SECTION SA TO
DIAGNOSE FOR A POSSIBLE SHORT·
TO GROUND IN THE SWITCHED
IGNITION CIRCUITRY. RETURN TO
FIRST STEP IN THIS CHART.

• INSPECT CKT 641 AND 32-WAY .EBCM HARNESS CONNECTOR FOR PHYSICAL : REFER TO SECTION SA TO REPAIR
DAMAGE WHICH MAY RESULT IN A SHORT TO GROUND WITH THE 32-WAY EBCM : A SHORT TO GROUND IN ONE OF
HARNESS CONNECTOR CONNECTED TO THE EBCM. CORRECT DAMAGE IF EVIDENT. I THE CKT 641 BRANCHES EXITING
• RECONNECT ALL CONNECTORS. : THE 5 AMP ABS IGN FUSE 5.
• IGNITION "ON." : REPLACE 5 AMP ABS IGN FUSE 5.
• WAIT 10 SECONDS THEN TURN IGNITION "OFF." I RETURN TO THE FIRST STEP IN
• REMOVE AND INSPECT 5 AMP ABS IGN FUSE 5. : THIS CHART.
IS FUSE BLOWN?

REPLACE EBCM. REPLACE

5 AMP ABS IGN FUSE 5.
RETURN TO FIRST STEP IN
THIS CHART.

7-7-93
PS 18932
5E1-22 ANTILOCK BRAKE SYSTEM

REFER TO EBCM
DATA LINK CONNECTOR SECTION 8A-50
(DLC)
C1

B+
(REFER TO
@11 r I IJ~----800TAN---S-2.. t-5--~A2_2~-sooTAN
C200A
SERIAL DATA LINE

SECTION C200D
8A-10) UNDERHOOD ELECTRICAL CENTER

FUSIBLE
r-----------------------,
ABS BAT
LINK "K" FUSE 1
502 R E D - - - + - - - - - A J , - - - - - - - - ; , - - - - - - - 4 4 0 ORN BATTERY FEED
IGNITION 5 AMP
(REFER TO

L
SECtlON 8A·10-3) ABS IGN
FUSES
300 O R N - - - + - - . r ' - . , - . - - - - - - - - - - t - - - - - - - - 6 4 1 BRN SWITCHED
IGNITION

ABS ENABLE
1632 PNK- 83 RELAY CONTROL
30.l RED--T---. 1633 RED SWITCHED
1633 RED BATTERY INPUT
302 RED --'-1- - - '
I
I
I 5180
I

L-----------------------J ABS SOLENOIDS

_L
t.
5111
651 BLK/WHT GROUND

C2
G101 6-29-93
PS 18838

DIAGNOSTIC SYSTEM CHECK

(Page 4 of 4)
System Description:
The diagnostic system check is an organized approach to identifying a problem created by an Antilock Brake
System (ABS) malfunction. It must be the starting point for any ABS complaint diagnosis because it directs the
service technician to the next logical step in diagnosing the complaint.
Serial data is transmitted by the EBCM through terminal "All". The EBCM is supplied switched ignition
voltage through terminal "Bll", battery voltage through terminal "BlO" and switched battery voltage through
terminal "D". The EBCM ground is provided through terminal "E".

Chart Test Description: Number(s) below refer to
circled number(s) on the diagnostic chart.
16. Checks for an open in CKT 440 or 502.
17. Checks for proper battery voltage at the EBCM.
18. Checks for high resistance in the battery feed
circuitry.
19. Ensures malfunction is not due to poor terminal
contact.
20. Checks for high resistance in the switched ignition
circuit between the fuse block and the EBCM.
Diagnostic Aids: Excessive resistance in the
ground or power supply circuits will not allow
communication with the EBCM. If communication
with the EBCM is not possible, ensure the ABS ground
connection is good and that there is no excessive
resistance in any of the power supply circuits.
 ANTILOCK BRAKE SYSTEM 5E1-23

DIAGNOSTIC SYSTEM CHECK

{Page 4 of 4)
r--------------------,
: CONTINUED FROM :
I DIAGNOSTIC SYSTEM CHECK I
: (PAGE 1 OF 4)
~-- -----------------~
@• DISCONNECT 32-WAY EBCM CONNECTOR.
• USING J 39200, MEASURE VOLTAGE BETWEEN GROUND AND 32-WAY
EBCM HARNESS CONNECTOR TERMINAL "810".
IS VOLTAGE GREATER THAN 10 VOLTS?

®••
DISCONNECT POSITIVE BATTERY CABLE.
USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE BATTERY CABLE
REPAIR OPEN IN CKT 440. RETURN
TO FIRST STEP IN THIS CHART.
TERMINAL AND 32-WAY EBCM HARNESS CONNECTOR TERMINAL "810".
IS RESISTANCE 20 OR LESS?

@ • IGNITION "ON." (THIS IS DONE TO PROVIDE CIRCUIT CONTINUITY.) REPAIR HIGH RESISTANCE
• USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE BATTERY CABLE IN CKT 440. RETURN TO
TERMINAL AND 32-WAY EBCM HARNESS CONNECTOR TERMINAL "811 ". FIRST STEP IN THIS CHART.
IS RESISTANCE 20 OR LESS?

@ • INSPECT EBCM AND EBCM

CONNECTOR TERMINALS FOR
®•
POOR TERMINAL CONTACT.
• INSPECT BATTERY TERMINALS
AND BATTERY CABLE TERMINALS
FOR A POOR CONNECTION.
REFER TO SECTION SA-4,
"CHECKING TERMINAL
0
CONTACT.
IS POOR TERMINAL CONTACT OR
A POOR CONNECTION EVIDENT?
•
IGNITION "OFF."
REMOVE ABS IGN 5 AMP FUSE 5.
• USING J 39200, MEASURE
RESISTANCE BETWEEN EACH ABS
IGN 5 AMP FUSE 5 BLOCK TERMINAL
AND 32-WAY EBCM HARNESS
CONNECTOR TERMINAL "811 ".
IS RESISTANCE 20 OR LESS FOR
EITHER MEASUREMENT?

~ ----------------------,:
: REFER TO SECTION SA TO REPAIR
I OPEN OR HIGH RESISTANCE
: BETWEEN POSITIVE BATTERY CABLE
: TERMINAL AND ABS IGN 5 AMP
I FUSE 5 BLOCK TERMINAL. RETURN
: TO THE FIRST STEP IN THIS CHART.
~-----------------------~
REPAIR OPEN OR HIGH
I RESISTANCE IN CKT641.
: INSTALL ABS IGN 5 AMP
: FUSE 5. RETURN TO FIRST
I STEP IN THIS CHART.
:

~
:•
-----------------------~
RECONNECT EBCM CONNECTORS : REPLACE TERMINALS OR REPAIR
I AND BATTERY CABLES. PROCEED I POOR CONNECTION INTEGRITY.
: TO SECTION SA-50. : RETURN TO FIRST STEP IN THIS CHART.
L-------------------------~
7-9-93
PS 18933
5E1-24 ANTILOCK BRAKE SYSTEM

DIAGNOSTIC TROUBLE CODE AND SYMPTOM TABLE

PAGE#
CHART SYMPTOM

A "ABS INOP" Lamp "ON" or "OFF" Constantly, No DTCs Stored SE1-24

B "ABS INOP" Lamp "ON" Intermittently, No DTCs Stored SE1-25
c "Low TRAC" Indicator Lamp "ON" With Ignition "OFF," No DTCs SE1-26
Stored
D Tech 1 Displays Undefined DTCs SE1-27

DIAGNOSTIC DESCRIPTION
TROUBLE CODE

11 ABS Warning or Low Trac Lamp Ckt Malfunction (1 of 2) SE1-28

14 ABS Enable Relay Contact Circuit Open (1 of 3) SE1-32
15 ABS Rly Contact Ckt Short to Batt or Always Closed SE1-38
16 ABS Enable Relay Coil Circuit Open SE1-40
17 ABS Enable Relay Coil Circuit Shorted to Gnd SE1-42
18 ABS Enable Relay Coil Circuit Shorted to Batt SE1-44
21 Left Front Wheel Speed = O SE1-46
22 Right Front Wheel Speed = O SE1-50
24 RearWheelSpeed = O SE1-54
25 Left Front Excessive Wheel Speed Variation SE1-58
26 Right Front Excessive Wheel Speed Variation SE1-62
28 Rear Excessive Wheel Speed Variation SE1-66
32 LF Wheel Speed Snr Ckt Open or Short to Gnd/Batt ( 1 fo 3) SE1-70
33 RF Wheel Speed Snr Ckt Open or Short to Gnd/Batt (1 of 3) SE1-72
35 RR Wheel Speed Snr Ckt Open or Short to Gnd/Batt (1 of 3) SE1-74
36 Low System Voltage (1 of 2) SE1-76
37 High System Voltage 5E1-78
38 Left Front ESB Will Not Hold Motor SE1-80
41 Right Front ESB Will Not Hold Motor SE1-82
42 Rear ESB Will Not Hold Motor 5E1-84
44 Left Front ABS Channel Will Not Move SE1-86
45 Right Front ABS Channel Will Not Move SE1-98
46 Rear ABS Channel Will Not Move SE1-90
47 Left Front ABS Motor Free Spins (1 of 2) SE1-92
48 Right Front ABS Motor Free Spins (1 of 2) SE1-96
51 Rear ABS Motor Free Spins (1 of 2) SE1-100
52 Left Front ABS Channel in Release Too Long SE1-104
53 Right Front ABS Channel In Release Too Long SE 1-106
54 Rear ABS Channel in Release Too Long SE1-108
55 EBCM Malfunction SE1-110
56 Left Front ABS Motor Circuit Open SE1-112
57 Left Front ABS Motor Circuit Shorted to Gnd SE1-114
58 Left Front ABS Motor Circuit Shorted to Batt SE1-116
 ANTILOCK BRAKE SYSTEM SE1-25

DIAGNOSTIC TROUBLE CODE AND SYMPTOM TABLE

PAGE#
DIAGNOSTIC DESCRIPTION
TROUBLE CODE

61 Right Front ABS Motor Circuit Open 5E1-118

62 Right Front ABS Motor Circuit Shorted to Gnd 5E1-120
63 Right Front ABS Motor Circuit Shorted to Batt 5E1-122
64 Rear ABS Motor Circuit Open 5E1-124
65 Rear ABS Motor Circuit Shorted to Ground 5E1-126
66 Rear ABS Motor Circuit Shorted to Battery 5E1-128
76 Left Front Sol Circuit Open or Shorted to Batt SE 1-130
77 Left Front Solenoid Circuit Shorted to Gnd 5E1-132
78 Right Front Sol Circuit Open or Shorted to Batt SE 1-134
81 Right Front Solenoid Circuit Shorted to Gnd 5E1-136
82 Calibration Malfunction 5E1-138
86 EBCM Turned "ON" the Red "BRAKE" Warning Lamp 5E1-140
87 Red "BRAKE" Warning Lamp Circuit Open 5E1-142
88 Red "BRAKE" Warning Lamp Ckt Shorted to Batt 5E1-144
91 Open Brake Switch During Deceleration 5E1-146
92 Open Brake Switch When ABS Was Required 5E1-148
93 DTC 91 or 92 Set in Current or Prev. lgn. Cycle 5E1-150
94 Brake Switch Contacts Always Closed 5E1-152
95 Brake Switch Circuit Open SE1-154
96 Rear Brake Lamp Circuit Open SE 1-156
5E1-26 ANTILOCK BRAKE SYSTEM

EBCM
DATA LINK CONNECTOR SEl.ftJ:Jf.so
{DLC)

~
C1

11 r I IM~. - - - - - 8 0 0 T A N - - - s.....
J.5---'~A~2~-----sooTAN
C200A
SERIAL DATA LINE

C200D
INSTRUMENT
CLUSTER

BRAKE WARNING
LAMP CONTROL

ABS ACTIVE LAMP

CONTROL

.. ____ ...
ABS WARNING
LAMP CONTROL

C200D
C200A

TO
CHMSL TO CRUISE
B+ BULBS CONTROL
{REFER TO {REFER TO TERMINAL "G"
SECTION (REFER TO

1
SECTION
SA-10) SA-110-1) SECTION SA-34)
[1~~!~~ STOP HAZARD t
1---• 1
'c:2 -
I,.; :...1
1~~ ~
20 AMP
140 ORN
·~
BJ L-? :-?
L- :.J c r
Ls20 YEL ~4Us20 YEL
5243 L .J s211
BRAKE SWITCH
INPUT
C200A BRAKE SWITCH C200D
C200D C200A

UNDERHOOD ELECTRICAL CENTER

r-----------------------,
FUSIBLE :
ABS BAT
LINK "K" IFUSE 1
502RED----i:c--------,~-------i--------4400RN BATTERY FEED
IGNITION : SAMP
(REFER TO I
SECtlON SA-10-3)
L 3000RN
1 ABS IGN
FUSES :
"LJ..-.,..._.--------;-------~641BRN SWITCHED
IGNITION

ABS ENABLE
1632 PNK- B3 RELAY CONTROL

302 RED 1633 RED SWITCHED

302 RED I
I
I
I
'C1

5175
ABS ENABLE RELAY
t
5180
1633 RED BATTERY INPUT

I
L-----------------------J ABS SOLENOIDS

_L 5111
1 651 BLK/WHT GROUND

C2
G101

6-29-93
NS 15663
Figure 6 -Wiring Diagram (1 of 2)
 ANTILOCK BRAKE SYSTEM 5E1-27

ABS JUMPER HARNESS

LF WHEEL SPEED
SIGNAL LOW

i---- 873 WHT

830 BLK ------~Bl- E1 =================~-
... 830873 YEL
LT BLU
LF WHEEL SPEED
SIGNAL HIGH
C120
LF WHEEL SPEED SENSOR

ABS JUMPER HARNESS

RF WHEEL SPEED

E1 ======~::::_-_-_-_-_-~-
SIGNAL LOW
i----- 833 BLK ----IE]BA...... 833 TAN Rf WHEEL SPEED
872 WHT 872 DK GRN SIGNAL HIGH
C130

RF WHEEL SPEED SENSOR

ABS JUMPER HARNESS r- - - r- - -

1---- 882 WHT ~ 882 BRN +a+- 882 BRN

REAR WHEEL SPEED
SIGNAL HIGH

. 883 BLK ~ 883 WHT ._

.__...,
tat--
__ 883 WHT
REAR WHEEL SPEED
SIGNAL LOW

REAR WHEEL SPEED SENSOR C405B C200A

C405C C200D

- - - - - - 1 2 8 8 DK GRN LF ABS SOLENOID

651 BLKIWHT CONTROL

- - - - - - 1 2 8 9 LT BLU RF ABS SOLENOID

CONTROL
C1

6101
7-10-93
NS 15664

Figure 7 • Wiring Diagram (2 of 2)

5E1-28 ANTILOCK BRAKE SYSTEM

r c:::l c:n
u,
A1 I n. . ~n.rt.;.
I-A16

rn rn rn rn rn rn rn rn rn rn rn rn rn rn rn rn
~@@@@@@@@@~~@@@~~
@@~~@@@~@@~@@~~~-
[] rn rn rn rn [] UJ [] rn rn [] UJ UJ mUJm
~
~
~
,L- - _J L
B1 t B16

EBCM 32-WAY CONNECTOR

CONNECTOR
TERMINAL CIRCUIT NO. COLOR CIRCUIT DESCRIPTION

A1 PLUGGED NOT USED

A2 PLUGGED NOT USED
A3 833 TAN RF WHEEL SPEED SIGNAL LOW
A4 872 DKGRN RF WHEEL SPEED SIGNAL HIGH
AS 883 WHT REAR WHEEL SPEED SIGNAL LOW
A6 882 BRN REAR WHEEL SPEED SIGNAL HIGH
A7 873 YEL LF WHEEL SPEED SIGNAL LOW
AS 830 LT BLU LF WHEEL SPEED SIGNAL HIGH
A9 1289 LTBLU RF ABS SOLENOID CONTROL
A10 PLUGGED NOT USED
All 800 TAN SERIAL DATA LINE
A12 PLUGGED NOT USED
A13 PLUGGED NOT USED
A14 PLUGGED NOT USED
A15 PLUGGED NOT USED
A16 PLUGGED NOT USED
81 1288 DKGRN LF ABS SOLENOID CONTROL
82 867 LTGRN ABS WARNING LAMP CONTROL
83 1632 PNK ABS ENABLE RELAY CONTROL
84 33 TAN/WHT BRAKE WARNING LAMP CONTROL
85 1537 DKBLU ABS ACTIVE LAMP CONTROL
86 PLUGGED NOT USED
87 PLUGGED NOT USED
88 PLUGGED NOT USED
89 PLUGGED NOT USED
810 440 ORN BATTERY FEED
811 641 BRN SWITCHED IGNITION
812 820 YEL BRAKE SWITCH INPUT
813 PLUGGED NOT USED
814 PLUGGED NOT USED
815 PLUGGED NOT USED
816 PLUGGED NOT USED

6-24-93
NS 15735

Figure 8- EBCM Connector Face View (1 of 2)

 ANTILOCK BRAKE SYSTEM SE1-29

EBCM 8-WAY CONNECTOR

PIN CIRCUIT NO. COLOR CIRCUIT

A 1280 BLK LFABS MOTOR HIGH

B 1281 PNK LF ABS MOTOR LOW
c 1284 DKGRN REAR ABS MOTOR HIGH
D 1633 RED SWITCHED BATTERY
E 651 BLK/WHT GROUND
F 1285 ORN REAR ABS MOTOR LOW
G 1282 PPL RF ABS MOTOR HIGH
H 1283 BLK RF ABS MOTOR LOW

6-23-93
NS 15736
Figure 9 - EBCM Connector Face View (2 of 2)
5E1-30 ANTILOCK BRAKE SYSTEM

CHART A
"ABS INOP" LAMP "ON" OR "OFF"
CONSTANTLY, NO DTCs STORED

NOTICE: DIAGNOSTIC SYSTEM CHECK

MUST BE COMPLETED BEFORE USING
THIS CHART.

• IGNITION "OFF."
• INSTALL TECH 1.
• IGNITION "ON."
• USING TECH 1, SELECT "F4: MISC. TESTS."
• SELECT "FS: LAMP TEST" AND ATTEMPT TO TURN "ON"
THE "ABS INOP" LAMP.
DID THE "ABS INOP" LAMP TURN "ON"?

• USING TECH 1 LAMP TEST, ATTEMPT

TO "FLASH" THE "ABS INOP" LAMP.
DID THE" ABS INOP" LAMP "FLASH"?

MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENTS INSPECT THE "ABS INOP" BULB
COULD BE CAUSED BY INCORRECT WIRING HARNESS ROUTING TO VERIFY BULB IS GOOD.
OR LOOSE CONNECTIONS. INSPECT ALL CONNECTORS AND REPLACE ANY BLOWN BULBS. IF
TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE OF BULB IS GOOD, REFER TO
CORROSION. REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF SECTION SA-81 FOR FURTHER
POOR TERMINAL CONTACT OR CORROSION. DIAGNOSIS OF INSTRUMENT
CLUSTER.

7-2-93
NS 16310
 ANTILOCK BRAKE SYSTEM SE1-31

CHARTB
NOTICE: DIAGNOSTIC SYSTEM ·· ABS 1Nop·· LAMP ··oN··
CHECK MUST BE COMPLETED
BEFORE USING THIS CHART. INTERMITTENTLY. NO DTCs STORED

8 •
•
IGNITION "OFF."
DISCONNECT 8-WA Y EBCM CONNECTOR .
•
•
DISCONNECT NEGATIVE BATTERY TERMINAL.
DISCONNECT POSITIVE BATTERY TERMINAL.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN THE NEGATIVE BATTERY CABLE
TERMINAL AND TERMINAL "E" OF THE 8-WAY EBCM HARNESS CONNECTOR.
• OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND CONNECTORS.
IS RESISTANCE ALWAYS 2Q OR LESS?

§] §]
0 •
•
DISCONNECT 32-WAY EBCM CONNECTOR .
USINGJ 39200, MEASURE THE RESISTANCE BETWEEN POSITIVE BATTERY CABLE
REPAIR INTERMITTENT OPEN OR
HIGH RESISTANCE IN CKT 651 .
TERMINAL AND TERMINAL "B10" OF THE 32-WAY EBCM HARNESS CONNECTOR. REFER TO SECTION SA-4,
• OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND "INTERMITTENTS AND POOR
CONNECTORS. CONNECTIONS."
IS RESISTANCE ALWAYS 2Q OR LESS?

§] §]
~• TURN IGNITION SWITCH "ON'' (THIS IS DONE TO COMPLETE THE IGNITION
CIRCUIT).
REPAIR INTERMITTENT OPEN OR
HIGH RESISTANCE IN CKTs440
• USING J 39200, MEASURE THE RESISTANCE BETWEEN POSITIVE BATTERY CABLE OR 502. REFER TO SECTION SA-
TERMINAL AND TERMINAL "B11" OF THE 32-WAY EBCM HARNESS CONNECTOR. 4, "INTERMITTENTS AND POOR
• OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND CONNECTIONS."
CONNECTORS.
IS RESISTANCE ALWAYS 2Q OR LESS?

@] §]
s• •
CHECK POSITIVE BATTERY TERMINAL AND POSITIVE BATTERY CABLE
TERMINAL FOR A POOR CONNECTION.
INSPECT TERMINALS "B11" AND "B10" OF THE 32-WAY EBCM
REPAIR INTERMITTENT OPEN OR
HIGH RESISTANCE IN CKTs641
OR 300. REFER TO SECTION SA-4,
CONNECTOR AND TERMINAL ''E'' OF THE 8-WAY EBCM CONNECTOR FOR "INTERMITTENTS AND POOR
POOR TERMINAL CONTACT AND EVIDENCE OF CORROSION. REFER TO CONNECTIONS."
SECTION SA-4, "CHECKING TERMINAL CONTACT."

. IS THERE EVIDENCE OF POOR TERMINAL CONTACT OR CORROSION?

El @]
G: •• IGNITION "OFF."
RECONNECT ALL CONNECTORS .
REPLACE TERMINALS THAT EXHIBIT
POOR TERMINAL CONTACT OR SIGNS
• IGNITION "ON."
IS "ABS INOP" LAMP "ON" INTERMITTENTLY WITH NO DTCs SET?
OF CORROSION. REPAIR CONNECTION
INTEGRITY IF POOR CONTACT EXISTS
AT BATTERY.
I
[§] §]
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENTS REPLACE EBCM. I
MAY BE CAUSED BY INCORRECT WIRING HARNESS ROUTING OR
LOOSE GROUND CONNECTIONS. REFER TO SECTION SA-4,
"INTERMITTENTS AND POOR CONNECTIONS."

7-7-93
NS 16311
SE1-32 ANTILOCK BRAKE SYSTEM

CHARTC
,.LOW TRAC" INDICATOR LAMP "ON"
WITH IGNITION "OFF," NO DTCs STORED

NOTICE: DIAGNOSTIC SYSTEM CHECK

MUST BE COMPLETED BEFORE USING
THIS CHART.

• IGNITION "OFF."
• OBSERVE THE "LOW TRAC" INDICATOR LAMP.
IS THE "LOW TRAC" INDICATOR LAMP "ON"'?

MALFUNCTION IS NOT PRESENT AT THIS TIME.

INTERMITTENTS COULD BE CAUSED BY INCORRECT I
REPAIR SHORT TO VOLTAGE
ONCKT 1537.
I
WIRING HARNESS ROUTING OR LQOSE CQN,..,ECTIONS.
INSPECT ALL CONNECTORS AND TERMINALS FOR
POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REPLACE ALL TERMINALS THAT EXHIBIT
SIGNS OF POOR TERMINAL CONTACT OR CORROSION.

7-2-93
NS16312
 ANTILOCK BRAKE SYSTEM 5E1-33

CHARTD
TECH 1 DISPLAYS UNDEFINED DTCs

[I] Important
• USE THIS CHART If ANY OF THE FOLLOWING UNDEFINED DTCs ARE SET •
12, 13, 23, 27, 31, 34, 43, 67, 68, 71, 72, 73, 75, 83, 84, 85, 97, OR 98.

0 • •
IGNITION "ON."
USING TECH 1, CLEAR DTCs.
DOES UNDEFINED OTC RESET?

REPLACE EBCM. MALFUNCTION IS NOT PRESENT

AT THIS TIME.

7-7-93
NS 15701
5E1-34 ANTILOCK BRAKE SYSTEM

EBCM
BRAKE
BRAKE COMBO
WARNING SWITCH

33 TAN/ t r,~-il t
33 TAN/
WHT S ~ W H T
BRAKE WARNING
LAMP CONTROL
I I
013 CHEV 1537 DK BLU ~ 1537 DK BLU ABS ACTIVE
AS PONT "LOW TRAC" ~ LAMP CONTROL
·---- I I
06 CHEV _lr:-;i!_ ABS WARNING
817 PONT 867LTGRN~867LTGRN
LAMP CONTROL
C2000
C200A

7-14-93
NS 15733

OTC 11
(Page 1 of 2)
ABS WARNING OR LOW TRAC LAMP CKT MALFUNCTION
Circuit Description:
This DTC checks the state of both the "ABS INOP" lamp and the "LOW TRAC" lamp to identify a situation in
which the driver could not be alerted to a system malfunction or of possible slippery driving conditions. Due to an
integral lamp driver module within the instrument panel cluster, the EBCM must provide a ground to turn the
"ABS INOP" lamp "OFF." The "LOW TRAC" lamp circuit is such that the EBCM provides a ground to turn "ON"
the "LOW TRAC" lamp.

OTC Will Set When: DTC 11 can only be set during the three second bulb check or when either of the lamps
are commanded "ON." If the EBCM cannot control either the "ABS INOP" lamp or the "LOW TRAC" lamp for
two seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored; however, ABS is not disabled.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Determines if the "ABS INOP" lamp can be
properly controlled.
2. Determines if the lamp is "ON" constantly.
3. Checks for other DTCs which could turn "ON" the
"ABS INOP" lamp.
4. Determines if the "ABS INOP" lamp can be turned
"OFF" manually.
5. Checks the integrity of the "ABS INOP" lamp
circuitry.
6. Checks for a short to voltage on the "ABS INOP"
lamp circuitry.
7. Determines if a malfunctioning EBCM is the cause
ofDTC 11.
8. Verifies that the other 1/P indicator lamps function
properly.
9. Determines if the "ABS INOP" lamp can be turned
"ON" manually.
10. Checks for a short to ground in the "ABS INOP"
lamp circuitry.
11. Verifies condition of the 10 amp "GAGES" Fuse 9.
12. Determines if DTC 11 was set due to an EBCM
malfunction.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The lamp test function of the Tech 1 may be used to
command the lamp "ON" while looking for an
intermittent malfunction in the "ABS INOP" lamp
circuitry.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as cau-;ing the
intermittent complaint should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-35

•
•
INSTALL TECH 1.
IGNITION "ON."
DTC 11
• USING TECH 1, SELECT "F4: MISC. TESTS."
• SELECT "FS: LAMP TEST" AND ATTEMPT TO TURN {Page 1 of 2)
"ON," THEN "FLASH" THE" ABS INOP" LAMP.
CAN THE" ABS INOP" LAMP BE BOTH TURNED
ABS WARNING OR LOW TRAC
"ON" AND FLASHED USING THE TECH 1? LAMP CKT MALFUNCTION

r -------------,
I DIAGNOSIS CONTINUED I
I ON FOLLOWING PAGE. .J1
L---------------

• IGNITION "OFF."
• DISCONNECT 32-WA Y EBCM
CONNECTOR. rg'I • IGNITION "OFF."
• IGNITION "ON." \...:.,) • DISCONNECT
• CONNECT A FUSED JUMPER 32-WAY EBCM
WIRE, SUCH AS J 36169, CONNECTOR.
WITH A 3 AMP FUSE • IGNITION "ON."
BETWEEN GROUND AND DOES "ABS
TERMINAL "82" OF THE 32- INOP" LAMP
WAY EBCM HARNESS TURN "ON"? REPAIR CHECK FOR
CONNECTOR. OPEN IN SHORT TO
DOES "ABS INOP" LAMP CKT39. GROUND ON
REMAIN "ON"? CKT 39 AND ALL
OTHER
CIRCUITS FROM
SPLICE S206.
REPAIR ANY
SHORTS TO
5 • IGNITION "OFF." ,:,.. • INSPECT TERMINAL .GROUND AND
• REMOVE JUMPER. \..:_,) "82" OF THE 32-WA Y
REPLACE FUSE.
• DISCONNECT 1/P EBCM CONNECTOR IFNO SHORTS
CLUSTER FOR POOR TERMINAL ARE FOUND,
CONNECTOR. CONTACT. REPLACE FUSE.
• USING J 39200, • IGNITION "OFF."
MEASURE THE • RECONNECT ALL
RESISTANCE CONNECTORS.
• IGNITION "OFF." IGNITION "OFF."
BETWEEN TERMINAL • IGNITION "ON."
• DISCONNECT 1/P • INSPECT TERMINAL "82"
"82" OF THE 32- DOES OTC 11 RESET?
CLUSTER OF THE 32-WA Y EBCM
WAY EBCM
CONNECTOR. CONNECTOR FOR BENT
HARNESS
CONNECTOR AND • USING J 39200, TERMINALS OR FOREIGN
MEASURE THE DEBRIS. CORRECT AS
TERMINAL "06"
(CHEVY) OR "817" RESISTANCE NECESSARY.
BETWEEN GROUND • RECONNECT ALL
(PONT) OF THE 1/P MALFUNCTION AND TERMINAL "82" CONNECTORS.
CLUSTER HARNESS IS NOT PRESENT OF32-WAY EBCM • IGNITION "ON."
CONNECTOR. AT THIS TIME. HARNESS DOES DTC 11 RESET?
IS RESISTANCE 2il REFER TO CONNECTOR.
OR LESS? "DIAGNOSTIC DOESJ 39200
AIDS" ON DISPLAY
FACING PAGE. RESISTANCE AS "OL"
(INFINITE)? MALFUNCTION
ISNOT
• IGNITION "ON." REPAIR OPEN
PRESENT AT
• USING J 39200, MEASURE THE OR HIGH
THIS TIME.
VOLTAGE BETWEEN GROUND RESISTANCE .--a----,r- --------,
AND TERMINAL "82" OF THE REFER TO
INCKT867. REPAIR REFERTO
I I
32-WAY EBCM HARNESS I
"DIAGNOSTIC
SHORT TOSECTION SA-81 1 AIDS" ON
CONNECTOR. GROUND: FOR FURTHER : FACING PAGE.
IS VOLTAGE 2 VOLTS OR LESS? INCKT867.
I DIAGNOSIS OF I
..___ _ _ 1 CLUSTER. I
L----------J
r-
I
--------------------1
REFER TO SECTION SA-81 FOR I
I FURTHER DIAGNOSIS OF CLUSTER. ]
L---------------------- 7-2-93
NS 15702
SE1-36 ANTILOCK BRAKE SYSTEM

EBCM
BRAKE
INSTRUMENT BRAKE COMBO
CLUSTER WARNING SWITCH
r----~ ~
SEEBA-11-4
---·-·-__......
c1_o_C_H_E_V... 33 TAN/ Ii ; ii . 33TAN/ BRAKE WARNING
"BRAKE" A10 PONT WHT s22sl ls213 WHT LAMP CONTROL
I I
013 CHEV 016 CHEV ABS ACTIVE
1537 DK BLU @1537 DK BLU
AS PONT "LOW TRAC" A 16 PONT LAMP CONTROL
I I
D6 CHEV _!r;;-! ABS WARNING
B17PONT 867LTGRN~867LTGRN
LAMP CONTROL
C200D
C200A

7-14-93
NS 15733

OTC 11
(Page 2 of 2)
ABS WARNING OR LOW TRAC LAMP CKT MALFUNCTION
Circuit Description.:
This DTC checks the state of both the "ABS INOP" lamp and the "LOW TRAC" lamp to identify a situation in
which the driver could not be alerted to a system malfunction or of possible slippery driving conditions. Due to an
integral lamp driver module within the instrument panel cluster, the EBCM must provide a ground to turn the
"ABS !NOP" lamp "OFF." The "LOW TRAC" lamp circuit is such that the EBCM provides a ground to turn "ON"
the "LOW TRAC" lamp.

OTC Will Set When: DTC 11 can only be set during the three second bulb check or when either of the lamps
are commanded "ON." If the EBCM cannot control either the "ABS !NOP" lamp or the "LOW TRAC" lamp for
two seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored; however, ABS is not disabled.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
13. Determines if the "LOW TRAC" lamp can be
properly controlled.
14. Determines if the "LOW TRAC" lamp is "ON"
constantly.
15. Checks for a short to ground in the "LOW TRAC"
lamp circuitry.
16. Determines if DTC 11 was set due to a EBCM
malfunction.
17. Determines if DTC 11 was set due to a EBCM
malfunction.
18. Determines if the "LOW TRAC" lamp can be
controlled manually.
19. Verifies the integrity of the "LOW TRAC" lamp
circuitry.
20. Determines if there is a short to voltage in the
"LOW TRAC" lamp circuitry.
21. Determines if DTC 11 was set due to an EBCM
malfunction.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The lamp test function of the Tech 1 may be used to
command the lamp "ON" while looking for an
intermittent malfunction in the "LOW TRAC" lamp
circuitry.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as causing the
intermittent complaint should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-37

DTC 11
r---------------,
I DIAGNOSIS CONTINUED I
{Page 2 of 2)
L FROM PREVIOUS PAGE_ J ABS WARNING OR LOW TRAC CKT MALFUNCTION
~ • STILL USING TECH 1 LAMPTEST,ATTEMPTTO TURN "ON," THEN "OFF" THE "LOW TRAC" LAMP.
~ CAN THE "LOW TRAC" LAMP BE TURNED BOTH "ON" AND "OFF" USING THE TECH 1?

/'.j.i\ •. IGNITION "OFF." f'.i7\ • IGNITION "OFF."

V REMOVE TECH 1. \:.Y • INSPECT ALL CONNECTORS FOR
• IGNITION "ON." POOR TERMINAL CONTACT.
DOES THE "LOW TRAC" • RECONNECT ALL CONNECTORS.
LAMP TURN "ON" AND • IGNITION "ON."
STAY "ON"? DOES OTC 11 RESET?

MALFUNCTION IS NOT
PRESENT AT THIS TIME.
REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.

• IGNITION "OFF." IGNITION "OFF."

• DISCONNECT 32-WAY • DISCONNECT 32-WAY EBCM CONNECTOR.
EBCM CONNECTOR. • IGNITION "ON."
• IGNITION "ON." • CONNECT A FUSED JUMPER WIRE, SUCH AS
DOES THE "LOW TRAC" J 36169, WITH A 3 AMP FUSE BETWEEN
LAMP TURN "ON"? GROUND AND TERMINAL "BS" OF THE 32-
WAY EBCM HARNESS CONNECTOR.
DOES THE "LOW TRAC" LAMP TURN "ON"?

t,6' • IGNITION "OFF." REPAIR SHORT

~ • INSPECT TERMINAL "85" TO GROUND
OF THE 32-WAY EBCM
CONNECTOR FOR BENT
ON CKT 1537. ~ •
,..________. \!!} •
IGNITION "OFF."
DISCONNECT 1/P CLUSTER
@ •• IGNITION "OFF."
INSPECT TERMINAL "85"
TERMINALS OR FOREIGN CONNECTOR. OF THE 32-WA Y EBCM
DEBRIS. CORRECT AS • USING J 39200, MEASURE THE CONNECTOR FOR POOR
NECESSARY. RESISTANCE BETWEEN TERMINAL CONTACT.
• RECONNECT ALL TERMINAL "85" OF THE 32· • RECONNECT ALL
CONNECTORS. WAY EBCM HARNESS CONNECTORS.
• IGNITION "ON." CONNECTOR AND TERMINAL • IGNITION "ON."
DOES OTC 11 RESET? "016" (CHEVY) OR "A16" DOES OTC 11 RESET?
(PONT) OF THE 1/P CLUSTER
HARNESS CONNECTOR.
IS RESISTANCE 20 OR LESS?

MALFUNCTION MALFUNCTION
ISNOT ISNOT
PRESENT AT PRESENT AT
THIS TIME. THIS TIME.
REFER TO fio\ • IGNITION "ON." REPAIR OPEN REFER TO
"DIAGNOSTIC ~ • USING J 39200, OR HIGH "DIAGNOSTIC
AIDS" ON MEASURE THE RESISTANCE AIDS" ON
FACING PAGE. VOLTAGE FROM IN CKT 1537. FACING PAGE.
GROUND TO
TERMINAL "85"
OF THE 32-WAY
EBCM HARNESS
CONNECTOR.
IS VOLTAGE 2
VOLTS OR LESS?

I REFER TO REPAIR
: SECTION SA-81 SHORT TO
I FOR FURTHER VOLTAGE IN
: DIAGNOSIS OF CKT 1537.
I CLUSTER.

7-2-93
NS 15760
SE1-38 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
!
3000RN ,-----------------641BRN-----o

~tSsfs
-5122
>------641 BRN 1632 PNK ABS ENABLE RELAY CONTROL
B+ SAMP
L~302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB 5272

6-23-93
NS 15732

DTC14
(Page 1 of 3)
ABS ENABLE RELAY CONTACT CIRCUIT OPEN
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies power to the motors and solenoids.

DTC Will Set When: OTC 14 can be set anytime after the EBCM commands the ABS enable relay "ON" (the
relay is first commanded "ON" during the three second bulb check). This test monitors the availability of
currentJvoltage to the motors and solenoids. This malfunction indicates voltage is not available and would
therefore not allow ABS operation ifrequired.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks to see if OTC 16 is also set as current or
history. If OTC 16 is also set, proceed to that chart
first.
2. Verifies that the malfunction is currently present.
3. Verifies that the relay can be turned "ON" and
provide voltage to the EBCM.
4. Checks for high resistance in the switched battery
circuit from the relay to the EBCM.
5. Checks for high resistance in the switched battery
circuit from the battery to the relay.
6. Checks for high resistance in the relay contacts.
7. Checks for poor terminal contact or corrosion at
the connectors.
8. Determines if the EBCM is the cause of the
malfunction.
Diagnostic Aids: An "Intermittent" problem may
be caused by a poor connection, rubbed through wire
insulation, or a wire that is broken inside the
insulation.
The frequency of the problem can be checked by
using the enhanced diagnostic function of the Tech 1,
as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as causing the
"Intermittent" complaint should be thoroughly
checked for backed out terminals, improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal to wiring connections or
physical damage to the wiring harness.
VIBRATION, TEMPERATURE EFFECTS:
Check for vibration effects by performing the relay
test function of the Tech 1. With the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay voltage. If the relay
voltage changes significantly, replace the relay.
If OTC 14 only sets when the vehicle is initially
started in cold ambient conditions (temperature less
than 32°F-0°C), replace the relay.
 ANTILOCK BRAKE SYSTEM 5E1-39

8 IS OTC 16 ALSO PRESENT OR IN HISTORY? I

I DTC 14
~ ,.
YES
-------------,
(Page 1 of 3)
ABS ENABLE RELAY
0 •• IGNITION "ON," ENGINE "OFF." I PROCEED TO OTC 16
I
I
USING TECH 1, SELECT DA TA LIST AND : CHART FIRST. I CONTACT CIRCUIT OPEN
OBSERVE EBCM BATTERY VOLTAGE.
DOES TECH 1 INDICATE THAT EBCM BATTERY
~--------------~
VOLTAGE IS GREATER THAN 10 VOLTS?
•
[§] s
0 •••
IGNITION "OFF." MALFUNCTION IS NOT
DISCONNECT 32-WAY AND 8-WAY EBCM CONNECTORS. PRESENT AT THIS TIME .
CONNECT A FUSED JUMPER, SUCH AS J 36169 WITH A 3 AMP FUSE BETWEEN REFER TO
GROUND AND TERMINAL "83" OF THE 32-WAY EBCM HARNESS CONNECTOR. "DIAGNOSTIC AIDS"
• IGNITION "ON." ON FACING PAGE.
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL
"D" OF THE 8-WAY EBCM HARNESS CONNECTOR.
. IS VOLTAGE 10 VOLTS OR GREATER?

s• ~
r- .- - - - - - - - ,

0 •
IGNITION "OFF."
DISCONNECT JUMPER USED IN STEP 3.
I DIAGNOSIS
: CONTINUED ON
I
I

•• DISCONNECT ABS ENABLE RELAY.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "C4" OF THE ABS
I NEXT PAGE .
L----------..J
I
I

ENABLE RELAY HARNESS CONNECTOR AND TERMINAL "D" OF THE 8-WAY

EBCM HARNESS CONNECTOR.
IS RESISTANCE 20 OR LESS?
I

s s
0: DISCONNECT NEGATIVE BATTERY CABLE.
DISCONNECT POSITIVE BATTERY CABLE.
REPAIR HIGH
RESISTANCE
• USING J 39200, MEASURE THE RESISTANCE BETWEEN POSITIVE BATTERY CABLE TERMINAL
AND TERMINAL "C1" OF THE ABS ENABLE RELAY HARNESS CONNECTOR.
IN CKT 1633.

IS RESISTANCE 20 OR LESS?
.

©
s @]
•• USING
USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE ABS ENABLE RELAY TO GROUND• REPAIR HIGH RESISTANCE
A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP FUSE, CONNECT TERMINAL INCKT302.
"85" ON THE ABS ENABLE RELAY TO B +. REFER TO SECTION SA.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "30" AND "87" ON THE
ABS ENABLE RELAY.
IS RESISTANCE 20 OR LESS?
I

8 8J
~• I
INSPECT ABS ENABLE RELAY AND ABS ENABLE RELAY HARNESS CONNECTOR FORA POOR REPLACE ABS
CONNECTION OR POOR TERMINAL CONTACT. ENABLE RELAY.
• INSPECT EBCM AND EBCM CONNECTOR TERMINALS "83" AND "D" FOR POOR TERMINAL
CONTACT.
• INSPECT POSITIVE BATTERY TERMINAL AND POSITIVE BATTERY CABLE TERMINAL FOR A
POOR CONNECTION. REFER TO SECTION SA-4, "CHECKING TERMINAL CONTACT."
IS POOR TERMINAL CONTACT OR A POOR CONNECTION EVIDENT?
I

0
s •
•
RECONNECT ALL CONNECTORS.
IGNITION "ON."
[$]
REPLACE TERMINALS THAT EXHIBIT
POOR TERMINAL CONTACT OR
DOES OTC 14 RESET? EVIDENCE OF CORROSION.
I

~
I
s
REPLACE EBCM. MALFUNCTION IS INTERMITTENT.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE. I 7-2-93
NS 15703
5E1-40 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
300 ORN . . - - - - - - - - - - - - - - - - 6 4 1 BRN-----t

~~ss~6s . · l
- 5122
- - - - - 6 4 1 BRN ABS ENABLE RELAY CONTROL
1632 PNK
B+ SAMP
t.. ~302RED
1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB 5272
5180

6-23-93
NS 15732

DTC14
(Page 2 of 3)
ABS ENABLE RELAY CONTACT CIRCUIT OPEN
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies power to the motors and solenoids.

OTC Will Set When: DTC 14 can be set anytime after the EBCM commands the ABS enable relay "ON" (the
relay is first commanded "ON" during the three second bulb check). This test monitors the availability of
currentJvoltage to the motors and solenoids. This malfunction indicates voltage is not available and would
therefore not allow ABS operation if required.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below VIBRATION, TEMPERATURE EFFECTS:

refer to circled number(s) on the diagnostic chart.
9. Checks for high resistance in the entire relay coil
circuit.
10. Verifies proper battery condition.
11. Verifies proper voltage is available at the ABS
enable relay.
12. Checks for an open in the switched battery circuit
from the relay to the EBCM.
13. Verifies the condition of the ABS enable relay.
Check for vibration effects by performing the relay
test function of the Tech 1. With the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay voltage. If the relay
voltage changes significantly, replace the relay.
If DTC 14 only sets when the vehicle is initially
started in cold ambient conditions (temperature less
than 32°F-0°C), replace the relay.

Diagnostic Aids: An "Intermittent" problem may

be caused by a poor connection, rubbed through wire
insulation, or a wire that is broken inside the
insulation.
The frequency of the problem can be checked by
using the enhanced diagnostic function of the Tech 1,
as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as causing the
"Intermittent" complaint should be thoroughly
checked for backed out terminals, improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal to wiring connections or
physical damage to the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-41

OTC 14
r----------------,
I DIAGNOSIS CONTINUED I (Page 2 of 3)
: FROM PREVIOUS PAGE. :
~- --------------~ ABS ENABLE RELAY
• IGNITION "OFF." CONTACT CIRCUIT OPEN
fn\ • REMOVE JUMPER WIRE INSTALLED IN STEP 3, IF NOT
~
9 ALREADY REMOVED.
• DISCONNECT NEGATIVE BATTERY CABLE.
• DISCONNECT POSITIVE BATTERY CABLE.
• WITH BATTERY STILL DISCONNECTED, TURN IGNITION
SWITCH TO "RUN." THIS COMPLETES THE IGNITION CIRCUIT
TO THE ABS ENABLE RELAY.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINAL "83" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND THE POSITIVE BATTERY CABLE TERMINAL.
IS RESISTANCE 950 OR LESS WHEN MEASURED AT
APPROXIMATELY 20 °C (68°F)?

• USING J 39200, MEASURE THE VOLTAGE BETWEEN

,...
I
----------,
DIAGNOSIS I
THE NEGATIVE AND POSITIVE BATTERY TERMINALS. : CONTINUED ON :
IS VOLTAGE 10 VOLTS OR GREATER? I NEXT PAGE. 1
~----------...J

r -------------,
• IGNITION "OFF." : REFER TO SECTION 603 I
• RECONNECT POSITIVE BATTERY CABLE. I TO CORRECT LOW :
• RECONNECT NEGATIVE BATTERY CABLE. I VOLTAGE CONDITION. 1
• DISCONNECT ABS ENABLE RELAY. L---------------J
• MEASURE THE VOLTAGE BETWEEN TERMINAL
"C1" OF THE ABS ENABLE RELAY HARNESS
CONNECTOR AND GROUND.
IS VOLTAGE 10 VOL TS OR GREATER?

• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"C4" OF THE ABS ENABLE RELAY HARNESS CONNECTOR AND
TERMINAL "D" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 20 OR LESS?

• USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE ABS

ENABLE RELAY TO GROUND.
• USING A FUSED JUMPER WIRE, SUCH ASJ 36169, WITH A 3 AMP
FUSE, CONNECT TERMINAL "85" ON THE ABS ENABLE RELAY TO
VOLTAGE.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINALS "30" AND "87" ON THE ABS ENABLE RELAY.
IS RESISTANCE 20 OR LESS?

MALFUNCTION WAS MOST LIKELY DUE TO A POOR

CONNECTION. INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION 8A·4,
"CHECKING TERMINAL CONTACT." REPLACE ALL
TERMINALS THAT EXHIBIT EVIDENCE OF POOR
TERMINAL CONTACT OR CORROSION.

7.9.93
NS 16313
5E1-42 ANTILOCK BRAKE SYSTEM

EBCM

1632 PNK ABS ENABLE RELAY CONTROL

1633 RED
SWITCHED BATTERY INPUT
1633 RED
5180 5272

6-23-93
NS 15732

DTC14
(Page 3 of 3)
ABS ENABLE RELAY CONTACT CIRCUIT OPEN
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies power to the motors and solenoids.

DTC Will Set When: DTC 14 can be set anytime after the EBCM commands the ABS enable relay "ON" (the
relay is first commanded "ON" during the three second bulb check). This test monitors the availability of
current/voltage to the motors and solenoids. This malfunction indicates voltage is not available and would
therefore not allow ABS operation if required.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
14. Checks for proper resistance of the relay coil.
15. Checks for high resistance in the ABS enable relay
control circuit between the relay and the EBCM.
16. Checks for high resistance in the ABS enable relay
control circuit between the battery and the relay.
Diagnostic Aids: An "Intermittent" problem may
be caused by a poor connection, rubbed through wire
insulation, or a wire that is broken inside the
insulation.
The frequency of the problem can be checked by
using the enhanced diagnostic function of the Tech 1,
as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as causing the
"Intermittent" complaint should be thoroughly
checked for backed out terminals, improper mating,
broken locks, improperly form1;d or damaged
terminals, poor terminal to wiring connections or
physical damage to the wiring harness.
VIBRATION, TEMPERATURE EFFECTS:
Check for vibration effects by performing the relay
test function of the Tech 1. With the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay voltage. If the relay
voltage changes significantly, replace the relay.
If DTC 14 only sets when the vehicle is initially
started in cold ambient conditions (temperature less
than 32°F -0°C), replace the relay.
 ANTILOCK BRAKE SYSTEM SE1-43

DTC 14
(Page 3 of 3)
ABS ENABLE RELAY
CONTACT CIRCUIT OPEN
r----------------,
' DIAGNOSIS CONTINUED '
: FROM PREVIOUS PAGE. :
L- --------------~

0: DISCONNECT ABS ENABLE RELAY.

USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINALS "85" AND "86" ON THE ABS ENABLE RELAY.
IS RESISTANCE 95Q OR LESS WHEN MEASURED AT
APPROXIMATELY 24°C (75°F}?

MEASURE THE RESISTANCE BETWEEN

TERMINAL "CS" OF THE ABS ENABLE RELAY
HARNESS CONNECTOR AND TERMINAL "83" OF
THE 32-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

'16" •
V:V
MEASURE THE RESISTANCE BETWEEN TERMINAL "C2"
OF THE ABS ENABLE RELAY HARNESS CONNECTOR AND
THE POSITIVE BATTERY CABLE TERMINAL.
IS RESISTANCE 2Q OR LESS?

MALFUNCTION WAS MOST LIKELY DUE TO A REPAIR OPEN OR HIGH RESISTANCE IN

POOR CONNECTION. INSPECT ALL CKT 641, CKT 300, IGNITION SWITCH,
CONNECTORS AND TERMINALS FOR POOR OR BATTERY FEED CIRCUIT TO
TERMINAL CONTACT AND EVIDENCE OF IGNITION SWITCH. REFER TO SECTION
CORROSION. REFER TO SECTION SA-4, SA FOR FURTHER INFORMATION.
"CHECKING TERMINAL CONTACT." REPLACE
ALL TERMINALS THAT EXHIBIT EVIDENCE OF
POOR TERMINAL CONTACT OR CORROSION.

7-9-93
NS 16314
SE1-44 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM

3000RN
t .--~~~~~~~~~~~~~~-641BRN~~---,,

~t\U
I~ ",,!i 641BRN 1632 PNK ABS ENABLE RELAY CONTROL

t
B+
~
SAMP
1 302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB 5272
5180

6-23-93
NS 15732

OTC 15
ABS RLY CONTACT CKT SHORT TO BATT OR ALWAYS CLOSED
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies power to the motors and solenoids.

OTC Will Set When: DTC 15 can be set only before the EBCM commands the relay "ON." This test
determines if the ABS enable relay is energized when it should not be. This malfunction would not allow the ABS
enable relay to remove power to the ABS system. If a second malfunction were to occur that requires the ABS
enable relay to be turned "OFF," that malfunction cannot be removed if the relay cannot be controlled. The
malfunction must be present for three consecutive drive cycles before the DTC is set.

Action Taken: A malfunction DTC is stored. ABS is not disabled.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Determines if any other DTCs are present.
2. Indicates that the EBCM is capable of controlling
the enable relay as commanded.
3. Checks for a possible short to battery voltage in
CKT 1633.
4. Determines whether the short to voltage is in CKT
1633 or as a result of a malfunctioning relay.
5. Checks for a possible intermittent in wiring or
connectors.
Diagnostic Aids; An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-45

DTC 15
ABS RLY CONTACT CKT SHORT
TO BAIT OR ALWAYS CLOSED

• IGNITION "ON," ENGINE "OFF."

• USING THE RELAYTESTFUNCTION OFTHE TECH 1,
COMMAND ABS ENABLE RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS ENABLE RELAY IS "OFF"
AND BATTERY VOLTAGE IS LESS THAN S VOLTS?

0 • •
IGNITION "OFF."
DISCONNECT 32-WAY ANDS-WAY EBCM HARNESS CONNECTORS.
MALFUNCTION IS NOT PRESENT AT THIS TIME.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
• IGNITION "ON."
• USINGJ 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "D" OF THE 8-WAY EBCM CONNECTOR.
IS VOLTAGE 2 VOLTS OR LESS?

0 • •
IGNITION"OFF ...
INSPECT CKT 1633 AND THE 8-WAY EBCM HARNESS CONNECTOR FOR DAMAGE
WHICH MAY RESULT IN A SHORT TO VOLTAGE WHEN ALL CONNECTORS ARE
CONNECTED. REPAIR DAMAGE IF EVIDENT.
• RECONNECT8-WAYAND32-WAY EBCMCONNECTORS.
• IGNITION "ON."
• USING RELAY TEST FUNCTION Of TECH 1,COMMANDABS ENABLE RELAY ".OFF."
DOES TECH 1 INDICATE THAT ABS ENABLE RELAY IS "OFF" AND BATTERY
VOLTAGE IS LESS THAN 5 VOLTS?

MALFUNCTION IS INTERMITTENT. REFER

TO"DIAGNOSTIC AIDS" ON FACING PAGE.

0 • •
IGNITION "OFF."
DISCONNECT ABS ENABLE RELAY.
• IGNITION "ON."
• MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "D"
OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS VOLTAGE 2 VOLTS OR LESS?

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs, AND TEST DRIVE VEHICLE FOR 3 DRIVE CYCLES TO VERIFY THAT DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING ABOVE 16 km/h (10 MPH), AND THEN KEYING DOWN. _ _
6 10 93
NS 15704
SE1-46 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
300 ORN - - - - - - - - - - - - - - - - 6 4 1 BRN----t

ABSl~N
FUSE!
1
5122
641 BRN 1632 PNK ABS ENABLE RELA V CONTROL
B+ SAMP
t ~ l302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB
5180 5272

6-23-93
NS 15732

OTC 16
ABS ENABLE RELAY COIL CIRCUIT OPEN
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the A.BS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies power to the motors and solenoids.

DTC Will Set When: DTC 16 can be set only after DTC 14 has been set. This test detects an open in the ABS
enable relay coil circuit. An open in this circuit will not allow the ABS enable relay to be energized thus
preventing voltage/current to the motors and solenoids. If this malfunction is present and the ignition is turned
"OFF" before 5 km/h (3 mph) is reached, OTC 14 is set alone.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Indicates the EBCM is capable of controlling the
ABS enable relay as commanded.
2. Checks to ensure that voltage is available to the
pull-in coil of the ABS enable relay.
3. Ensures that there is continuity throug·h the pull-
in coil of the ABS enable relay.
4. Verifies the integrity of the relay control circuit.
5. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
If the frequency of the malfunction is high, but is
currently intermittent, check for high coil resistance
by measuring between relay terminals "C4" and "C5"
using a ,J 39200. If resistance shows greater than
lOOQ, replace the relay.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-47

OTC 16
G). IGNITION "ON," ENGINE "OFF." ABS ENABLE RELAY COIL
• USING THE RELAY TEST FUNCTION OF THE TECH 1,
COMMAND THE ABS ENABLE RELAY "ON." CIRCUIT OPEN
DOES TECH 1 INDICATE ABS ENABLE RELAY "ON" AND
BATTERY VOLTAGE ABOVE 10 VOLTS?

USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND MALFUNCTION IS NOT PRESENT AT THIS
AND TERMINAL "C2" OF THE ABS ENABLE RELAY CONNECTOR. TIME. REFER TO "DIAGNOSTIC AIDS"' ON
IS VOLTAGE 10 VOLTS OR GREATER? FACING PAGE.

0 • USING THE RELAY TEST FUNCTION OF THE TECH 1, COMMAND THE ABS
ENABLE RELAY "OFF."
REPAIR OPEN OR HIGH
RESISTANCE IN CKT 641
• MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "CS" OF THE OR
ABS ENABLE RELAY CONNECTOR. ABS IGN FUSE 5.
IS VOLTAGE 10 VOLTS OR GREATER?

IGNITION "OFF." CHECK FOR INTERMITTENT CONNECTIONS

DISCONNECT 32-WAY EBCM CONNECTOR. AT ABS ENABLE RELAY. IF OK, REPLACE
• IGNITION "ON." ABS RELAY.
• MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "83"
OF THE 32-WAY EBCM HARNESS CONNECTOR.
IS VOLTAGE 10 VOL TS OR GREATER?

IGNITION "OFF."
• INSPECT 32-WAY EBCM CONNECTOR TERMINAL "83" FOR POOR TERMINAL
CONTACT OR EVIDENCE OF CORROSION. REFER TO SECTION SA-4 "CHECKING
TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
DOES OTC 16 SET AS A CURRENT OTC?

REPLACE EBCM.
MALFUNCTION WAS MOST LIKELY
CAUSED BY A POOR CONNECTION.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.

6-28-93
NS 15705
5E1-48 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
l
300 ORN , - - - - - - - - - - - - - - - - - 6 4 1 BRN----1

~tss~6s
_ S122
- - - - - 6 4 1 BRN 83 ABS ENABLE RELAY CONTROL
1632 PNK -----1

B+ SAMP
t ~ l302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB
S272

6-23-93
NS 15732

OTC 17
ABS ENABLE RELAY COIL CIRCUIT SHORTED TO GND
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and ct1rrent to be supplied to the EBCM,
which supplies voltage to the motors and solenoids.

OTC Will Set When: DTC 17 can be set before the EBCM commands the ABS enable relay "ON." This test
determines if the ABS enable relay is energized when it should not be. This malfunction would not allow the ABS
enable relay to remove power to the ABS system. If a second malfunction were to occur that requires the ABS
enable relay to be turned "OFF," that malfunction cannot be removed if the relay cannot be controlled.

Action Taken: A malfunction DTC is stored. ABS is not disabled.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Indicates that the EBCM is capable of controlling
the ABS enable relay as commanded.
2. Checks to ensure that the ABS enable relay or
control CKT 1632 are not shorted to ground.
3. Checks to see if the EBCM is internally shorted to
ground. A grounded terminal "B3" would cause
the ABS enable relay to be energized any time the
ignition was in the "ON" position.
4. Checks for a short to ground in control CKT 1632
or a defective relay.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-49

DTC 17
ABS ENABLE RELAY COIL CIRCUIT SHORTED TO GND

0 • •
IGNITION "ON," ENGINE "OFF."
USING THE RELAY TEST FUNCTION OF THE TECti 1, COMMAND
THE ABS ENABLE RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS ENABLE RELAY IS "OFF" AND
BATTERY VOLTAGE IS LESS THAN 5 VOL TS?

0 • •
IGNITION "OFF."
DISCONNECT 32-WAY EBCM CONNECTOR.
MALFUNCTION IS NOT PRESENT AT THIS
TIME. REFER TO "DIAGNOSTIC AIDS"
• IGNITION "ON." ON FACING PAGE.
• USING J 39200, MEASURE THE VOLTAGE BETWEEN
TERMINAL "83" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND B +.
IS VOLTAGE 2 VOLTS OR LESS?

0 • •
IGNITION "OFF."
INSPECT CKT 1632 AND TERMINAL "83" OF THE
IGNITION "OFF."
DISCONNECT ABS ENABLE RELAY,
32-WAY EBCM CONNECTOR FOR DAMAGE WHICH • MEASURE VOLTAGE BETWEEN
MAY RESULT IN A SHORT TO GROUND WITH ALL TERMINAL "CS" OF THE ABS ENABLE
CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF RELAY CONNECTOR AND B +.
EVIDENT. IS VOLTAGE 2 VOLTS OR LESS?
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
DOES OTC 17 SET AS A CURRENT OTC?

REPLACE ABS ENABLE

RELAY.

MALFUNCTION IS
INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.

7-7-93
NS 15706
SE1-50 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
300 ORN

B+
ABS l~N
FUSE:

5AMP
!
. . . . . - - - - - - - - - - - - - - - - 6 4 1 BRN----

5122
641 BRN 1632 PNK ABS ENABLE RELAY CONTROL

t ~ - - l 302 RED 1633 RED

SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB
5180 5272

6-23-93
NS 15732

OTC 18
ABS ENABLE RELAY COIL CIRCUIT SHORTED TO BATT
Circuit Description:
Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
created closes the ABS enable relay contacts and allows battery voltage and current to be supplied to the EBCM,
which supplies voltage to the motors and solenoids.

OTC Will Set When: DTC 18 can be set after the EBCM commands the ABS enable relay "ON." This test
monitors the availability of current/voltage to the motors and solenoids. A malfunction of this type will not allow
voltage to be available to the motors and solenoids; therefore, ABS operation would not be allowed if required.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
l. Indicates that the EBCM is capable of controlling
the ABS enable relay as commanded.
2. Checks for a short to voltage on the relay control
circuit.
3. Verifies that the relay coil has the appropriate
resistance.
4. Checks for relay contacts that are failed closed.
5. Checks for possible poor terminal contact at the
EBCM.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-51

DTC18
G) • IGNITION "ON," ENGINE "OFF." ABS ENABLE RELAY COIL CIRCUIT
• USING RELAY TEST FUNCTION OF TECH 1,
COMMAND ABS ENABLE RELAY "ON."
SHORTED TO BATT
DOES TECH 1 INDICATE ABS ENABLE RELAY
"ON" AND BATTERY VOLTAGE ABOVE 10
VOLTS?

0 • •
IGNITION "OFF."
DISCONNECT ABS ENABLE RELAY.
MALFUNCTION IS NOT PRESENT AT THIS TIME.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
• DISCONNECT 32-WAY EBCM CONNECTOR.
• IGNITION "ON."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL "83" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 2 VOLTS OR LESS?

0 • •
IGNITION "OFF."
USING J 39200, MEASURE THE
RESISTANCE BETWEEN TERMINAL
"C2" AND TERMINAL "CS" OF THE
ABS ENABLE RELAY.
IS RESISTANCE 400 OR GREATER?

USING J 39200, MEASURE THE RESISTANCE

BETWEEN TERMINALS "30" AND "87" OF
THE ABS ENABLE RELAY.
DOESJ 39200 DISPLAY RESISTANCE AS "OL"
(INFINITE)?

0 • INSPECT CKT 1632 AND TERMINAL "83" OF THE

32-WAY EBCM CONNECTOR FOR DAMAGE
WHICH MAY RESULT IN A SHORT TO VOLTAGE
WITH ALL CONNECTORS CONNECTED. REPAIR
ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
DOES OTC 18 SET AS A CURRENT OTC?

MALFUNCTION IS INTERMITTENT. REFER TO

"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.

7-7-93
NS 15707
5E1-52 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

LF WHEEL SPEED SIGNAL

::: ::T___....,ffi:=====-8-3::: ::~ =======

C120
LOW
LF WHEEL SPEED SIGNAL
HIGH

LF WHEEL SPEED SENSOR

6·23-93
NS 15728

DTC21
LEFT FRONT WHEEL SPEED =0
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: DTC 21 can be set when the vehicle is not in an ABS stop. If the left front wheel
speed= Oand the vehicle's reference speed is greater than 8 km/h (5 mph), a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-53

DTC21
[I] Important LEFT FRONT WHEEL
• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE ....
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN
SPEED = 0
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.

G). •' IGNITION "OFF."

• PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED SENSOR, LEFT FRONT
WHEEL SPEED SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

0
'
e· DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR
REPLACE WHEEL SPEED SENSOR AND/OR
JUMPER HARNESS IF DAMAGED. DRIVE
TERMINALS "A" AND "B." 'VEHICLE ABOVE 24 km/h (15 MPA)'TO ENSURE
IS RESISTANCE BETWEEN 1020 AND 11370 WHEN SENSOR IS 20°C(68°F)? OTC 21 DOES NOT SET.
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN
20°C (68°F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR .
TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE.

SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mv (VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?

IGNITION "OFF."
DISCONNECT 32-WAV EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A 7"
AND" AS" OF THE 32-WAY EBCM HARNESS CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INflNffE)?

INSPECT CKTs 830 AND 873 AND 32-WAV EBCM CONNECTOR FOR REPAIR SHORT BETWEEN CKTs 830 AND 873.
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs 830 AND 873
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES OTC 21 SET AS A CURRENT OTC?

MALFUNCTION IS INTERMITTENT. REFER

FRONT WHEEL SPEED SENSdR TO "DIAGNOSTIC AIDS" ON FACING PAGE.

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP. TEMP. RESISTANCE
c·q (•F) (OHMS)
-34 T04 -30T040 804 TO 1066
5T043 41TO 110 956 TO 1240
44T093 111T0200 1112101463

7-9-93
NS 16188 ·
5E1-54 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

833WHT ----1(;] ~~~~--

...... 833TAN RF WHEEL SPEED SIGNAL
LOW
t---- 872 BLK -----10 8 872 DK GRN RF WHEEL SPEED SIGNAL
HIGH
C130

RF WHEEL SPEED SENSOR

6-23-93
NS 15729

DTC22
RIGHT FRONT WHEEL SPEED =0
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

DTC Will Set When: DTC 22 can be set when the vehicle is not in an ABS stop. If the right front wheel
speed=O and the vehicle's reference speed is greater than 8 km/h (5 mph), a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."
DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-55

DTC22
[I] Important RIGHT FRONT
• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE.
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN
WHEEL SPEED = 0
INDICA TEO STEP OF THIS CHART. THIS Will ENSURE THAT AN INTERMITTENT CONNECTION
Will NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.

G) • IGNITION "OFF." .
• PHY SICA LLY INSPECT THE RIGHT FRONT WHEEL SPEED SENSOR, RIGHT FRONT
WHEEL SPEED SENSOR JUMPER HARNESS, ANO CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

• DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR. REPLACE WHEEL SPEED SENSOR AND/OR
• USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR JUMPER HARNESS IF DAMAGED. DRIVE
TERMINALS" A" AND "B." VEH1CLE ABOVE 24 km/h (15 MPH) TO ENSURE .
IS RESISTANCE BETWEEN 1020 AND 1137il WHEN SH!SOR IS 20°C(68°F)? DTC 22 DOES NOT SET.
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN 20°C
(68°F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR,
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FO.R TEMPERA(URf
OF THE SENSOR, NOT AIR TEMPERATURE.)

WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE.

SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE Will INCREASE AS
WHEEL SPEED INCREASES)?

IGNITION "OFF."
DISCONNECT 32-WAY EBCM CONNECTOR.
• USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A3"
AND" A4" OF THE 32-WAY EBCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANC'E AS "OL" (INFINITE)?

• INSPECT CKTs 833 AND 872 AND 32-WAY EBCM CONNECTOR FOR REPAIR SHORT BETWEEN CKTs 833 AND 872.
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs 833 AND 872
WITH All CONNECTORS CONNECTED .. REPAIR All DAMAGE IF EVIDENT.
• RECONNECT All CONNECTORS.
• TEST DRIVEVEHICLE ABOVE 24km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES DTC 22 SET AS'A CURRENT DTC?

MALFUNCTION IS INTERMITTENT'. REFER

FRONT WHEEL SPEED SENSOR TO "DIAGNOSTIC AIDS" ON FACING PAGE.

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP. TEMP. RESISTANCE
1·q (°F) (OHMS)
-34 T04 -30 T040 804 TO 1066
5T043 41 TO 110 956 T0.1240
44 T093 111 T0200 1112T01463

. 7-9-93
NS16189
5E1-56 ANTILOCK BRAKE SYSTEM

EBCM

f- _,
r--,
ABS JUMPER HARNESS

B 882WHT~882BRN~882BRN REAR WHEEL SPEED

SIGNAL HIGH

883 BLK -H
I

L __ J
I I
883 WHT ~ 8 8 3 WHT
L __ J
I
REAR WHEEL SPEED
SIGNAL LOW

C405B C200A
REAR WHEEL SPEED SENSOR
C405C C200D

6-27-93
NS15730

DTC24
REAR WHEEL SPEED =0
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: OTC 24 can be set when the vehicle is not in an ABS stop. If the rear wheel speed= 0 and
the vehicle's reference speed is greater than 8 km/h (5 mph), a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. Verifies that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If OTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM SE1-57

IT]lmportant
DTC24
• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE. REAR WHEEL
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN SPEED= 0
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.

G) • IGNITION "OFF."
• PHYSICALLY INSPECT THE REAR WHEEL SPEED SENSOR, WHEEL SPEED
SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

0 • •
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR
REPLACE WHEEL SPEED SENSOR AND/OR
WHEEL SPEED SENSOR JUMPER HARNESS IF
TERMINALS "A" AND "B." DAMAGED. DRIVE VEHICLE ABOVE 24 km/h
IS RESISTANCE BETWEEN 969 AND 11850 WHEN SENSOR IS 2o·c (68°F)? (15 MPH) TO ENSURE OTC 24 DOES NOT SET.
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN
20°C (68°F). REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR
TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE.

VEHICLE TRANSMISSION IN NEUTRAL.
• SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?

0 • •
IGNITION "OFF."
DISCONNECT32-WAY EBCMCONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" AS"
AND" A6" OF THE 32-WAY EBCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

INSPECT CKTs 882 AND 883 AND 32-WAY EBCM CONNECTOR FOR REPAIR SHORT.BETWEEN CKTs 882 AND 883.
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs882 AND883
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES OTC 24 SET AS A CURRENT OTC?

MALFUNCTION IS INTERMITTENT. REFER

TO "DIAGNOSTIC AIDS" ON FACING PAGE.

REAR WHEEL SPEED SENSOR

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP. TEMP. RESISTANCE
{°q {°F) {OHMS)
-34 T04 -30 T040 763 TO 1110
ST043 41T0110 908 TO 1292
44 T093 111 T0200 1057TO 1525
7-12-93
PS 18177
5E1-58 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

873 WHT G]i-'---- 873 YEL ----1 LF WHEEL SPEED SIGNAL

LOW
830 BLK ----101-'-·-~
C120
830 LT BLU ----1 LF WHEEL SPEED SIGNAL
HIGH

LF WHEEL SPEED SENSOR

6-23-93
'NS 15728

DTC25
LEFT FRONT EXCESSIVE WHEEL.SPEED VARIATION
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

DTC Will Set When: DTC 25 can be set when the brake is "OFF." The purpose of this test is to detect a
situation in which the left front wheel acceleration or deceleration is beyond specified limits.

Action Taken: A malfunction OTC is stored, ABS is disabled and the ABS warning lamp is turned "ON.''

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
l. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, .clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM SE1-59

rn
•
Important
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE.
DTC25
LEFT FRONT
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN EXCESSIVE
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
WHEEL SPEED
VARIATION

G) • IGNITION "OFF."
• PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED SENSOR, LEFT FRONT
WHEEL SPEED SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

G) • DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR. REPLACE WHEEL SPEED SENSOR AND/OR
• USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR JUMPER HARNESS IF DAMAGED. DRIVE
TERMINALS" A" AND "8." VEHICLE ABOVE 24 km/h (15 MPH) TO ENSURE
IS RESISTANCE BETWEEN 1020 AND 1137!! WHEN SENSOR IS 20°C (68°F)? DTC 25 DOES NOT SET.
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN
2o•c (68°F}, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR
TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.}

G) • WITH J 39200 STILL CONNECTED, SELECT A/CVOLTAGE SCALE.

• SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?

0 • •
IGNITION "OFF."
DISCONNECT 32-WAY EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A7"
AND" AS" OF THE 32-WAY EBCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

INSPECT CKTs 830 AND 873 AND 32-WAY EBCM CONNECTOR FOR
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs 830 AND 873
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES DTC 25 SET AS A CURRENT DTC?

MALFUNCTION IS INTERMITTENT. REFER

FRONT WHEEL SPEED SENSOR TO "DIAGNOSTIC AIDS" ON FACING PAGE.

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP. TEMP. RESISTANCE
c·q (°F) (OHMS)
804 TO 1066
-34 T04 -30 T04Q
5T043 41 TO 110 956 TO 1240
441093 11110200 1112101463
7-9-93
PS 18185
SE1-60 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

RFWHE'l!l SPEED SIGNAL

LOW
RF WHEEL SPEED SIGNAL
HIGH
(130

RF WHEEL SPEED SENSOR

6-23-93
NS 15729

DTC26
RIGHT FRONT EXCESSIVE WHEEL SPEED VARIATION
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: DTC 26 can be set when the brake is "OFF." The purpose of this test is to detect a
situation in which the right front wheel acceleration or deceleration is beyond specified limits.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray dowh
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) abov.e
24 .km/h (15 mph) for at least 30 seconds. If OTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, .should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-61

rn
•
Important
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE.
DTC26
RIGHT FRONT
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN EXCESSIVE
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
WHEEL SPEED
VARIATION
G) • IGNITION "OFF."
• PHYSICALLY INSPECT THE RIGHT FRONT WHEEL SPEED SENSOR, RIGHT FRONT
WHEEL SPEED SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

0 • •
DISCONNECT RIGHTFRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR
REPLACE WHEEL SPEED SENSOR AND/OR
JUMPER HARNESS IF DAMAGED. DRIVE
TERMINALS "A" AND "B." VEHICLE ABOVE 24 km/h (15 MPH) TO ENSURE
IS RESISTANCE BETWEEN 1020 AND 1137Q WHEN SENSOR IS 20°C (68°F)? OTC 26 DOES NOT SET.
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN 2o·c
(68°F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE
OF THE SENSOR, NOT AIR TEMPERATURE.) ..

G) • WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE.

• SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?

Q •• IGNITION "OFF."
DISCONNECT 32-WAY EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A3"
AND "A4" OF THE 32-WAY EBCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

(v • INSPECT CKTs 833 AND 872 AND 32-WAY EBCM CONNECTOR FOR
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs 833 AND 872
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES OTC 26 SET AS A CURRENT OTC?

MALFUNCTION IS INTERMITTENT. REFER

TO "DIAGNOSTIC AIDS" ON FACING PAGE.
FRONT WHEEL SPEED SENSOR
TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP. TEMP. RESISTANCE
{"Cl (•F) (OHMS)
-34 T04 -30 T040 804 TO 1066
5T043 41 TO 110 956 TO 1240
44 T093 111 T0200 1112101463

7-9-93
PS 18173
5E1-62 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

r--, f- - ,
B 882 WHT -+-GJ-+ 882 BRN ~ 882 BRN REAR WHEEL SPEED
SIGNAL HIGH

883 BLK -+G-!-

I I

L __ J
883 WHT -B+
I

L __ J
I
883 WHT REAR WHEEL SPEED
SIGNAL LOW

C405B C200A
REAR WHEEL SPEED SENSOR C200D
C405C

6-27-93
NS 15730

DTC28
REAR EXCESSIVE WHEEL SPEED VARIATION
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: DTC 28 can be set when the brake is "OFF." The purpose of this test is to detect a
situation in which the right rear wheel acceleration or deceleration is beyond specified limits.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
6. Checks rear sensor toothed ring for physical
damage.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-63

[I] Important DTC28

• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE. REAR EXCESSIVE
CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WHEEL SPEED
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND. VARIATION
G). IGNITION "OFF."
• PHYSICALLY INSPECT THE REAR WHEEL SPEED SENSOR, WHEEL SPEED
SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?

s
0 • DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR .
sREPLACE WHEEL SPEED SENSOR
• USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR TERMINALS" A •• AND
"B."
AND/OR WHEEL SPEED SENSOR
JUMPER HARNESS IF DAMAGED.
IS RESISTANCE BETWEEN 969 AND 11850 WHEN SENSOR IS 20°C(68°F)? DRIVE VEHICLE ABOVE 24 km/h
(IF TEMPERATURE OF THE'SENSOR IS SUSPECTED TO BE OTHER THAN 2o•c (68°F), REFER (15 MPH) TO ENSURE DTC 28
TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN DOES NOT SET.
THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
.
~ ~
G). WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE. REPLACE WHEEL SPEED SENSOR.
•• VEHICLE TRANSMISSION IN NEUTRAL.
SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?

s
0 • IGNITION "OFF."
~
REPLACE WHEEL SPEED SENSOR•
•
•
DISCONNECT 32-WAY EBCM CONNECTOR .
USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "AS"
AND" A6" OF THE 32-WA Y EBCM HARNESS CONNECTOR.

. DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

G) •
~ s
INSPECT CKTs 882 AND 883 AND 32-WA Y EBCM CONNECTOR FOR DAMAGE WHICH MAY
RESULT IN A SHORT BETWEEN CKTs 882 AND 883 WITH ALL CONNECTORS CONNECTED.
REPAIR ALL DAMAGE IF EVIDENT.
REPAIR SHORT BETWEEN CKTs
882 AND883.
I
• RECONNECT ALL CONNECTORS .
• TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS .
DOES DTC 28 SET AS A CURRENT DTC?

~ ~
0 • INSPECT REAR SENSOR TOOTHED RING IN REAR AXLE DIFFERENTIAL FOR
MISSING TEETH OR OTHER PHYSICAL DAMAGE. REFER TO SECTION 48.
MALFUNCTION IS
INTERMITTENT. REFER TO
IS ANY PHYSICAL DAMAGE INDICATED? "DIAGNOSTIC AIDS" ON
FACING PAGE.
I
sREPLACE EBCM. I
REAR WHEEL SPEED SENSOR
TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
[$]
REPLACE TOOTHED RING. ,
(APPROXIMATE) REFER TO SECTION 48.
TEMP. TEMP. RESISTANCE
(°C} (°F} (OHMS}
-34 T04 -30T040 763TO 1110
ST043 41 TO 110 908 TO 1292
44 T093 111 TO 200 1057T01525 7-16-93
PS 18177
5E1-64 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

LF WHEEL SPEED SIGNAL

::: ::T___. ffi:=====-8-3:::

. C120
::~ =======
LOW
LF WHEEL SPEED SIGNAL
HIGH

LF WHEEL SPEED SENSOR

6-23-93
NS 15728

DTC32
{Page 1 of 3)
LF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring often referred to as the air gap.

OTC Will Set When: DTC 32 can be set anytime after initialization. If either of the left front wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for proper resistance of the wheel speed
sensor coil.
2. Checks for a short to ground in the wheel speed
sensor wiring.
3. Checks for a short to voltage in the wheel speed
sensor wiring.
4. Checks for a short to voltage in CKT 873.
5. Checks for a short to voltage in CKT 830.
6. Ensures that the malfunction was not due to
physical damage of the circuitry.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM. SE1-65

rn
•
Important
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE
DTC32
(Page 1 of 3)
DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOTTO DISTURB ANY LF WHEEL SPEED SNR CKT
ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS
CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL
OPEN OR SHORT TO GND/BATT
NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS
FOUND.

8 • •
IGNITION "OFF."
USING A 5% SALTWATER SOLUTION {TWO TEASPOONS OF SALT TO 12 OZ. WATER}, THOROUGHLY SPRAY THE LEFT
FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
• DISCONNECT 32-WAY EBCM HARNESS CONNECTOR.
• USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "A7" AND "AS" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137Q WHEN SENSOR IS 20°C{68°F}? {IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 20°C (68°F), REFER TO THE TABLE ON PAGE 2 OF 2 OF THIS DTC CHART FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.}

r- --------------,
MEASURETHE RESISTANCE BETWEEN GROUND AND TERMINAL "A7" I DIAGNOSIS CONTINUED I
OF THE 32-WAY EBCM HARNESS CONNECTOR. : ON PAGE 2 OF 3 OF THIS :
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INFINITE}? I DTCCHART. I
....,~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;:.~L~-~---------------~

0 • •
IGNITION"ON."
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
r- - - - - - - - - - - - - - - ,
: DIAGNOSIS CONTINUED
I ON PAGE 3 OF3 OF THIS
•
:
TERMINAL" A7" OF THE 32-WAY EBCM HARNESS CONNECTOR. I DTCCHART. I
IS VOLTAGE 1 VOLT OR LESS? L----------------~

(v •
•
IGNITION "OFF."
DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT
0 • •
IGNITION "OFF."
INSPECT TERMINALS" A 7" AND" AS" OF THE
SENSOR. 32-WA Y EBCM HARNESS CONNECTOR FOR
• IGNITION "ON." POOR TERMINAL CONTACT AND
• USINGJ 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND CONTAMINATION. ALSO INSPECT CKTs 830
TERMINAL "A7" OF THE 32-WAY EBCM HARNESS CONNECTOR. AND 873 FOR DAMAGE WHICH MAY RESULT
IS VOLTAGE 1 VOLT OR LESS? IN AN OPEN CIRCUIT, SHORT TO GROUND, OR
SHORT TO VOLTAGE. REPAIR ALL DAMAGE IF
EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
USING J 39200, MEASURE THE DOES OTC 32 SET AS A CURRENT OTC?
VOLTAGE BETWEEN GROUND AND
TERMINAL" AS" OF THE 32-WAY
EBCM HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?
MALFUNCTION IS
INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
MALFUNCTION IS INTERMITTENT. REPAIR SHORT
INSPECT ALL CONNECTORS AND TO VOLTAGE IN
HARNESSES FOR DAMAGE WHICH CKT830.
MAY RESULTIN A SHORT TO VOLTAGE
WHEN ALL COMPONENTS ARE
CONNECTED. REPAIR ALL DAMAGE If
FOUND. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE FOR MORE
INFORMATION.

7-9-93
NS 15712
SE1-66 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

LF WHEEL SPEED SIGNAL

LOW
LF WHEEL SPEED SIGNAL
HIGH
(120

LF WHEEL SPEED SENSOR

6-23-93
NS15728

DTC32
(Page 2 of 3)
LF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring often referred to as the air gap.

OTC Will Set When: OTC 32 can be set anytime after initialization. If either of the left front wheel speed
circuits are open or shorted to voltage or groun~, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
7. Checks for high resistance in C KT 873.
8. Checks for high resistance in CKT 830.
9. Verifies proper resistance of the wheel speed
sensor coil
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear OTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If OTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if repl~cing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM SE1-67

DTC32
(Page 2 of 3)
LF WHEEL SPEED SNR CKT
r------------------, OPEN OR SHORT TO GND/BATT
: DIAGNOSIS CONTI NU ED :
: FROM PAGE 1 OF 3 OF THIS :
I OTC CHART. 1

0 • DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT

SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A7"
OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL "B" OF
THE LEFT FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

0 • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"AS" OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL
REPAIR HIGH RESISTANCE IN CKT 873 (WHEEL
SPEED SENSOR JUMPER MUST BE REPLACED IF
"A" OF THE LEFT FRONT WHEEL SPEED SENSOR HARNESS DAMAGED).
CONNECTOR.
IS RESISTANCE 2Q OR LESS?

Cv • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"A" AND TERMINAL "B" OF THE LEFT FRONT WHEEL SPEED
REPAIR HIGH RESISTANCE IN CKT 830 (WHEEL
SPEED SENSOR JUMPER MUST BE REPLACED IF
SENSOR CONNECTOR. DAMAGED).
IS RESISTANCE BETWEEN 1020 AND 1137Q WHEN SENSOR IS 2o·c
(68°F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER
THAN 20°C (68°F). REFER TO THE TABLE BELOW FOR APPLICABLE
SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE
FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE INFORMATION.
REPAIR ALL DAMAGE IF FOUND.

FRONT WHEEL SPEED SENSOR

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)

TEMP. TEMP. RESISTANCE

c·c> (°F) (OHMS)

-34 TO 4 -30 TO 40 804 TO 1066

5T043 41T0110 956TO 1240
44 TO 93 111TO 200 1112T01463

7-9-93
PS 18996
5E1-6S ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

LF WHEEL SPEED SIGNAL

LOW
LF WHEEL SPEED SIGNAL
HIGH
C120

LF WHEEL SPEED SENSOR

6-23-93
NS15728

DTC32
(Page 3 of 3)
LF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring often referred to as the air gap.

DTC Will Set When: DTC 32 can be set anytime after initialization. If either of the left front wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
10. Checks for a short to ground in CKT 873.
11. Checks for a short to ground in CKT 830.
12. Checks for a short to ground in the wheel speed
sensor jumper harness.
13. Verifies that the wheel speed sensor is not
internally shorted to ground.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM SE1-69

DTC32
r------------------,
IDIAGNOSIS CONTINUED I {Page 3 of 3)
: FROM PAGE 1 OF 3 OF THIS
I DTC CHART.
:
1
LF WHEEL SPEED SNR CKT OPEN
L_ ----------------J OR SHORT TO GND/BATT
@• DISCONNECT CONNECTOR C120 (LOCATED LH INNER
FRAME RAIL).
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL" A7" OF THE 32-WAY EBCM
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@• USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL" AS" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@ • THOROUGHLY RESPRAY THE LEFT FRONT WHEEL SPEED SENSOR

JUMPER HARNESS WITH THE SALT WATER SOLUTION.

IMPORTANT: DO NOT ALLOWWATERTO ENTER ANY WHEEL

SPEE'D SENSOR CONNECTOR.

• DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT

SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND
AND TERMINAL" A," THEN "B" OF THE LEFT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE) FOR BOTH
MEASUREMENTS?

@· USINGJ 39200, MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL" A" OF THE LEFT FRONT WHEEL SPEED
REPLACE LEFT FRONT WHEEL
SPEED SENSOR JUMPER HARNESS.
SENSOR CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN A SHORT TO
GROUND WHEN ALL COMPONENTS ARE CONNECTED. PAY
PARTICULAR ATTENTION TO THE JUMPER l:IARNESS, SMALL NICKS
OR CUTS CAN CAUSE A MALFUNCTION. REPAIR ANY DAMAGE IF
FOUND. JUMPER HARNESS MUST BE REPLACED IF DAMAGED.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATIQl\l.

7-10-93
PS 18997
SE1-70 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

RF WHEEL SPEED SIGNAL

~-- ::: ::T-----1~:====-8-72:::::

(130
LOW
RF WHEEL SPEED SIGNAL
HIGH

Rf WHEEL SPEED SENSOR

6-23-93
NS15729

DTC33
(Page 1 of 3)
RF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: DTC 33 can be set anytime after initialization. If either of the right front wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for proper resistance of the wheel speed
sensor coil.
2. Checks for a short to ground in the wheel speed
sensor wiring.
3. Checks for a short to voltage in the wheel speed
sensor wiring.
4. Checks for a short to voltage in CKT 833.
5. Checks for a short to voltage in CKT 872.
6. Ensures that the malfunction was not due to
physical damage of the circuitry.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTI.LOCK BRAKE.SYSTEM SE1-71

[XJ1mportant
DTC33
• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE
{Page 1 of 3)
DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB ANY RF WHEEL SPEED SNR CKT
ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS
CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL
OPEN OR SHORT TO
NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS GND/BATT
FOUND.

• IGNITION "OFF."
• USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE RIGHT
FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
• DISCONNECT 32-WAY EBCM HARNESS CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "Al" AND" A4" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 11370 WHEN SENSOR IS 20°C (68°F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 20°C (68°F), REFER TO THE TABLE ON PAGE 2 OF 2 OF THIS OTC.CHART FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

r- -- . --------,. -,
MEASURE THE RESISTANCE BETWEEN GROUND AND TERMINAL" Al" 1 DIAGNOSIS CONTINUED I
OF THE 32-WAY EBCM HARNESS CONNECTOR. : ON PAGE 2 OF 3 OF THIS :
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)1 1 OTC CHART. 1
--,;;;;;;;;;;;;;;;;;;~~~;;;;;;~;;;;;;~;;;;~;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;,~L~-;.-- ------------J
r- --------------,
(v • IGNITION "ON." I DIAGNOSIS CONTINUED I
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND : ONPAGE30F30FTHIS :
TERMINAL" Al" OF THE 32-WAY EBCM HARNESS CONNECTOR. I OTC CHART. I
IS VOLTAGE 1 VOLT OR LESS? L----~-----------J

IGNITION "OFF."
DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR OIRECTL Y AT
0 • •
IGNITION "OFF."
INSPECT TERMINALS" Al" AND" A4" OF THE
SENSOR. 32-WAY EBCM HARNESS CONNE<;TOR FOR
• IGNITION "ON.". ~OOR TERMINAL CONT ACT AND
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND CONTAMINATION. ALSO INSPECT CKTs833
TERMINAL" Al" OF THE 32-WAY EBCM HARNESS CONNECTOR. AND 872 FOR DAMAGE WHICH MAY RESULT
ISVOLTAGE 1 VOLT OR LESS? IN AN OPEN CIRCUIT, SHORT TO GROUND, OR
SHORT TO VOLTAGE. REPAIR ALL DAMAGE IF
EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
USING J 39,200, MEASURE THE QOES OTC 33 SE.T AS A CURRENT OTC?
VOLTAGE BETWEEN GROUND ANO
TERMINAL" A4" OF THE 32-WAY
EBCM HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR '-ESS?
MALFUNCTION IS
INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
MALFUNCTION IS INTERM.ITTENT. REPAIR SHORT
INSPECT ALL CONNECTORS AND TO VOLTAGE IN
HARNESSES FOR DAMAGE WHICH CKT872.
MAY RESULT IN A SHORT TO VOLTAGE
WHEN ALL COMPONENTS ARE
CONNECTED. REPAIR ALL DAMAGE IF
FOUND. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE FOR MORE
INFORMATION.

7-8-93
NS 15713
SE1-72 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

8:==~~--
RF WHEEL SPEED SIGNAL
833WHT _ _ _ __.G]B 833TAN LOW
1---- 872 BLK 872 DK GRN RF WHEEL SPEED SIGNAL
HIGH
C130

RF WHEEL SPEED SENSOR

6-23-93
NS15729

DTC33
. (Page 2 of 3)
RF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

OTC Will Set When: OTC 33 c~nbe set anytime afte~ initialization. If either of the right front wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists.

Action Taken: A malfunction OTC is stqred, ABS is disabled and the ABS warning lamp is turned "ON."
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
7. Checks for high resistance in CKT 833.
8. Checks for high resistance in CKT 872.
9. Verifies proper resistance of the wheel speed
sensor coil.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If OTC is not
current, clear OTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If OTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosio.n
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-73

DTC33
(Page 2 of 3)
RF WHEEL SPEED SNR CKT
OPEN OR SHORT TO GND/BATT
r------------------~
: DIAGNOSIS CONTINUED :
: FROM PAGE 1 OF 3 OF THI.S :
I OTC CHART. 1
----------------J

8 • DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR DIRECTLY AT

SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A3"
OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL "A" OF
THE RIGHT FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL
"A4" OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL
"B" OF THE RIGHT FRONT WHEEL SPEED SENSOR HARNESS
CONNECTOR.
IS RESISTANCE 2Q OR LESS?
R.~PAIR HIGH .RESISTANCE IN CKT 833 (WHEEL
SPEED SENSOR JUMPER MUST BE REPLACED IF
DAMAGED).

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL REPAIR HIGH RESISTANCE IN CKT872 (WHUL
"A" AND TERMINAL "8" OF THE RIGHT FRONT WHEEL SPEED SPEED SENSOR JUMPER MUST BE REPLACED IF
SENSOR CONNECTOR. DAMAGED).
IS RESISTANCE BETWEEN 1020 AND 11370 WHEN SENSOR IS 2o·c
(68°F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER
THAN 20°C (68°F), REFER TO THE TABLE BELOW FOR APPLICABLE
SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE
FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER TO
"DIAGNOSTIC AID,S" ON FACING PAGE FOR MORE INFORMATION.
REPAIR ALL DAMAGE If FOUND.

FRONT WHEEL SPEED SENSOR

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)

TEMP. TEMP. RESISTANCE

("C) ("F) (OHMS)

-34 TO 4 -30 TO 40 804TO 1066

ST043 41 T0110 956 TO 1240
44 TO 93 111 TO 200 1112TO 1463

7-9-93
PS 18994
5E1-74 ANTILOCK BRA.KE SYSTEM

EBCM

ABS JUMPER HARNESS

RF WHEEL SPEED SIGNAL

LOW
RF WHEEL SPEED SIGNAL
HIGH
C130

RF WHEEL SPEED SENSOR

6·23-93
NS,15729

DTC33
. . (P~ge, .,3 of 3)
RF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Descriptic>n:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. Th~
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
'.toothed ring, often referred to as the air gap.

DTC Will Set W~e,n: DTC 33 can be set anytime after initialization. If either of the right front wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists. ·

Action Taken: A malfunction DTC is stored, ABS is·disabled and the ABS warning lamp is turned ''ON."
DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
10. Checks for a short to ground in CKT 833.
11. Checks for a short to ground in CKT 872.
12. Checks for a short to ground in the wheel speed
sensor jumper harness.
13. Verifies that the wheel speed sensor is not
internally shorted to ground.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is· not
::current, clear DTCs and simulate the effects of water
int.rusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
re.turns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section;
 ANTILOCK BRAKE SYSTEM SE1-75

DTC33
r------------------,
IDIAGNOSIS CONTINUED I
{Page 3 of 3)
: FROM PAGE 1 OF 3 OF THIS : RF WHEEL SPEED SNR CKT
I OTC CHART.
L- ----------------J
1
OPEN OR SHORT TO GND/BATT
@• DISCONNECT CONNECTOR C130 (LOCATED RH INNER
FRAME RAIL).
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL" A3" OF THE 32-WAY EBCM
HARNESS CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@• USINGJ 39200,MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL" A4" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@ • THOROUGHLY RESPRAY THE RIGHT FRONT WHEEL SPEED

SENSOR JUMPER HARNESS WITH THE SALT WATER SOLUTION.

IMPORTANT: DO NOT ALLOW WATER TO ENTER ANY WHEEL

SPEED SENSOR CONNECTOR.

• DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR DIRECTLY AT

SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND
AND TERMINAL" A," THEN "B" OF THE RIGHT FRONT WHEEL
SPEED SENSOR HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE) FOR BOTH
MEASUREMENTS?

@ • USING J39200, MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL" A" OF THE RIGHT FRONT WHEEL SPEED
SENSOR CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN A SHORT TO
GROUND WHEN ALL COMPONENTS ARE CONNECTED. PAY
PARTICULAR ATTENTION TO THE JUMPER HARNESS, SMALL NICKS
OR CUTS CAN CAUSE A MALFUNCTION. REPAIR ANY DAMAGE IF
FOUND. JUMPER HARNESS MUST BE REPLACED IF DAMAGED.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATION.

7.9.93
PS 18995
SE1·76 ANTILOCKBRAJ(E SYSTEM

EBCM

ABS JUMPER HARNES.S

r--, r- _l
88.2 WHT ~ 8 8 2 BRN ~ 8 8 2 BRN REAR WHEEL SPEED
SIGNAL HIGH

883 BLK -ET-

I

L__ J
I
883 WHT +Bf
I

L__ J
I
883 WHT REAR WHEEL SPEED
SIGNAL LOW

(4058 C200A
REAR WHEEL SPEED SENSOR
(405( C200D

6-27-93
NS 15730

DTC35
(Page 1 of3)
RR WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed s~hsor to the
toothed ring, often referred to as the air gap.

DTC Will Set When: DTC 35 can be set anytime after init.ialization. If either of the right .rear wheel speed
.circuits are open or shorted to voltage or ground, a malfunction exists. .

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."
DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for proper resistance of the wheel speed
sensor coil.
2. Checks for a short to ground in the wheel speed
sensor wiring.
3. Checks for a short to voltage in the wheel speed
sensor wiring.
4. Checks for a short to voltage in CKT 883.
5. Checks for a short to voltage in CKT 882.
6. Ensures that the malfunction was not due to
physical damage of the circuitry.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
environ:qiental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicl~
over various road surfaces (bumps,· turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical darp.age to
the wiring harness.
Resistance of the whe.el speed sensor will increase
with an increase in sensor tE!mperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-77

DTC35
[I] Important (Page 1 of 3)
• WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE
DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOTTO DISTURB ANY RR WHEEL SPEED SNR CKT
ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS OPEN OR SHORT TO GND/BATI
CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL
NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS
FOUND.

G). IGNITION "OFF."

• USING A 5% SALTWATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER). THOROUGHLY SPRAY THE REAR
WHEEL SPEED SENSOR JUMPER HARNESS.
• DISCONNECT 32-WAY EBCM HARNESS CONNECTOR .
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "AS" AND "A6" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 969 AND 1185Q WHEN SENSOR IS 20°C (68°F)? (IFTEMPERATUREOFSENSORIS SUSPECTED TO
OTHER THAN 20°C (68°F}. REFER TO THE TABLE ON PAGE 2 OF 2 OF THIS DTC CHART FOR APPLICABLE SENSOR RESISTANCE

. VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

[$] ~ -- - - - - - - - - - - - - ,
G) • MEASURE THE RESISTANCE BETWEEN GROUND AND TERMINAL" AS"
OF THE 32-WAY EBCM HARNESS CONNECTOR.
r
: DIAGNOSIS CONTINUED
I ON PAGE 2 OF 3 OF THIS
I
I
I
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)? ~DTCCHART. ________ _!

[$] ~-
G). IGNITION "ON."
1
I
-------------,
DIAGNOSIS CONTINUED I
I
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND : ON PAGE 3 OF 3 OF THIS
I DTCCHART.
I
I
TERMINAL" AS" OF THE 32-WAY EBCM HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS? ~----------------~

G) •
~
IGNITION "OFF."
s
G) • IGNITION "OFF."
•• DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.
IGNITION "ON."
• INSPECT TERMINALS" AS" AND" A6" OF THE
32-WAY EBCM HARNESS CONNECTOR FOR
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND POOR TERMINAL CONTACT AND
TERMINAL" AS" OF THE 32-WAY EBCM HARNESS CONNECTOR. CONTAMINATION. ALSO INSPECTCKTs882
IS VOLTAGE 1 VOLT OR LESS? AND 883 FOR DAMAGE WHICH MAY RESULT
IN AN OPEN CIRCUIT, SHORT TO GROUND, OR

s
" •
0 USING J 39200, MEASURE THE
~
REPAIR SHORT TO I •
•
SHORT TO VOLTAGE. REPAIR ALL DAMAGE IF
EVIDENT.
RECONNECT ALL CONNECTORS .
IGNITION "ON."
VOLTAGE BETWEEN GROUND AND VOLTAGE IN CKT883. DOES OTC 35 SET AS A CURRENT OTC?
TERMINAL "A6" OF THE 32-WAY
EBCM HARNESS CONNECTOR.
.
IS VOLTAGE 1 VOLT OR LESS?
~ ~
s
MALFUNCTION IS INTERMITTENT.
~
REPAIR SHORT
REPLACE EBCM. I MALFUNCTION IS
INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
INSPECT ALL CONNECTORS AND TO VOLTAGE IN
HARNESSES FOR DAMAGE WHICH CKT882.
MAY RESULT IN A SHORT TO VOLTAGE
WHEN ALL COMPONENTS ARE
CONNECTED. REPAIR ALL DAMAGE IF
FOUND. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE FOR MORE
INFORMATION.

7-8-93
NS 15714
 SE1-78 ANTILOCK BRAKE SYSTEM

EBCM

r--,
ABS JUMPER HARNESS r __ ,
B 882WHT~882BRN~882BRN REAR WHEEL SPEED
SIGNAL HIGH
I I I I
883 BLK ~ 8 8 3 WHT ~ 883 WHT REAR WHEEL SPEED
SIGNAL LOW
L __ J L __ J
C405B C200A
REAR WHEEL SPEED SENSOR
C405C C200D

6-27-93
NS 15730

DTC35
(Page 2 of 3)
RR WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

DTC Will Set When: DTC 35 can be set anytime after initialization. If either of the right rear wheel speed
circuits are open or shorted to voltage or ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."
DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
7. Checks for high resistance in CKT 833.
8. Checks for high resistance in CKT 882.
9. Verifies proper resistance of the wheel speed
sensor coil.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
.wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ABS
warning lamp is "ON" only during moist
. environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
.the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-79

DTC35
(Page 2 of 3)
RR WHEEL SPEED SNR CKT OPEN
OR SHORT TO GND/BATT

: DIAGNOSIS CONTINUED :
: FROM PAGE 1 OF 3 OF THIS :
I OTC CHART. I
L- ----------------J
G) • DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" AS"
OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL" A" OF
THE REAR WHEEL SPEED SENSOR HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

0 • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"A6" OF THE 32-WAY EBCM HARNESS CONNECTOR AND TERMINAL
"B" OF THE REAR WHEEL SPEED SENSOR HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?
REPAIR HIGH RESISTANCE IN CKT 883 (WHEEL
SPEED SENSOR JUMPER MUST BE REPLACED IF
DAMAGED).

(v • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL REPAIR HIGH RESISTANCE IN CKT 882 (WHEEL
"A" AND TERMINAL "B" Of THE REAR WHEEL SPEED SENSOR SPEED SENSOR JUMPER MUST BE REPLACED IF
CONNECTOR. DAMAGED).
IS RESISTANCE BETWEEN 969 AND 1185Q WHEN SENSOR IS 20°C
(68°F)? (/F TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER
THAN 20°C (68°F), REFER TO THE TABLE BELOW FOR APPLICABLE
SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE
FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

MALFUNCTION IS INTERMITTENT. 1.NSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE INFORMATION.
REPAIR ALL DAMAGE IF FOUND.

REAR WHEEL SPEED SENSOR

TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)

TEMP. TEMP. RESISTANCE

. ("C) ("F) (OHMS)

-34 TO 4 -30 TO 40 763 TO 1110

5 T043 41TO 110 908TO 1292
44 TO 93 111 TO 200 1057 TQ 1525

7-9-93
PS18993
5E1-80 ANTILOCK BRAKE SYSTEM

EBCM

ABS JUMPER HARNESS

r--, r __ l
B 882WHT~882BRN~882BRN REAR WHEEL SPEED
SIGNAL HIGH

883 BLK ---+0-!-

I

L __ J
I
883 WHT -Bf
I

L __ J
I
883 WHT REAR WHEEL SPEED
SIGNAL LOW

C405B C200A
REAR WHEEL SPEED SENSOR
C405C C200D

6-27-93
NS 15730

DTC35
(Page 3 of 3)
RR WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BATT
Circuit Description:
As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.

DTC Will Set When: DTC 35 can be set anytime after initialization. If either of the right rear wheel speed
circuits are open or shorted to voltage or ground, a malfunction exii;;ts.

Action Taken: A malfunction DTC is stored, ABS is disabled and the ABS warning lamp is turned "ON."
DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
10. Checks for a short to ground in CKT 883.
11. Checks for a short to ground in CKT 882.
12. Checks for a short to ground in the wheel speed
sensor jumper harness.
13. Verifies that the wheel speed sensor is not
internally shorted to ground.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the
Tech 1, as described in "Tech 1 Diagnostics" found in
this section.
If the customer's comments reflect that the ·ABS
warning lamp is "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly forrp.ed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
jumper harness. Likewise, if replacing a wheel speed
sensor jumper harness, inspect sensor terminals. If
evidence of corrosion or water intrusion exists, replace
wheel speed sensor. Refer to "On-Vehicle Service" in
this section.
 ANTILOCK BRAKE SYSTEM 5E1-81

DTC35
r------------------,
IDIAGNOSIS CONTINUED I
{Page 3 of 3)
: FROM PAGE 1 OF 3 OF THIS : RR WHEEL SPEED SNR CKT OPEN
I DTC CHART. 1
L_ ----------------J OR SHORT TO GND/BATT
@• DISCONNECTCONNECTORC405B, C40SC(LOCATED ON
THE LH SIDE REAR UNDER BODY, BEHIND REAR SEAT).
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL "AS" OF THE 32-WAY EBCM
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@• USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL "A6" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

@• THOROUGHLY RESPRAY THE REAR WHEEL SPEED SENSOR

JUMPER HARNESS WITH THE SALTWATER SOLUTION.

IMPORTANT: DO NOT ALLOWWATERTO ENTER ANY WHEEL

SPEED SENSOR CONNECTOR.

• DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

• USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND
AND TERMINAL" A," THEN "B" OF THE REAR WHEEL SPEED
SENSOR HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE) FOR BOTH
MEASUREMENTS?

USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL" A" OF THE REAR WHEEL SPEED SENSOR
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN A SHORT TO
GROUND WHEN ALL COMPONENTS ARE CONNECTED. PAY
PARTICULAR ATTENTION TO THE JUMPER HARNESS, SMALL NICKS
OR CUTS CAN CAUSE A MALFUNCTION. REPAIR ANY DAMAGE IF
FOUND. JUMPER HARNESS MUST BE REPLACED If DAMAGED.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATION.

7-10-93
PS 18992
SE1-82 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
300 ORN . - - - - - - ~ - - - - - - - - - - - 6 4 1 BRN------1

ABSl~N .· ··1 ·
FUSE: 5122
641 BRN 1632 PNK ABS ENAB.LE RELAY CONTROL
B+ SAMP
·~_r302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKS
5180 5272 ·

6-23-93
NS 15732

DTC36
(Page 1 of 2)
LOW SYSTEM VOLTAGE
Circuit Description:
This DTC is used to monitor the voltage level available to the EBCM controller. If the voltage drops below
11.5 volts, full performance of the ABS system cannot be guaranteed. During ABS operation, there are several
current requirements that will cause battery voltage to drop. Because of this, voltage is monitored prior to ABS
to indicate good charging system condition and also during ABS when voltage may drop significantly.

OTC Will Set When: DTC 36 can only be set if the vehicle's speed is greater than 5 km/h (3 mph). If the
switched battery voltage is less than 11.5 volts non-ABS or.; less than 9.0 volts ABS, a malfunction exists.

Action Taken: A malfunction DTC is stox:ed, ABS.is disabled and.the "ABS INOP" lamp is turned "ON."
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the.diagnostic chart.
1. Checks to see what voltage is readily available at
terminal "D" of the EBCM. If voltage is
representative of good charging system condition,
a malfunction is not present. . .
2. Isolates the condition to high circuit resistance, or ·
improper charging system operation.
3. Isolates which circuit is the source of the low
voltage condition.
4. Checks for high resistance in CKT 302.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for hacked out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
While performing a voltage load test, if it is noted
that only ignition voltage drops below acceptable
voltage levels, CKT 641 should be checked for high
resistance or an open condition.
 ANTILOCK BRAKE SYSTEM 5E1-83

DTC36
(Page 1 of 2)
LOW SYSTEM VOLTAGE

Q • START ENGINE.
• USING TECH 1, SELECT "F3: SNAPSHOT."
• SELECT "F4: SINGLE DTC"; THEN ENTER "36".
• DRIVE VEHICLE ABOVE 5 km/h (3 MPH).
DID TECH 1 TRIGGER?

YES

• WITH ENGINE RUNNING, USE TECH 1 AND SELECT "F4: MISC. TESTS."
• PERFORM "VOLTAGE LOAD" TEST.
ARE IGNITION AND BATTERY VOLTAGES GREATER THAN 10 VOLTS?

REFER TO SECTION 603 TO DIAGNOSE CHARGING SYSTEM.

IS CHARGING SYSTEM OK?

r- -------------,
• IGNITION "OFF." • REFER TO SECTION 603 1
I DISCONNECT 8-WAY AND 32-WAY EBCM CONNECTORS. : TO CORRECT LOW :
I DISCONNECT ABS ENABLE RELAY. I VOLTAGE CONDITION. 1
I USING J 39200 MEASURE RESISTANCE BETWEEN TERMINAL L---------------J
"C4" OF THE ABS ENABLE RELAY HARNESS CONNECTOR AND
TERMINAL "D" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

0 • •
DISCONNECT NEGATIVE BATTERY CABLE.
DISCONNECT POSITIVE BATTERY CABLE.
• REPAIR HIGH
RESISTANCE
• USING J 39200 MEASURE RESISTANCE BETWEEN THE INCKT1633.
POSITIVE BATTERY CABLE TERMINAL AND TERMINAL "C1"
OF THE ABS ENABLE RELAY HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

YES

• REPAIR HIGH
RESISTANCE
INCKT302.

r --------,
I DIAGNOSIS I
: CONTINUED :
I ON PAGE 2 1
: OF 2 OF THIS :
I DTC CHART. I
L---------J

7-7-93
NS 15715
SE1-84 ANTILOCK BRAKE SYSTEM

TO
IGN3 EBCM
t
300 ORN , . . . . . . . - ~ - - - - - - - - - - - - - 6 4 1 BRN-----1

~t~~!
I~ [
s122!
1632 PNK ---1 83 ABS ENABLE RELAY CONTROL
B+ SAMP
l~302RED 1633 RED
SWITCHED BATTERY INPUT
~302RED 1633 RED
LINKB
5180 5272

6-23-93
NS 15732

DTC36
(Page 2 of 2)
LOW SYSTEM VOLTAGE
Circuit Description:
This OTC is used to monitor the voltage level available to the EBCM controller. If the voltage drops below
11.5 volts, full performance of the ABS system cannot be guaranteed. During ABS operation, there are several
current requirements that will cause battery voltage to drop. Because of this, voltage is monitored prior to ABS
to indicate good charging system condition and also during ABS when voltage may drop significantly.

OTC Will Set When: OTC 36 can only be set if the vehicle's speed is greater than 5 km/h (3 mph). If the
switched battery voltage is less than 11.5 volts non-ABS or less than 9.0 volts ABS, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
5. Checks for high resistance in CKT 641.
6. Checks for high resistance in the ignition fuse feed
circuit.
7. Checks for malfunctioning EBCM.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
While performing a voltage load test, if it is noted
that only ignition voltage drops below acceptable
voltage levels, CKT 641 should be checked for high
resistance or an open condition.
 ANTILOCK BRAKESYSTElyt 5.E1~ss

DTC36
{Page 2 of 2)
LOW SYSTEM VOLTAGE

r------------------------------------
I DIAGNOSIS
--,
CONTINUED FROM PAGE 1 OF 2 OF THIS OTC CHART. I
L --------------------------------------J
0 • •
REMOVE ABS IGN 5 AMP FUSE 5.
USING J 39200 MEASURE RESISTANCE BETWEEN EACH ABS IGN 5 AMP FUSE 5 BLOCK
TERMINAL AND TERMINAL "811" OF THE 32-WAY EBCM HARNESS CONNECTOR.
IS EITHER MEASUREMENT 20 OR LESS?

@ • WITH BATTERY CABLES DISCONNECTED, TURN IGNITION "ON" {THIS

PROVIDES IGNITION CIRCUIT CONTINUITY).
• USINGJ 39200, MEASURE RESISTANCE BETWEEN POSITIVE BATTERY
CABLE TERMINAL AND EACH ABS IGN 5 AMP FUSE 5 BLOCK TERMINAL.
IS EITHER MEASUREMENT 20 OR LESS?

r -------------------,
• IGNITION "Off." : REF.ER TO SECTION .BA TO REPAIR I
I HIGH RESISTANCE IN THE - .. :
• INSPECT ABS ENABLE RELAY AND ABS ENABLE RELAY HARNESS
: ..IGNITION SWITCH 'RUN' FUSE I
CONNECTOR FOR POOR TERMINAL CONTACT. INSPECT 8-WAY I FEED" CIRCUIT. :
AND 32-WAY EBCM HARNESS CONNECTORS FOR A POOR
CONNECTION TO THE EBCM. INSPECT 'POSITIVE BATTERY
~---. ----------------J
CABLE TERMINAL FOR POOR CONTACT TO THE BATTERY.
REFER TO SECTION 8A-4, "CHECKING TERMINAL CONTACT."
REPLACE.TERMINALS IF POOR CONTACT.IS .EVIDENT.
• RECONNECT ALL CONNECTORS.
• DRIVE VEHICLE ABOVE 5 km/h (3 MPH).
DOES OTC 36 SET AS A CURRENT OTC?

MALFUNCTION IS MOST LIKELY DUE

TO A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

7-2-93
PS 18940
SE1-86 ANTILOCK BRAKE SYSTEM

EBCM

1632 PNK ---1 83 ABS ENABLE RELAY CONTROL

1633 RED
SWITCHED BATTERY INPUT
1633 RED
5180 5272

6-23·93
NS 15732

DTC37
HIGH SYSTEM VOLTAGE
Circuit Description:
This DTC is designed to detect high vehicle voltage levels prior to any required motor movement
(initialization or ABS). If excessive voltage exists, demagnetization of the motor magnets may occur, which
would eventually affect or eliminate ABS performance.

OTC Will Set When: DTC 37 can only be set if the vehicle's speed is greater than 5 km/h (3 mph). If the
switched battery voltage is greater than 17 volts, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is dj_sablfld and the "ABS INOP;' lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks the voltage level being received by the
EBCM.
2. Checks to see if high voltage condition .is due to
charging system malfunction.· ·. · by using the enhanced diagnostic function of the Tech
3. Checks for poor terminal contact which may cause
an intermittent malfunctioning, or a
malfunctioning EBCM.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-87

DTC37
HIGH SYSTEM VOLTAGE

r.j'\ • TURN All ACCESSORIES "OFF."

\..:..) • START ENGINE.
• USING TECH 1, SELECT "FO: DATA LIST" AND MONITOR EBCM
BATTERY VOLTAGE WHILE RUNNING ENGINE AT
APPROXIMATELY 2000 RPM.
IS EBCM BATTERY VOLTAGE LESS THAN 16 VOLTS?

0 • •
IGNITION "OFF."
DISCONNECT ABS ENABLE RELAY.
MALFUNCTION NOT PRESENT AT
THIS TIME. REFER TO "DIAGNOSTIC
• START ENGINE. AIDS" ON FACING PAGE.
• USING J 39200, MEASURE VOLTAGE BETWEEN ABS ENABLE
RELAY HARNESS CONNECTOR TERMINAL "C1" AND GROUND
WHILE RUNNING ENGINE AT APPROXIMATELY 2000 RPM.
IS VOLTAGE LESS THAN 16 VOLTS?

r- --------------------,
: REFER TO SECTION 603 TO CHECK :
I CHARGING SYSTEM OPERATION. I
0 •
•
IGNITION "OFF.·
RECONNECT ABS ENABLE RELAY.
L----------------------J • DRIVE VEHICLE ABOVE 5 km/h (3 MPH).
DID OTC 37 SET AS A CURRENT OTC?

MALFUNCTION IS
INTERMITTENT. REFER
TO "DIAGNOSTIC AIDS"
ON FACING PAGE.

7-7-93
NS 15716
SE1-88 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

OTC38
LEFT FRONT ESB WILL NOT HOLD MOTOR
Circuit Description:
This DTC is designed to detect a slipping left front ESB. During initialization and braking, the left front
motor is re-homed. If the ESB slips, the motor/piston will move. During the next key "ON" initialization, a re-
home of the motor verifies the motor/piston remained at the home position. If motor movement is detected, the
ESB must be slipping.

DTC Will Set When: DTC 38 can be set during initialization. If the EBCM detects that the ESB could not
hold the piston in the home position, a malfunction exists. DTC 86 is always set with DTC 38.
', ,,;

Action Taken: If an ESB cannot hold a piston in the home position, the piston may be backdriven when the
brake pedal is applied, causing the brake pedal to drop. A malfunction DTC is stored, ABS is disabled, and the
"ABS INOP" lamp and the red"BRAKE" warning lamp are turned "ON."

DTC Chart Test Description: Number(s) below Diagnostic Aids: An "Intermittent" malfunction in
refer to circled number(s) on the diagnostic chart. this DTC may result from a mechanical part of the
1. Checks the left front ESB. A broken or defective system that sticks, binds, or slips.
ESB would result in the left front piston being The frequency of the malfunction can be checked
backdriven by hydraulic pressure and pedal by using the enhanced diagnostic function of the Tech
movement would result. 1, as described in "Tech 1 Diagnostics" found in this
2. This step ensures that the proper motor circuits section.
are located in the proper,connector cavities. The static modulator test function of the Tech 1 dr
3. Checks for high resistance in the ABS motor T-100 may be used to locate an intermittent
"HIGH" circuitry. malfunction associated with the ESB.
4. This step checks for high resistance in the ABS
motor "LOW" circuitry.
5. Checks for proper resistance of the ABS motor
windings.
6. Checks for poor terminal contact or corrosion in
the connectors.
7. Checks for a malfunctioning EBCM.
 ANTILOCK BRAKE SYSTEM 5E1-89

,;"'.,

0 •• IGNITION ''ON," ENGINE "OFF."

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE. DTC38
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION .
• SELECT MOTOR APPLY FUNCTION OF THE LEFT FRONT ABS
CHANNEL AND APPLY THE MOTOR.
LEFT FRONT ESB WILL NOT
• WAIT 5 SECONDS.
HOLD MOTOR
• APPLY FIRM PRESSURE ON BRAKE PEDAL.
DID BRAKE PEDAL FALL? NOTICE: J 39200 TEST LEADS MUST
BE "ZEROED" PRIOR TO MAKING ANY

.0•
r"I
§]
VISUALLY INSPECT THE 6-WAY ABS MOTOR PACK AND 8-WAY EBCM
s RESISTANCE MEASUREMENTS.
REFER TO J 39200 USER'S MANUAL.

IREPLACE ABS MOTOR PACK. I

·.

CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY

COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?
.
',,..........,
0
8
• IGNITION "OFF."
sUSING THE CIRCUIT DIAGRAMS
• DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND 8-WAY LOCATED IN THE FRONT OF THIS
EBCM CONNECTOR. SECTION, PLACE THE PROPER
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A" WIRES INTO THE PROPER
OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND CONNECTOR CAVITIES. CLEAR
TERMINAL" A" OF THE 8-WAY EBCM HARNESS CONNECTOR. DTCs AND RECHECK SYSTEM.
IS RESISTANCE 1.50 OR LESS?

s
•

/'""""
8
~ • MEASURE THE RESISTANCE BETWEEN TERMINAL "B" OF THE REPAIR HIGH RESISTANCE IN CKT 1280.1
6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND
TERMINAL "B" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.50 OR LESS?
.
,;"'.,
~
§]
• MEASURE THE RESISTANCE BETWEEN TERMINAL "A" AND TERMINAL "B"
sREPAIR HIGH RESISTANCE IN CKT 1281. I
OF THE ABS MOTOR PACK CONNECTOR.
15 RESISTANCE 1.50 OR LESS?

s
I

,;"'.,
~
s• INSPECT THE 6-WAY ABS MOTORPACKCONNECTORAND8-WAY EBCM REPLACE ABS MOTOR PACK. I
CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO
SECTION 8A-4, "CHECKING TERMINAL CONTACT."
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF CORROSION?
•

~
§] 8
0 •• IGNITION "OFF."
RECONNECT ALL CONNECTORS.
REPLACE TERMINALS THAT EXHIBIT
POOR TERMINAL CONTACT OR
• START ENGINE WITH FOOT OFF BRAKE . EVIDENCE OF CORROSION.
•• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS .
REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 38 SET IN THE LAST THREE IGNITION CYCLES?

8
REPLACE EBCM. I
8
MALFUNCTION IS INTERMITTENT. REFER I
TO "DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES 6 _24 _93
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN KEYING DOWN. NS 16171
5E1-90 ANTILOCKBRAKE SYSTEM

EBCIV(

----------------- 1282PPL R/F MOTOR HIGH

~h~S~
MOTOR PACK
0®
6 WAY CONNECTOR
M
F - - - - - ' - - - - - - - 1283 BLK/PNK
.
R/F MOTOR LOW

6-17-92
MS12768

DTC41
RIGHT FRONT ESB WILL NOT HOLD MOTOR
Circuit Description:
This OTC is designed to detect a slipping right front ESB. During initialization and braking, thedghtfront
motor is re-homed. If the ESB slips, the motor/piston will move. During the n,ext key "ON" initialization, a re-
home of the motor verifies the motor/piston remained at the home position. If motor movement is detected, the
ESB must be slipping.

OTC Will Set When: OTC 41 can be set during initialization. If the EBCM detects that the ESB could not
hold the piston in the home position, a malfunction exists. DTC86 is always set with OTC 41.

Action Taken: If an ESB cannot hold a piston in the home position, the piston may be backdriven when the
brake pedal is applied, causing the brake pedal to drop. A malfunction DTC is stored, ABS is disabled, and the
"ABS INOP" lamp and the red "BRAKE" warning lamp are turned "ON."

OTC Chart Test Description: Number(s) below Diagnostic Aids: An "Intermittent" malfunction in
refer to circled number(s) on the diagnostic chart. this DTC may result from a mechanical part of the
1. Checks the right front ESB. A broken or defective system that sticks, binds, or slips.
ESB would result in the right front piston being The frequency of the malfunction can pe checked
backdriven by hydraulic pressure, and pedal by using the enhanced diagnostic function of the Tech
movement would result. · 1, as described. in "Tecb 1 Diagnostics" found in this
2. Ensures that the proper motor circuits are located section.
in the proper connector ca vities. The static modulator test function of the Tech 1 or
3. Checks for high resistance in the ABS motor T-100 may be used to l.ocate an intermittent
"HIGH" circuitry. malfunction associated with the ESB.
4. This step checks for high resistance in the ABS
motor "LOW" circuitry.
5. Checks for proper resistance of the ABS motor
windings.
6. Checks for poor terminal contact or corrosion in
the connectors.
7. Checks for a malfunctioning EBCM.
 ANTILOCK BRAKE SYSTEM SE1-91

G). IGNITION "ON," ENGINE "OFF."

• PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE. DTC41
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION .
RIGHT FRONT ESB WILL NOT
• SELECT MOTOR APPLY FUNCTION OF THE RIGHT FRONT ABS
CHANNEL AND APPLY THE MOTOR.
• WAIT 5 SECONDS.
HOLD MOTOR
• APPLY FIRM PRESSURE ON BRAKE PEDAL.
NOTICE: J 39200 TEST LEADS MUST
DID BRAKE PEDAL FALL? BE "ZEROED" PRIOR TO MAKING ANY

G).
s VISUALLY INSPECT THE 6-WA Y ABS MOTOR PACK AND 8-WAY EBCM
8
RESISTANCE MEASUREMENTS.
REFER TO J 39200 USER'S MANUAL.

REPLACE ABS MOTOR PACK. I

CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY
COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?

s
I

s
.G) • IGNITION "OFF." USING THE CIRCUIT DIAGRAMS LOCATED
• DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND 8-WAY IN THE FRONT OF THIS SECTION, PLACE
EBCM CONNECTOR. THE PROPER WIRES INTO THE PROPER
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" CONNECTOR CAVITIES. CLEAR DTCs AND
OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND RECHECK SYSTEM.
TERMINAL "G" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.50 OR LESS?

Q •
s MEASURE THE RESISTANCE BETWEEN TERMINAL "F" OF THE
sREPAIR HIGH RESISTANCE IN CKT 1282. ,
6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND
TERMINAL "H" OF THE 8,WAY EBCM HARNESS CONNECTOR.

. IS RESISTANCE 1.50 OR LESS?

G) •
s MEASURE THE RESISTANCE BETWEEN TERMINAL ''E'' AND
sREPAIR HIGH RESISTANCE IN CKT 1283. I
TERMINAL "F" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE 1.50 OR LESS?
•
s
Cv •
.
INSPECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND 8-WAY EBCM
sREPLACE ABS MOTOR PACK. I
CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO
SECTION 8A-4, "CHECKING TERMINAL CONTACT."
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF CORROSION?

s s
I

8 • •
IGNITION "OFF."
RECONNECT ALL CONNECTORS.
REPLACE TERMINALS THAT EXHIBIT
POOR TERMINAL CONTACT OR
• START ENGINE WITH FOOT OFF BRAKE. EVIDENCE OF CORROSION.
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
• REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES .
DID DTC 41 SET IN THE LAST THREE IGNITION CYCLES?

s
•

s REPLACE EBCM. I MALFUNCTION IS INTERMITTENT. REFER I

TO "DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES 6-24-93
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH} AND THEN KEYING DOWN. NS 16172
SE1 .. 92 ANTILOCK BRAKE SYSTEM

EBCM

C REAR ABS MOTOR HIGH

1---------------- 1285 ORN -----' F REAR ABS MOTOR LOW

ABS MOTOR PACK

6 WAY CONNECTOR

6-18-93
MS 12769

DTC42
REAR ESB WILL NOT HOLD MOTOR
Circuit Description:
This DTC is designed to detect a slipping rear axle ESB. During initialization and braking, the rear motor is
re-homed. If the ESB slips, the motor/piston will move. During the next key "ON" initialization, a re-home of the
motor verifies the motor/piston remained at the home position. If motor movement is detected, the ESB must be
slipping.

OTC Will Set When: DTC 42 can be set during initialization. If the EBCM detects that the ESB could not
hold the piston in the home position, a malfunction exists. DTC 86 is always set with DTC 42.

Action Taken: If an ESB can hold a piston in the home position, the piston may be backdriven when the brake
pedal is applied, causing the brake pedal to drop. A malfunction DTC is stored, ABS is disabled, and the "ABS
INOP" lamp and the red "BRAKE" warning lamp are turned "ON."

OTC Chart Test Description: Number(s) below Diagnostic Aids: An "Intermittent" malfunction in
refer to circled number(s) on the diagnostic <:hart. this .DTC ~ay resu,lt from a mechanical part of the
1. Checks the rear axle ESB. A broken or defective system that sticks, binds, or slips.
ESB would result in the rear axle pistons being The frequency of the malfunction can be checked
backdriven by hydraulic pressure and wheel by using the enhanced diagnostic function of the Tech
movement would result. 1, as described in "Tech 1 Diagnostics" found in this
2. Ensures that the proper motor circuits are located section.
in the proper connector cavities. The static modulator test function of the Tech 1 or
3. Checks for high resistance in the ABS motor T-100 may be used to locate an intermittent
"HIGH" circuitry. malfunction associated with the ESB.
4. Checks for high resistance m the ABS motor
"LOW" circuitry.
5. Checks for proper resistance of the ABS motor
windings.
6. Checks for poor terminal contact or corrosion in
the connectors.
7. Checks for a malfunctioning EBCM.
 ANTILOCK BRAKE SYSTEM SE1-93

~
DTC42
~ • APPROXIMATELY
RAISE THE VEHICLE SUCH THAT THE REAR WHEELS ARE
SIX INCHES OFF THE FLOOR. REAR ESB WILL NOT
• IGNITION "ON," ENGINE "OFF." HOLD MOTOR
•• APPLY
PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE .
FIRM PRESSURE ON BRAKE PEDAL AND RELEASE. NOTICE: J 39200 TEST LEADS MUST
• REAPPLY VERY FIRM PRESSURE ON BRAKE PEDAL AND HAVE AN BE "ZEROED" PRIOR TO MAKING ANY
ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND. RESISTANCE MEASUREMENTS. REFER
COULD ASSISTANT SPIN THE REAR WHEELS? TO J 39200 USER'S MANUAL.

,,,-.......,
~
s
• VISUALLY INSPECT THE 6-WAY ABS MOTOR PACK AND 8-WAY EBCM
sREPLACE ABS MOTOR PACK. I
CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?
•

v--,,
0
SJ
• IGNITION "OFF."
sUSING THE CIRCUIT DIAGRAMS
• DISCONNECT 6-WA Y ABS MOTOR PACK CONNECTOR AND 8-WAY EBCM CONNECTOR. LOCATED IN THE FRONT OF THIS
• USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF THE 6-WAY
ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "C" OF THE 8-WAY EBCM
SECTION, PLACE THE PROPER
WIRES INTO THE PROPER
HARNESS CONNECTOR. CONNECTOR CAVITIES. CLEAR
IS RESISTANCE 1.50 OR LESS? DTCs AND RECHECK SYSTEM .

s
•

~
~ • MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF THE 6-WAY ABS MOTOR PACK
sREPAIR HIGH
HARNESS CONNECTOR AND TERMINAL 'T' OF THE 8-WAY EBCM HARNESS CONNECTOR. RESISTANCE
IS RESISTANCE 1.50 OR LESS? INCKT 1284.
•

,::....,
\2.) •
SJ MEASURE THE RESISTANCE BETWEEN TERMINAL "C" AND
§]
REPAIR HIGH
TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR. RESISTANCE
INCKT 1285.
. IS RESISTANCE 1.50 OR LESS?

r-....
~
§
• INSPECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND 8-WAY EBCM
sREPLACE ABS
CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO MOTOR PACK.
SECTION 8A-4, "CHECKING TERMINAL CONTACT."
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF CORROSION?
I

G) •
~
IGNITION "OFF."
sREPLACE TERMINALS
• RECONNECT ALL CONNECTORS . THAT EXHIBIT POOR
•
t
START ENGINE WITH FOOT OFF BRAKE .
ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
TERMINAL CONTACT
OR EVIDENCE OF
t REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES. CORROSION.
DID OTC 42 SET IN THE LAST THREE IGNITION CYCLES?

s
REPLACE EBCM. I
sI
MALFUNCTION IS INTERMITTENT. REFER I
TO "DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR OTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY DTC DOES NOT 6-24-93
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN KEYING DOWN. NS 16173
5E1-94 ANTILOCK BRAKE SYSTEM

EBCM

®
~~~~~~~~~~~~~~~~ 1280BLK Lf ABS MOTOR HIGH

~o~~~A
~
M
-
_ _ _ _ __
1281PNK Lf ABS MOTOR LOW
ABS MOTOR PACK B
6 WAY CONNECTOR

6-18-93
MS 12767

DTC44
LEFT FRONT ABS CHANNEL WILL NOT MOVE
Circuit Description:
This DTC is designed to detect bound-up ESB, a stuck ABS motor, or a seized hydraulic modulator. When the
release is commanded during initialization, the ESB should release the ABS motor, resulting in sensed current
being less than commanded current (motor is spinning freely). If the ABS motor is not moving, sensed current
will be equal to stall current.

OTC Will Set When: DTC 44 can be set during normal operation. If the EBCM detects a condition in which it
cannot move the motor in either direction, a malfunction exists.

Action Taken: This malfunction indicates the channel cannot be moved properly. A malfunction DTC is
stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Ensures that proper motor circuits are located in
the proper connector cavities.
2. Checks for proper ABS motor movement during
apply and release commands from the Tech 1.
3. Compares EBCM command current to motor
feedback current.
4. Checks for a short circuit between the ABS motor
"HIGH" and ABS motor "LOW" circuits.
5. Checks for an ABS motor that is internally
shorted.
6. Determines if the malfunction is caused by a
defective EBCM or poor terminal contact.
7. Verifies that the ABS motor can actually apply
when commanded.
8. Checks for proper hydraulic modulator gear and
piston movement.
Diagnostic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. DTC 44 may set after modulator disassembly
if the modulator pistons are positioned at the bottom of
their bore.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-95

VISUALLY INSPECT THE 6-WAY ABS MOTOR PACK AND THE 8-WAY EBCM
CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY DTC44
COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES? LEFT FRONT ABS CHANNEL
WILL NOT MOVE

IGNITION "ON," ENGINE "OFF." USING THE CIRCUIT DIAGRAMS

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE. LOCATED IN THE FRONT OF THIS
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION. SECTION, PLACE THE PROPER WIRES
• SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE IN THE PROPER CONNECTOR
MOTOR. CAVITIES. CLEAR DTCs AND
• APPLY FIRM PRESSURE ON BRAKE PEDAL. RECHECK SYSTEM.
• SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE
MOTOR.
DID BRAKE PEDAL FALL?

FIRM PRESSURE STILL "ON" BRAKE PEDAL.

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DID BRAKE PEDAL RISE?

MALFUNCTION IS INTERMITTENT. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.

G) •. REMOVE FOOT FROM BRAKE PEDAL.

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY
OBSERVING THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS THE FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?

~
\V
•. EXIT TECH 1 MANUAL CONTROL FUNCTION.
IGNITION "OFF."
0 • USING TECH 1 MISC. TESTS, PERFORM GEAR
TENSION RELIEF FUNCTION.
• DISCONNECT THE 8-WAY EBCM CONNECTOR ANO THE • IGNITION "OFF."
6-WAY ABS MOTOR PACK CONNECTOR. • REMOVE HYDRAULIC MODULATOR/MOTOR PACK
• USING J 39200, MEASURE THE RESISTANCE BETWEEN ASSEMBLY FROM VEHICLE. REFER TO "ON
TERMINAL" A" AND TERMINAL "B" OF THE 8-WAY EBCM VEHICLE SERVICE'' IN THIS SECTION:
HARNESS CONNECTOR. • SEPARATE ABS MOTOR PACK FROM HYDRAULIC
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)? MODULATOR.
• GRASP THE GEAR ON THE HYDRAULIC
MODULATOR (THE HYDRAULIC MODULATOR IS
THE UNIT WITH THE THREE LARGE GEARS)
FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO
MEASURE THE RESISTANCE BETWEEN REPAIR SHORT MOVE THE GEAR.
TERMINAL" A" AND TERMINAL "B" OF BETWEENCKT CAN THE GEAR BE ROTATED AT LEAST 10 FULL
THE ABS MOTOR PACK CONNECTOR. 1280ANDCKT TURNS LOCK TO LOCK?
IS RESISTANCE 0.40 OR GREATER? 1281.

RECONNECT All CONNECTORS. REPLACE

IGNITION "OFF." ABS
• START ENGINE WITH FOOT OFF BRAKE. MOTOR
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS. PACK.
• REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO
MORE TIMES.
DID OTC 44 SET IN THE LAST THREE IGNITION CYCLES?

MALFUNCTION IS INTERMITTENT. INSPECT All CONNECTORS FOR

CONTAMINATION AND POOR TERMINAL CONTACT. REPLACE ANY TERMINALS
THAT EXHIBIT POOR TERMINAL CONTACT OR EVIDENCE OF CORROSION.

* AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT
OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), AND
THEN KEYING DOWN. ANO THEN KEYING DOWN. 7-3-93
NS 16174
SE1-96 ANTILOCK BRAKE SYSTEM

EBCM

-----------------
®
1282 PPL RF ABS MOTOR HIGH

~~~~ M
F - - - - - - - 1283BLK
~ RF ABS MOTOR LOW
ABS MOTOR PACK
6 WAY CONNECTOR

6-21-93
MS12768

DTC45
RIGHT FRONT ABS CHANNEL WILL NOT MOVE
Circuit Description:
This DTC is designed to detect bound-up ESB, a stuck ABS motor, or a seized hydraulic modulator. When the
release is commanded during initialization, the ESB should release the ABS motor, resulting in sensed current
being less than commanded current (motor is spinning freely). If the ABS motor is not moving, sensed current
will be equal to stall current.

OTC Will Set When: DTC 45 can be set during normal operation. If the EBCM detects a condition in which it
cannot move the ABS motor in either direction, a malfunction exists.

Action Taken: This malfunction indicates the channel cannot be moved properly. A malfunction DTC is
stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Ensures that proper ABS motor circuits are
located in the proper connector cavities.
2. Checks for proper ABS motor movement during
apply and release commands from the Tech 1.
3. Compares EBCM command current to motor
feedback current.
4. Checks for short between CKT 1282 and CKT
1283.
5. Checks for an ABS motor that is internally
shorted.
6. Checks to see if malfunction is due to poor
terminal contact or the EBCM.
7. Verifies that the motor can actually apply when
commanded.
8. Checks for proper hydraulic modulator gear and
piston movement.
Diagnostic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. DTC 45 may set after modulator disassembly
if the modulator pistons are positioned at the bottom of
their bore.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-97

G) • CONNECTORS
VISUALLY INSPECT THE 6-WAY ABS MOTOR PACK AND THE 8-WAY EBCM
FOR PROPER WIRE COLOR/CONNECTOR CAVITY DTC45
COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?
RIGHT FRONT ABS
CHANNEL WILL NOT MOVE

0 • •
IGNITION "ON," ENGINE "OFF."
PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
USING THE CIRCUIT DIAGRAMS
LOCATED IN THE FRONT OF THIS
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION. SECTION, PLACE THE PROPER WIRES
• SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE IN THE PROPER CONNECTOR
MOTOR. CAVITIES. CLEAR DTCs AND
• APPLY FIRM PRESSURE ON BRAKE PEDAL. RECHECK SYSTEM.
• SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND
RELEASE MOTOR.
DID BRAKE PEDAL FALL?

'7" • FIRM PRESSURE STILL "ON" BRAKE PEDAL.

\..!....} • SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR.
DID BRAKE PEDAL RISE?

MALFUNCTION IS INTERMITTENT. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.

0 • •
REMOVE FOOT FROM BRAKE PEDAL.
SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY
OBSERVING THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS THE FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?

0 • •
IGNITION "OFF."
DISCONNECT THE 8-WAY EBCM CONNECTOR AND THE
0 • USING TECH 1 MISC. TESTS, PERFORM GEAR
TENSION RELIEF FUNCTION.
6-WA Y ABS MOTOR PACK CONNECTOR. • IGNITION "OFF."
• USING J 39200, MEASURE THE RESISTANCE BETWEEN • REMOVE HYDRAULIC MODULATOR/MOTOR PACK
TERMINAL "G" AND TERMINAL "H" OF THE 8-WAY EBCM ASSEMBLY FROM VEHICLE. REFER TO "ON
HARNESS CONNECTOR. VEHICLE SERVICE" IN THIS SECTION.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)? • SEPARATE ABS MOTOR PACK FROM HYDRAULIC
MODULATOR.
• GRASP THE GEAR ON THE HYDRAULIC
MODULA TOR (THE HYDRAULIC MODULA TOR IS
THE UNIT WITH THE THREE LARGE GEARS)
FURTHEST REARWARD WHEN THE UNIT IS
MEASURE THE RESISTANCE BETWEEN REPAIR SHORT INSTALLED IN THE VEHICLE AND ATTEMPT TO
TERMINAL "E" AND TERMINAL "F" OF BETWEEN CKT MOVE THE GEAR.
THE ABS MOTOR PACK CONNECTOR. 1282 ANDCKT CAN THE GEAR BE ROTATED AT LEAST 10 FULL
IS RESISTANCE 0.4 il OR GREATER? 1283. TURNS LOCK TO LOCK?

0 • •
RECONNECT ALL CONNECTORS.
EXIT TECH 1 MANUAL CONTROL FUNCTION.
• IGNITION "OFF."
• START ENGINE WITH FOOT OFF BRAKE.
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
• REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO
MORE TIMES.
DID DTC 45 SET IN THE LAST THREE IGNITION CYCLES?

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS FOR

CONTAMINATION AND POOR TERMINAL CONTACT. REPLACE ANY TERMINALS
THAT EXHIBIT POOR TERMINAL CONTACT OR EVIDENCE OF CORROSION.

* AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO
VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING 7-3-93
OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN. NS 16175
 SE1-98 ANTILOCK BRAKE SYSTEM

EBCM

r---------------- 1284 DK GRN - - - - t C REAR ABS MOTOR HIGH

1---------------- 12850RN - - - - . F REAR ABS MOTOR LOW

ABS MOTOR PACK

6WAYCONNECTOR

6-18-93
MS 12769

DTC46
REAR ABS CHANNEL WILL NOT MOVE
Circuit Description:
This DTC is designed to detect bound-up ESB, a stuck ABS motor, or a seized hydraulic modulator. When the
release is commanded during initialization, the ESB should release the ABS motor, resulting in sensed current
being less than commanded current (motor is spinning freely). If the ABS motor is not moving, sensed current
will be equal to stall current.

DTC Will Set When: DTC 46 can be set during normal operation. If the EBCM detects a condition in which it
cannot move the motor in either direction, a malfunction exists.

Action Taken: This malfunction indicates the channel cannot be moved properly. A malfunction DTC is
stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Ensures that proper ABS motor circuits are
located in the proper connector cavities.
2. Checks for proper ABS motor movement during
apply and release commands from the Tech 1.
3. Compares EBCM command current to ABS motor
feedback current.
4. Checks for a short circuit between the ABS motor
"HIGH" and ABS motor "LOW" circuits.
5. Checks to see if malfunction is due to poor
terminal contact or the EBCM.
6. Verifies that the motor can actually release when
commanded.
7. Checks for proper hydraulic modulator gear and
piston movement.
Diagnostic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks or binds.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. DTC 46 may set after modulator disassembly
if the modulator pistons are positioned at the bottom of
their bore.
Depending on the frequency of the malfunction, a
physical inspection of the mechanical parts suspected
may be necessary.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-99

VISUALLY INSPECT THE 6-WA Y MOTOR PACK AND THE 8-WA Y EBCM
CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?
DTC46
REAR ABS CHANNEL
WILL NOT MOVE
,::\ • RAISE AND SUPPORT THE VEHICLE SUCH THAT THE REAR WHEELS ARE USING THE CIRCUIT DIAGRAMS
2
\..!..) APPROXIMATELY SIX INCHES OFF THE FLOOR. LOCATED IN THE FRONT OF THIS
• IGNITION "ON," ENGINE "OFF." SECTION, PLACE THE PROPER WIRES
• PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE. IN THE PROPER CONNECTOR
• APPLY FIRM PRESSURE ON BRAKE PEDAL. CAVITIES. CLEAR DTCs AND
• USING TECH 1 ABS TESTS, SELECT MANUAL CONTROL FUNCTION. RECHECK SYSTEM.
• SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
• HAVE AN ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.
COULD ASSISTANT SPIN THE REAR WHEELS?

t,\ • FIRM PRESSURE STILL "ON" BRAKE PEDAL.

6
\.V SELECT REAR AXLE MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
• HAVE AN ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.
COULD ASSISTANT SPIN THE REAR WHEELS?

MALFUNCTION IS INTERMITTENT. REFER TO

"DIAGNOSTIC AIDS" ON FACING PAGE.

G) •. REMOVE FOOT FROM BRAKE PEDAL.

SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY OBSERVING
THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS THE FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?

•
•
IGNITION "OFF."
DISCONNECT THE 8-WAY EBCM CONNECTOR AND THE
G) • USING TECH 1 ABS TESTS, PERFORM GEAR
TENSION RELIEF FUNCTION.
6-WAY MOTOR PACK CONNECTOR. • IGNITION "OFF."
• USING J 39200, MEASURE THE RESISTANCE BETWEEN . • REMOVE HYDRAULIC MODULATOR/MOTOR PACK
TERMINAL ."C" AND TERMINAL "F" OF THE 8-WAY EBCM ASSEMBLY FROM VEHICLE. REFER TO "ON
HARNESS CONNECTOR. VEHICLE SERVICE" IN THIS SECTION.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)? • SEPARATE MOTOR PACK FROM HYDRAULIC
MODULATOR.
• GRASP THE MIDDLE GEAR ON THE HYDRAULIC
MODULATOR (THE HYDRAULIC MODULATOR IS
THE UNIT WITH THE THREE LARGE GEARS) AND
A TT EMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED AT LEAST 7 FULL
TURNS LOCK TO LOCK?
G). RECONNECT ALL CONNECTORS. REPAIR SHORT
• START ENGINE AND TEST DRIVE
VEHICLE, ACHIEVING AT LEAST 16 km/h
BETWEEN CKT 1284
ANDCKT 1285.
(10MPH).
• TURN IGNITION "OFF."
• START ENGINE AND TEST DRIVE
VEHICLE A SECOND TIME, ACHIEVING
AT LEAST 16 km/h (10 MPH).
DOES OTC A046 RESET?

MALFUNCTION IS INTERMITTENT.
INSPECT ALL CONNECTORS FOR
CONTAMINATION AND POOR TERMINAL
CONTACT. REPLACE ANY TERMINALS
THAT EXHIBIT POOR TERMINAL CONTACT
OR EVIDENCE OF CORROSION.

* AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), 01-04-93
AND THEN KEYING DOWN. NS 16176
 SE1-100 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

DTC47
(Page 1 of 2)
LEFT FRONT ABS MOTOR FREE SPINS
Circuit Description:
This DTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled ABS motor. If this does not occur, the
ABS motor must be spinning with little or no resistance, indicating a nut/screw or gear malfunction.

OTC Will Set When: OTC 47 can only be set during initialization. If the feedback current is less than the
command current for a specified period of time, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks to see if the corresponding open motor OTC
is also set.
2. Verifies that the ABS motor was actually applied
as command by observing feedback current.
3. Verifies that the ABS motor can release.
4. Verifies that the ABS motor can be applied by
observing pedal movement.
5. Checks for an open in the ABS motor "HIGH"
circuitry.
6. Checks for an open in the ABS motor "LOW"
circuitry.
7. Checks for an ABS motor that is internally
shorted.
Diagnostic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. If the OTC only occurs once and OTC 56 also
occurs, refer to OTC 56. If intermittent and enhanced
diagnostics shows this DTC occurs during ABS, refer
to OTC 56.
Depending on the frequency of the malfunction, a
physical inspection of the mechanical parts suspected
may be necessary.
 ANTILOCK,BRAKE SYSTEM SE1-101

DTC47
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO MAKING
ANY RESISTANCE MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
(Page 1 of 2)
LEFT FRONT ABS MOTOR
FREE SPINS

0 .• IGNITION "ON," ENGINE "OFF."

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION.
• SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND CURRENT
AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT 10 AMPS?

0 • •
APPLY FIRM PRESSURE ON BRAKE PEDAL.
SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH COMMAND AND FEEDBACK
CURRENT 6 AMPS?

~ • FIRM PRESSURE STILL ON BRAKE PEDAL.

\:J • SELECT LEFT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE.)
DID BRAKE PEDAL RISE?

fs\ • USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION. MALFUNCTION IS INTERMITTENT.
REFER TO "DIAGNOSTIC AIDS"
\.:.,) • IGNITION"OFF."
• DISCONNECT6-WAY ABS MOTORPACKCONNECTORAND8-WAY ON FACING PAGE.
EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A" OF
THE 6-WA Y ABS MOTOR PACK HARNESS CONNECTOR AND
TERMINAL" A" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.50 OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL "B" OF

THE 6-WAY ABS MOTOR PARK HARNESS CONNECTOR AND
TERMINAL "B" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.50 OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL" A" AND

TERMINAL "B" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE 1.50 OR LESS?

r- - - - - - - - - - - - - - - - - - - - - - - - - ,
I DIAGNOSIS CONTINUED ON NEXT PAGE. 1
L--------------------------J

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
6-25-93
NS16177
 5E1-102 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

DTC47
(Page 2 of 2)
LEFT FRONT ABS MOTOR FREE SPINS
Circuit Description:
This DTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled motor. If this.does not occur, the motor
.must be spinning with little or no resistance, indicating a nut/screw or gear malfunction.

DTC Will Set When: DTC 47 can only be set during initialization. If the feedback current is less than the
command current for a specified period of time, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
8. Checks for a stripped gear on the ABS motor pack
(unit with three small gears).
9. Checks for a stripped gear on the hydraulic
modulator (unit with three large gears).
10. Checks to see if the ABS motor pack has an
internal malfunction.
11. Checks for a malfunctioning hydraulic modulator.
12. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids: An "Intermittenr malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech. 1 Diagnostics" found in this
section. If the DTC only occurs once and DTC 56 also
occurs, refer to DTC 56. If intermittent and enhanced
diagnostics shows this DTC occurs during ABS, refer
toDTC56.
Depending on the frequency of the malfunction, a
physical inspection of the mechanical parts suspected
may be necessary.
 ANTILOCK BRAKE SYSTEM 5E1-103

-----------------
: DIAGNOSIS CONTINUED : DTC47
: FROM PREVIOUS PAGE. :
~-.------------~-~ (Page 2 of 2)
LEFT FRONT ABS
© • REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE
(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION). MOTOR FREE SPINS
• REMOVE GEAR COVER..
• CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR PACK IS THE
UNIT WITH THE THREE SMALL GEARS. THE LEFT FRONT GEAR IS THE GEAR
FURTHEST FORWARD WHEN THE ASSEMBLY IS INSTALLED IN THE VEHICLE.
IS THE ABS MOTOR PACK GEAR STR.IPPED?
•
~ ~
0 • CH ECK FOR A STRIPPED GEAR ON HYDRAULIC MODULA TOR; MODULA TOR IS
THE UNIT WITH THE THREE LARGE GEARS. THE LEFT FRONT GEAR IS THE
IREPLACE ABS MOTOR PACK.
GEAR FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
IS THE MODULATOR GEAR STRIPPED?
•
8J §
@ •• RECONNECT ELECTRICAL CONNECTORS
SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN
IREPLACE HYDRAULIC
MODULA TOR GEAR.
I
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
OBSERVED. BE CAREFUL NOT TO DAMAGE .GEAR SET OR ALLOW THE HYDRAULIC
MODULATOR TO MOVE WHILE TESTING.
• IGNITION "ON."
• USING TECH 1 MISC. TESTS SELECT MANUAL CONTROL FUNCTION.
• SELECT LEFT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING
THE GEAR SET FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN. TH.E VEHICLE.
• SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR
WHILE STILL OBSERVING THE GEAR SET.
• SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?
.
~ ~
@ •• IGNITION
USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION.
"OFF."
REPLACE ABS MOTOR PACK. I
• SE PARATE THE ABS MOTOR PACK FROM THE HYDRAULIC MODULATOR.
• GRASP THE GEAR ON THE HYDRAULIC MODULATOR (HIE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST FORWARD
WHEN THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED MORE THAN 13 FULL TURNS LOCK TO LOCK?
•
~ §]
@ • INSPECT ALL CONNECTORS AND.TERMINALS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION BA-4 "CHECKING TERMINAL
REPLACE THE HYDRAULIC
MODULATOR.
CONTACT." REPLACE ALL TERMINALS THAT EXH"IT SIGNS OF POOR TERMINAL
CONTACT OR CORROSION.
• REINSTALL HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE.
•• RECONNECT ALL CONNECTORS .
IGNITION "OFF."

••
START ENGINE WITH FOOT OFF BRAKE .
ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS .
t REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 47 SET IN THE LAST THREE IGNITION CYCLES?
I

~ ~
REPLACE EBCM. I MALFUNCTION IS MOST
LIKELY CAUSED BY A
POOR CONNECTION.
REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
7-2-93
NS 16044
 5E1-104 ANTILO.CK BRAKE SYSTEM

EBCM

0®
~~~~~~~~~~~~~~~~ 1282PPL RF ABS MOTOR HIGH

~~~~~ M - - - - - -
F - 1283 BLK RF ABS MOTOR LOW
ABS MOTOR PACK
6WAYCONNECTOR

6-21-93
MS 12768

DTC48
(Page 1 of 2)
RIGHT FRONT ABS MOTOR FREE SPINS
Circuit Description:
This DTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled ABS motor. If this does not occur, the
ABS motor must be spinning with little or no resistance, indicating a nuUscrew or gear malfunction.

DTC Will Set When: DTC 48 can only be set during initialization. If the feedback current is less than the
command current for a specified period of time, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks to see if the corresponding open motor DTC
is also set.
2. Verifies that the ABS motor was actually applied
as command by observing feedback current.
3. Verifies that the ABS motor can release.
4. Verifies that the ABS motor can be applied by
observing pedal movement.
5. Checks for high resistance in the ABS motor
"HIGH" circuitry.
6. Checks for high resistance m the ABS motor
"LOW" circuitry.
7. Checks for proper resistance of the ABS motor
windings.
. DiagnO$tic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. If the DTC only occurs once and DTC 6i also
occurs, refer to DTC 61. If intermittent and enhanced
diagnostics shows this DTC occurs during ABS, refer
to DTC 61.
Depending on the frequency of the malfunction, a
physical· inspection of the mechanical parts suspected
may be necessary.
 ANTILOCK BRAKE SYSTEM SE1-105

NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO MAKING DTC48

ANY RESISTANCE MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
(Page 1 of 2)
0 IS OTC 61 ALSO CURRENTLY SET? RIGHT FRONT ABS
MOTOR FREE SPINS

r.;\ • IGNITION "ON;" ENGINE "OFF.''

\V • PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION.
• SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY
THE MOTOR WHILE CAREFULLY OBSERVING THE COMMAND
CURRENT AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT 10 AMPS?

0: APPLY FIRM PRESSURE ON BRAKE PEDAL.

SELECT RIGHT FRONT ABS MOTOR RELEASE
FUNCTION AND RELEASE THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH
COMMAND AND FEEDBACK CURR~.NT 6 AMPS?

'4\ • FIRM PRESSURE STILL ON BRAK~ PEDAL. . . ..

\..::..) • SELECT RIGHT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE.)
DID BRAKE PEDAL RISE?

• USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION. MALFUNCTION IS INTERMITTENT.
• IGNITION"OFF." REFER TO "DIAGNOSTIC AIDS"
• DISCONNECT 6-WAY ABS MOTO.R PACK CONNECTOR AND 8-WA Y ON FACING PAGE.
EBCM CONNECTOR. .
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL ''E'' OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND
TERMINAL "G" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.sn OR LESS?

MEASURE THE RESISTANCE BETWEEN. TERMINAL "F" OF THE 6-WAY

ABS MOTOR PARK HARNESS CONNECTOR AND TERMINAL "H" OF
THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.sn OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL ''E'' AND

TERMINAL "F" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE 1.sn OR LESS?

r- - - - - - - - - - - - - - - - - - - - - - - - - ,
I DIAGNOSIS CONTINUED ON NEXT PAGE. 1
L--------------------------J
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
7-8-93
NS 16178
SE1-106 Af,JTILOCKBRAKE SYSTEM

EBCM

®
---------------------------------1282PPL RF ABS MOTOR HIGH

~~~~i~~
ABS MOTOR PACK
.M
F - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ 1283BLK RF ABS MOTOR LOW

6WAYCONNECTOR

6-2'1-93
MS12768

DTC48
(Page 2 of 2)
RIGHT FRONT ABS MOTOR FREE SPINS
Circuit Description:
This OTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled ABS motor. If this does not occur, the
ABS motor must be spinning with little or no resistance, indicatiqg a nut/screw or gear malfunction.

OTC Will Set When: DTC 48 can only be set during initialization. If the feedback current is less than the
command current for a specified period of time, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled, and the. "ABSINOP." lamp is turned"ON.".
OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
8. Checks for a stripped gear on the ABS motor pack
(unit with three small gears).
9. Checks for a stripped gear on the hydraulic
modulator (unit with three large gears).
10. Verifies that the ABS motor can be applied under a
load situation.
11. Verifies that the hydraulic modulator is
functioning properly.
12. Ensures malfunction was not d.ue to poor terminal
contact.
Diagnostic Aids: An "Intermittent" m~lfunction in
this OTC may result from a mechanical part ;of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. If the OTC only occurs once and OTC 61 also
occurs, refer to OTC 61. If intermittent and enhanced
diagnostics shows this DTC occurs during ABS, refer
to OTC 61.
Depending on the frequency of the malfunction, a
physical inspection of the mechanical parts suspected
may be necessary.
 ANTILOCKBRAKE SYSTEM 5E1-107

r----------------,
: DIAGNOSIS CONTINUED :
DTC48
.
·-·--
I FROM PREVIOUS PAGE.

•
1
-- ··--- - ~----·
(Page 2 of 2)
0 REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE •
(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.) RIGHT FRONT ABS
•
•
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR PACK IS THE
MOTOR FREE SPINS
UNIT WITH THE THREE.SMALL GEARS. THE RIGHT FRONT GEAR IS THE GEAR
FURTHEST REARWARD WHEN THE ASSEMBLY IS INSTALLED IN THE VEHICLE.
IS THE ABS MOTOR PACK GEAR STRIPPED?

8J
•
sI I
0 CHECK FOR A STRIPPED GEAR ON HYDRAULIC MODULATOR; MODULATOR IS
THE UNIT WITH THE THREE LARGE GEARS. THE RIGHT FRONT GEAR IS THE
REPLACE ABS MOTOR PACK.
.
GEAR FURTHEST REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
IS THE MODULATOR GEAR STRIPPED?

@•
8J
RECONNECT ELECTRICAL CONNECTORS .
s
IREPLACE HYDRAULIC I
• SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
MODULATOR GEAR•

OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOyYTHE HYDRAULIC

MODULATOR TO MOVE WHILE TESTING.
• IGNITION "ON."
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION .
• SELECT RIGHT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE
OBSERVING THE GEAR SET FURTHEST REARWARD WHEN THE UNIT IS INSTALLED IN
THE VEHICLE.
• SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR
WHILE STILL OBSERVING THE GEAR SET.
• SELECT RIGHT FRONT ABS MOTO~ APPLY FUNCTION AND APPLY THE MOTOR.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?
•
~ ~
@ • IGNITION
USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION . IREPLACE ABS MOTOR PACK. I
• •
OFF." ff

SEPARATE THE ABS MOTOR PACK FROM THE HYDRAULIC MODULATOR. '
• GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC MODULATOR
IS THE UNIT WITH THE THREE LARGE GEARS)FURTHEST REARWARD WHEN THE UNIT
IS INSTALLED IN THE VEHICLE AND ATTEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED MORE THAN 13 FULL TURNS LOCK TO LOCK?
-
~ §
®· INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION 8A-4 "CHECKING TERMINAL
REPLACE THE HYDRAULIC
MODULATOR. . I
CONTACT. REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL
ff

CONTACT OR CORROSION.
• REINSTALL HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE.
t RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
t START ENGINE WITH FOOT OFF BRAKE.
• ALLOW ENGINE TO RUN FORATLEAST 10 SECONDS.
• REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 48 SET IN THE LAST THREE IGNITION CYCLES?
I

~ ~
REPLACE EBCM. I MALFUNCTION WAS MOST LIKELY CAUSED
BY A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTERDIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN. 7-2-93
NS 16045
SE1-108 ANTILOCK BRAKE,SYSTEM

EBCM

C 1284 DK GRN, C REAR ABS MOTOR H.IGH

yo-
R~T~:s / ( M - - - - - - - - - - - - - - - · · 128SORN - - - - 1
F
0
REARABSMOT RLOW

ABS MOTOR ;ACK , . .

6WAYCONNECTOR

6-18-93
MS 12769

DTC51
(Page 1 of 2)
REAR ABS MOTOR FREE SPINS
Circuit Description:
This OTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top ofthe bore resulting in a stalled ABS motor. If this does not occur, the
ABS motor must be spinning with little or no resistance, indicating a nut/screw or gear malfunction.

OTC Will Set When: DTC 51 can be set during initialization. If the feedback current is less than the
·command current for a specified period of time, a malfunction exists .

.Action Taken: A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below .Diagnostic Aids: An "Intermittent" malfunction in
refer to circled number(s) on the diagnostic chart. this DTC may result from a mechanical part of the
1. Checks to see if the corresponding open ABS motor · System that sticks; binds,'or slips.
DTC is also set. The frequency of the malfunction can be checked
.2. Verifies that the ABS motor was actually applied by using the enhanced diagnostic function of the Tech
as command by observing feedback current. 1, as desc~ibed in "Tech 1 Diagnostics" found in this
3. Verifies that the ABS motor can release. section. If the DTC only occurs once and DTC 64 also
4. Verifies that the ABS motor can be applied by occurs, refer to DTC 64. If intermittent ap.d enhanced
observing pedal movement. diagnostics show this DTC occurs during ABS, refer to
5. Checks for high resistance in the ABS motor · DTC64.
"HIGH" circuitry. Depending on th,e frequency of the malfunction, a
6. Checks for high resistance in the ABS motor physical inspection of the mechanical parts suspected
"LOW" circuitry. may be necessary.
7. Checks for proper resistance of the ABS motor
windings.
 ANTILOCK BRAKE SYSTEM SE1-109

NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO MAKING

ANY RESISTANCE MEASUREMENTS. REFER TO J 39200 USER'S MANUAL. DTC51
(Page 1 of 2)
REAR ABS MOTOR
FREE SPINS
• IGNITION "ON," ENGINE "OFF."
• PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION.
• SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND CURRENT
AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT 10 AMPS?

0 • •
APPLY FIRM PRESSURE ON BRAKE PEDAL.
SELECT REAR AXLE ABS MOTOR RELEASE
FUNCTION AND RELEASE THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH
COMMAND AND FEEDBACK CURRENT 6 AMPS?

©• •
FIRM PRESSURE STILL ON BRAKE PEDAL.
SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY
THE MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE.)
DID BRAKE PEDAL RISE?

• USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION. MALFUNCTION IS INTERMITTENT.
• IGNITION"OFF." REFER TO "DIAGNOSTIC AIDS"
• DISCONNECT 6-WA Y ABS MOTOR PACK CONNECTOR AND 8-WAY ON FACING PAGE.
EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND
TERMINAL "C" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.SQ OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF

THE 6-WAY ABS MOTOR PARK HARNESS CONNECTOR AND
TERMINAL "F" OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS RESISTANCE 1.SQ OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL "C" AND

TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE 1.SQ OR LESS?

r- ------------------------,
I DIAGNOSIS CONTINUED ON NEXT PAGE. 1
L--------------------------J

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN. 6- _
25 93
NS 16179
5E1-110 ANTILOCK BRAKE SYSTEM

EBCM

1 - - - - - - - - - - - - - - - 1284DKGRN ----1 C REARABSMOTORHIGH

1 - - - - - - - - - - - - - - - - 1285 ORN ----1 F REAR ABS MOTOR LOW

ABS MOTOR PACK

6WAYCONNECTOR

6-18-93
MS 12769

OTC 51
(Page 2 of 2)
REAR ABS MOTOR FREE SPINS
Circuit Description:
This DTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled motor. If this does not occur, the ABS
motor must be spinning with little or no resistance, indicating a nut/screw or gear malfunction.

OTC Will Set When: DTC 51 can be set during initialization. If the feedback current is less than the
command current for a specified period of time, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
8. Checks for a stripped gear on the ABS motor pack
(unit with three small gears).
9. Checks for a stripped gear on the hydraulic
modulator (unit with three large gears).
10. Verifies that the motor can be applied under a load
situation.
11. Verifies that the hydraulic modulator is
functioning properly.
12. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids: An "Intermittent" malfunction in
this DTC may result from a mechanical part of the
system that sticks, binds, or slips.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. If the DTC only occurs once and DTC 64 also
occurs, refer to DTC 64. If intermittent and enhanced
diagnostics show this DTC occurs during ABS, refer to
DTC64.
Depending on the frequency of the malfunction, a
physical inspection of the mechanical parts suspected
may be necessary.
 ANTILOCK BRAKE SYSTEM 5E1-111

DTC51
: DIAGNOSIS CONTINUED :
(Page 2 of 2)
: FROM PREVIOUS PAGE. :
REAR ABS MOTOR
fs' • REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM FREE SPINS
\V VEHICLE (REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION).
• REMOVEGEARCOVE~
• CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR PACK IS
THE UNIT WITH THE THREE SMALL GEARS. THE REAR AXLE GEAR IS THE
MIDDLE GEAR OF THE THREE.
IS THE ABS MOTOR PACK GEAR STRIPPED?

CHECK FOR A STRIPPED GEAR ON HYDRAULIC MODULATOR; MODULA TOR IS

THE UNIT WITH THE THREE LARGE GEARS. THE REAR AXLE GEAR IS THE
MIDDLE GEAR OF THE THREE.
IS THE MODULATOR GEAR STRIPPED?

@ •
•
RECONNECT ELECTRICAL CONNECTORS
SE CU RELY POSITION HYDRAULIC MODULA TOR/MOTOR PACK ASSEMBLY IN
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE HYDRAULIC
MODULATOR TO MOVE WHILE TESTING.
• IGNITION "ON."
• USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION.
• SELECT REAR AXLE ABS MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING
THE MIDDLE GEAR SET.
• SELECT REAR AXLE ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR
WHILE STILL OBSERVING THE GEAR SET.
• SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?

'1i" • USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION.
~ • IGNITION "OFF."
• SEPARATE THE ABS MOTOR PACK FROM THE HYDRAULIC MODULATOR.
• GRASP THE MIDDLE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) AND ATTEMPT TO
MOVE THE GEAR.
CAN THE GEAR BE ROTATED MORE THAN 8 FULL TURNS LOCK TO LOCK?

@2 • INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT

AND EVIDENCE OF CORROSION. REFER TO SECTION SA:4 "CHECKING TERMINAL
CONTACT." REPLACE All TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL
CONTACT OR CORROSION.
• REINSTALL HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE.
• RECONNECT All CONNECTORS.
• IGNITION "OFF."
• START ENGINE WITH FOOT OFF BRAKE.
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
• REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 51 SET IN THE LAST THREE IGNITION CYCLES?

MALFUNCTION WAS MOST

LIKELY CAUSED BY A POOR
CONNECTION. REFER TO
"DIAGNOSTIC AIDS HON
FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN. __
7 2 93
NS 16046
5E1-112 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

DTC52
LEFT FRONT ABS CHANNEL IN RELEASE TOO LONG
Circuit Description:
This DTC will diagnose an ABS motor that is energized longer than expected. This could occur if a wheel
speed sensor is malfunctioning, the ABS motor does not turn, the left front solenoid mechanically fails open, or
the ABS motor wires are crossed.

OTC Will Set When: DTC 52 can be set only during an ABS stop. If the EBCM commands the left front ABS
channel in release for three seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Identifies a problem in a wheel speed sensor that
may cause the system to be in release too long.
2. Identifies an ABS motor as being failed or wired
incorrectly.
3. Checks for a solenoid that may have mechanically
failed open.
4. Verifies proper solenoid operation.
5. If Step 3 has failed, this serves to isolate the cause
of the hydraulic problem, to either the solenoid or
the ABS hydraulic modulator assembly.
6. Determines whether a malfunctioning motor pack
or hydraulic modulator is the reason for DTC 52
being set.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a mechanical part of the system that
sticks or binds.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. DTC 52 may occur if on ice and steering wheel
is turned to lock during braking. Using the Tech 1,
perform hydraulic test to ensure total brake system is
functional.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-113

[I] Important DTC52

EXCESSIVE DRAG OR HIGH RESISTANCE IN THE
BASE BRAKE OR SUSPENSION SYSTEM MUST BE LEFT FRONT ABS CHANNEL IN RELEASE
INSPECTED AND CORRECTED BEFORE TOO LONG
PROCEEDING WITH DTC DIAGNOSIS.

ARE ANY WHEEL SPEED DTCs CURRENTLY SET?

YES
r"' --------------,
• USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A STEADY :PROCEED TO THAT OTC :
DECEL CONDITION FROM 35 MPH TOO MPH WHILE MONITORING ALL WHEEL ,CHART FIRST. 1
SPEEDS. L..---------------'
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT OPERATION?

YES
IGNITION "ON."
r -----------------,
1PROCEEDTOWHEELSPEED =0 1
• USING TECH 1 MANUAL CONTROL FUNCTION, SELECT LEFT FRONT ABS Lore FOR AFFECTED WHEEL. __ J
MOTOR APPLY AND APPLY MOTOR.
• APPLY FIRM PRESSURE ON BRAKE PEDAL.
• SELECT LEFT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
DID BRAKE PEDAL FALL?

G) • REMOVE FOOT FROM BRAKE PEDAL.

BRAKE PEDAL ROSE
• USING TECH 1 MANUAL CONTROL FUNCTION, SELECT
LEFT FRONT SOLENOID AND COMMAND THE
SOLENOID "ON." REPAIR CROSSED WIRES
• APPLY FIRM PRESSURE TO BRAKE PEDAL. (CKTs 1280 and 1281) TO
DID BRAKE PEDAL FALL? LEFT FRONT ABS MOTOR.

@ • USING TECH 1 PERFORM GEAR TENSION RELIEF

FUNCTION.
__.c..._____~,•
0• FIRM PRESSURE STILL APPLIED TO
BRAKE PEDAL.
IGNITION "OFF."
REMOVE HYDRAULIC MODULATOR/MOTOR PACK
ASSEMBLY FROM VEHICLE.
• USING TECH 1, COMMAND LEFT • SEPARATE ABS MOTOR PACK FROM HYDRAULIC
FRONT SOLENOID "OFF." MODULATOR.
DID BRAKE PEDAL FALL? • GRASP THE GEAR ON THE HYDRAULIC MODULATOR
(HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE
LARGE GEARS) FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE ANDATTEMPTTO ROTATE
NO THE GEAR IN EITHER DIRECTION.

0 • •
REMOVE FOOT FROM BRAKE PEDAL.
IGNITION "OFF."
CAN THE GEAR BE MOVED BY HAND?

• PHYSICALLY SWITCH THE LEFT FRONT

SOLENOID WITH RIGHT FRONT SOLENOID.
• IGNITION "ON."
• USING TECH 1 MANUAL CONTROL FUNCTION.
SELECT LEFT FRONT SOLENOID AND COMMAND MALFUNCTION IS NOT PRESENT AT THIS TIME.
THE SOLENOID "ON." REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
• APPLY FIRM PRESSURE TO BRAKE PEDAL.
DID BRAKE PEDAL FALL?

REPLACE ABS HYDRAULIC MODULA TOR. REPLACE THE SOLENOID WHICH WAS
ORIGINALLY IN THE LEFT FRONT CHANNEL.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY DTC
DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16km/h (10 MPH) AND THEN
KEYING DOWN. 7-2-93
NS 16180
5E1-114 ANTILOCK BRAKE SYSTEM

EBCM

/;®
~~~~~~~~~~~~~~~~-1282PPL RF ABS MOTOR HIGH

~~~~~ M
F - - - - - - - - 1283 BLK RF ABS MOTOR LOW

ABS MOTOR PACK

6WAV CONNECTOR

6·21-93
MS 12768

DTC53
RIGHT FRONT ABS CHANNEL IN RELEASE TOO LONG
Circuit Description:
This DTC will diagnose a motor that is energized longer than expected. This could occur if a wheel speed
sensor is malfunctioning, the motor does not turn, the right front solenoid mechanically fails open, or the ABS
motor wires are crossed.

OTC Will Set When: DTC 53 can be set only during an ABS stop. If the EBCM commands the right front
channel in release for three seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Identifies a problem in a wheel speed sensor that
may cause the system to be in release too long.
2. · Identifies a motor as being failed or wired
incorrectly.
3. Checks for a solenoid that may have mechanically
failed open.
4. If Step 3 has failed, this serves to isolate the cause
of the hydraulic problem, to either the solenoid or
the ABS hydraulic modulator assembly.
5. Checks for a solenoid that may have mechanically
failed closed.
6. Determines whether a malfunction motor pack or
hydraulic modulator is the reason for OTC 53
being set.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a mechanical part of the system that
sticks or binds.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. OTC 53 may occur on ice if steering wheel is
turned to lock during braking. Using the Tech 1
perform hydraulic test to ensure total brake system is
functional.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-115

rn Important
EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE BRAKE OR
DTC 53
RIGHT FRONT ABS CHANNEL IN
SUSPENSION SYSTEM MUST BE INSPECTED AND CORRECTED
RELEASE TOO LONG
BEFORE PROCEEDING WITH DTC DIAGNOSIS .

.ARE ANY WHEEL SPEED DTCs CURRENTLY SET? I

~ ~
r --------------------,
• USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A STEADY
DECEL CONDITION FROM 35 MPH TOO MPH WHILE MONITORING ALL WHEEL L-----------------------~
I PROCEED TO THAT OTC CHART FIRST. 1

SPEEDS.
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT OPERATION?

~ ~-----------------~
~
• IGNITION "ON." :PROCEEDTOWHEELSPEED = 0:
• USING TECH 1 MANUAL CONTROL FUNCTION, SELECT RIGHT FRONT ABS MOTOR I OTC FOR AFFECTED WHEEL.
APPLY AND APPLY MOTOR. ~-------------------~ 1

• APPLY FIRM PRESSURE ON BRAKE PEDAL.

• SELECT RIGHT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.

. DID BRAKE PEDAL FALL?

L¥J NOj

• REMOVE FOOT FROM BRAKE PEDAL BRAKE PEDAL DID NOT MOVE I BRAKE PEDAL ROSE I
• USING TECH 1 MANUAL CONTROL FUNCTION, SELECT
REPAIR CROSSED WIRES
RIGHT FRONT SOLENOID AND COMMAND THE
(CKTs 1282 AND 1283) TO
SOLENOID "ON."
RIGHT FRONT ABS MOTOR.
• APPLY FIRM PRESSURE TO BRAKE PEDAL
DID BRAKE PEDAL FALL?

G) ••
I USING TECH 1 PERFORM GEAR TENSION RELIEF FUNCTION .
IGNITION "OFF."

~ $ • REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBL y

FROM VEHICLE.
• FIRM PRESSURE STILL APPLIED PROCEED TO • SEPARATE ABS MOTOR PACK FROM HYDRAULIC MODULATOR.

•
TO BRAKE PEDAL
USING TECH 1,COMMAND
STEP 5 OF THIS • GRASP THE GEAR ON THE HYDRAULIC MODULATOR
(HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE LARGE
CHART.
RIGHT FRONT SOLENOID GEARS) FURTHEST REARWARD WHEN THE UNIT IS INSTALLED IN
"OFF." THE VEHICLE AND ATTEMPT TO ROTATE THE GEAR IN EITHER

. DID BRAKE PEDAL FALL? DIRECTION.

CAN THE GEAR BE MOVED BY HAND?

~ iii]§] YES
~
•
•
•
REMOVE FOOT FROM BRAKE PEDAL
IGNITION "OFF."
PHYSICALLY SWITCH THE RIGHT FRONT SOLENOID
REPLACE ABS
MOTOR PACK.
I REPLACE ABS HYDRAULIC
MODULATOR.
I
•
•
WITH THE LEFT FRONT SOLENOID.
IGNITION "ON."
USING TECH 1 MANUAL CONTROL FUNCTION,
MALFUNCTION IS NOT PRESENT AT THIS TIME. REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE.
I
SELECT RIGHT FRONT SOLENOID AND COMMAND
THE SOLENOID "ON."
• APPLY FIRM PRESSURE TO BRAKE PEDAL.
. DID BRAKE PEDAL FALL?

~ [ill
REPLACE ABS HYDRAULIC MODULA TOR. j REPLACE THE SOLENOID WHICH WAS
ORIGINALLY IN THE RIGHT FRONT CHANNEL.
I
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY OTC
DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16km/h (10 MPH) AND THEN 7-2-93
KEYING DOWN. NS 16182
5E1-116 ANTILOCK BRAKE SYSTEM

EBCM

REAR A t s
~ c- - - - - - - - - - - - - 1284 DK GRN ---r:s: REAR ABS MOTOR HIGH

MOTOR r-:-
D - - - - - - - - - - - - - - 1285 ORN ----1._!.._ REAR ABS MOTOR LOW

ABS MOTOR PACK

6 WAY CONNECTOR

6-18-93
MS 12769

DTC54
REAR ABS CHANNEL IN RELEASE TOO LONG
Circuit Description:
This DTC will diagnose an ABS motor that is energized longer than expected. This could occur if a wheel
speed sensor is malfunctioning, the ABS motor does not turn, or the ABS motor wires are crossed.

OTC Will Set When: DTC 54 can be set only during an ABS stop. If the EBCM commands the rear axle
channel in release for three seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Identifies a problem in a wheel speed sensor that
may cause the system to be in release too long.
2. Checks for a wheel that may stick or bind because
of a mechanical fault.
3. Checks to see if the ABS motor is capable of
moving and applying the hydraulic piston for the
rear wheels.
4. Ensures that the ABS motor wiring is not crossed.
5. Isolates the fault of a "no-apply" situation to either
the ABS motor pack or ABS hydraulic modulator
assembly.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a mechanical part of the system that
sticks or binds.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. Using the Tech 1, perform hydraulic test to
ensure total brake system is functional.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-117

IMPORTANT: EXCESSIVE DRAG OR HIGH

RESISTANCE IN THE BASE BRAKE OR DTC54
SUSPENSION SYSTEM MUST BE INSPECTED AND
CORRECTED BEFORE PROCEEDING WITH OTC REAR ABS CHANNEL IN RELEASE TOO LONG
DIAGNOSIS.

ARE ANY WHEEL SPEED DTCs CURRENTLY SET?

r ----------------------,
1 PROCEED TO THAT OTC CHART FIRST.
USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A
STEADY DECEL CONDITION FROM 35 MPH TOO MPH WHILE
L
-----------------------~ I

MONITORING ALL WHEEL SPEEDS ON TECH 1 DATA LIST.

DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT
OPERATION?

0 • •
RAISE REAR OF VEHICLE AND SUPPORT AS INDICATED IN SECTION OA.
SPIN BOTH REAR WHEELS AND CONFIRM PHYSICAL CONDITION OF
r- ------------------,
: PROCEED TO WHEEL SPEED = 0 :
I OTC FOR AFFECTED WHEEL. 1
BASE BRAKE SYSTEM. L--------------------~
COULD BOTH REAR WHEELS BE SPUN FREELY BY HAND?

Cv ••
IGNITION "ON," ENGINE "OFF."
USING MANUAL CONTROL FUNCTION OF TECH 1, SELECT REAR AXLE
REPAIR SOURCE OF RESISTANCE
IN BASE BRAKE SYSTEM.
ABS MOTOR APPLY.
• APPLY FIRM PRESSURE ON BRAKE PEDAL
• COMMAND APPLY OF REAR ABS MOTOR AND TRY TO SPIN REAR
WHEELS BY HAND.
COULD REAR WHEELS BE SPUN BY HAND?

(v • WITH FIRM PRESSURE ON BRAKE PEDAL STILL APPLIED, MALFUNCTION IS NOT PRESENT AT THIS TIME.
COMMAND A RELEASE OF THE REAR AXLE ABS MOTOR. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
CAN WHEELS BE MOVED?

• USING TECH 1, PERFORM GEAR TENSION RELIEF FUNCTION.

• IGNITION "OFF."
• REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE.
• SEPARATE ABS MOTOR PACK FROM HYDRAULIC MODULATOR.
• CONNECT ABS MOTOR PACK WIRING.
• IGNITION "ON."
• USING TECH 1, PERFORM MOTOR TEST.
DO ALL THREE ABS MOTOR PACK GEARS (SMALL GEARS) SPIN FREELY?

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES
TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE DRIVING
OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN. 7-7-93
NS 16183
5E1-118 ANTILOCK BRAKE SYSTEM

EBCM

·····@
1282 PPL RF ABS MOTOR HIGH

MOTOR
F 1283 BLK RF ABS MOTOR LOW

6WAVABSMOTOR 1280 BLK LF ABS MOTOR HIGH

PACK CONNECTOR

1281 PNK LF ABS MOTOR LOW

1284DKGRN REAR ABS

MOTOR HIGH
REAR ABS~
MOTOR
D 12850RN REAR ABS
MOTOR LOW

6·18-93
MS 12771

DTCSS
EBCM MALFUNCTION
Circuit Description:
This OTC identifies a malfunction detected by the MDI custom IC. It also ensures the cause of the
malfunction is not a result of a problem with the ABS enable relay under a OTC 55 malfunction.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below

refer to circled number(s) on the diagnostic chart.
1. Checks to see if the malfunction is still present.
2. Checks to see if the malfunction is intermittent.
 ANTILOCKBRAKE SYSTEM 5E1-119

DTCSS
EBCM MALFUNCTION

G) • IGNITION HON," ENGINE "OFF.ff

• USING TECH 1, READ DTCs.
IS OTC 55 CURRENTLY SET?

0 ••
USING TECH 1,CLEARDTCs.
TEST DRIVE VEHICLE FOR THREE (3) DRIVE
CYCLES. A DRIVE CYCLE CONSISTS OF
KEY-ON, DRIVE VEHICLE OVER 16 km/h
(10 MPH), THEN KEY DOWN.
DOES DTC 55 RESET?

REPLACE EBCM. MALFUNCTION IS INTERMITTENT.

7-3-93
NS 15427
5E1-120 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS12767

DTC56
LEFT FRONT ABS MOTOR CIRCUIT OPEN
Circuit Description:
This DTC identifies an ABS motor that cannot be energized due to an open in its circuitry.

OTC Will Set When: DTC 56 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out of range voltage on either of the left front ABS motor circuits indicating an open circuit, a malfunction
exists.

Action Taken: An open ABS motor will not activate when requested. A malfunction DTC is stored, "ABS is
disabled and the ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for proper resistance of the ABS motor.
2. Checks for an open in the ABS motor "HIGH"
circuitry.
3. Checks for an open in the ABS motor "LOW"
circuitry.
4. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the motor, an intermittent malfunction
may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-121

DTC56
LEFT FRONT ABS MOTOR CIRCUIT OPEN
DOES DTC 56 .OCCUR INTERMITTENTLY?

8 • •
IGNITION "OFF."
DISCONNECT 6-WA Y ABS MOTOR PACK CONNECTOR.
REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
• USING J 39200, MEASURE RESISTANCE ACROSS ABS
MOTOR PACK TERMINALS "A" AND "B".
IS RESISTANCE BELOW 2000Q?

DISCONNECTS-WAY CONNECTOR AT EBCM.

• USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL" A" OF
THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL" A" OF THE
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

0 • USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "B" OF

THE B-WAY EBCM HARNESS CONNECTOR AND TERMINAL "B" OF THE
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

0 • INSPECT THE 6-WAY ABS MOTOR PACK AND S·WA Y EBCM

CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SEC.TION SA-4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVEVEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 56 SET IN THE LAST Tt,iREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY

CAUSED BY A POOR CONNECTION.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN. 6-21-93
MS 12772
5E1-122 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

DTC57
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO GND
Circuit Description: ·
This DTC identifies an ABS motor circuit that is shorted to ground. This malfunction will not allow the ABS
motor to be controlled at the commanded current rate or will cause the driver circuit to allow current directly to
ground.

OTC Will Set When: DTC 57 can be set anytime. If the EBCM detects an out of range voltage on either of the
left front ABS motor circuits indicating a cir~uit shorted to ground, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to ground i.n the ABS motor
"HIGH" circuitry.
2. Checks for a short to ground in the ABS motor
"LOW" circuitry.
3. Checks for an ABS motor that is internally shorted
to ground.
4. Ensures malfunction was not due to physical.
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the motor, an intermittent malfunction
may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the .enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-123

DTC57
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO GND

DOES OTC 57 OCCUR INTERMITTENTLY?

IGNITION "OFF."
• DISCONNECT THE 6-WA Y ABS MOTOR PACK CONNECTOR
AND THE B-WAY EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL" A" OF THE 6-WAY ABS
MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

G) • MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "B" OF THE 6-WAY ABS MOTOR PACK
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

0 • MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL" A" OF THE ABS MOTOR PACK.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

INSPECT CKTs 1280 AND 1281 AND RfLA TED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHORT TO GROUND
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE
IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST.DRIVE VEHICLE, ACHIEVING AT
LEAST 16 km/h (10 MPH).
• REPEAT ABOVE DRiVE CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 57 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
6-17-93
MS 12773
SE1-124 ANTILOCK BRAKE SYSTEM

EBCM

LF ABS MOTOR HIGH

LF ABS MOTOR LOW

6-18-93
MS 12767

DTC58
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
Circuit Description:
This DTC identifies an ABS motor circuit that is shorted to battery or an ABS motor that has low or no
resistance. This malfunction will not allow the ABS motor to be controlled at the commanded current rate or will
cause the ABS motor to turn in the opposite direction, or not at all.

OTC Will Set When: DTC 58 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out ofrange voltage on either of the left front ABS motor circuits indicating a circuit shorted to battery or an
ABS motor shorted, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS I.NOP" lamp is turned."ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
l. Checks for a short to voltage in the ABS motor
"HIGH" circuitry.
2. Checks for a short to voltage in the ABS motor
"LOW" circuitry.
3. Checks for a short between the "HIGH" and
"LOW" motor circuits.
4. Checks for an ABS motor that is internally
shorted.
5. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise ABS motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-125

NOTICE: J 39200 TEST LEADS MUST BE "ZEROED"

PRIOR TO MAKING ANY RESISTANCE MEASUREMENTS.
DTC58
REFER TO J 39200 USER'S MANUAL. LEFT FRONT ABS MOTOR CIRCUIT
SHORTED TO BATT
DOES OTC 58 OCCUR INTERMITTENTLY?

IGNITION "OFF."
• DISCONNECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND THE S-
WAY EBCM CONNECTOR.
• IGNITION "ON."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL" A" OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 • MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "B"

OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

G) • IGNITION "OFF."
• USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A" AND
TERMINAL "B" OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

G) • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL" A"

AND TERMINAL "B" OF THE ABS MOTOR PACK.
IS RESISTANCE GREATER THAN 0.4!1?

INSPECT CKTs 1280 AND 1281 AND RELATED CONNECTORS FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS CONNECTED.
REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST 16 km/h (10 MPH).
• REPEAT AIJOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 58 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY

CAUSED BY A POOR CONNECTION.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN.
6-17-93
MS 12774
5E1-126 ANTILOCK BRAKE SYSTEM

EBCM

----------------- 1282 PPL RF ABS MOTOR HIGfi

~~~~~
ABS MOTOR PACK
6 WAY CONNECTOR
0® M
F -
-~~~~~~~~~~~~~~- 1283 BLK RF ABS MOTOR LOW

6-21-93
MS 12768

DTC61
RIGHT FRONT ABS MOTOR CIRCUIT OPEN
Circuit Description:
This DTC identifies an ABS motor that cannot be energized due to an open in its circuitry. This malfunction
will not allow proper front ABS operation.

OTC Will Set When: DTC 61 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out of range voltage on either of the right front ABS motor circuits indicating an open circuit, a malfunction
exists.

Action Taken: An open motor will not activate when requested. A malfunction DTC is stored, ABS is disabled
and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for proper resistance of the ABS motor.
2. Checks for an open in the ABS motor "HIGH"
circuitry.
3. Checks for an open in the ABS motor "LOW"
circuitry.
4. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise ABS motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-127

DTC61
RIGHT FRONT ABS MOTOR CIRCUIT OPEN

DOES DTC 61 OCCUR INTERMITTENTLY?

G) • IGNITION "OFF." REFER TO "DIAGNOSTIC

• DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR. AIDS" ON FACING PAGE.
• USING J 39200, MEASURE RESISTANCE ACROSS ABS
MOTOR PACK TERMINALS "E" AND "F".
IS RESISTANCE BELOW 2000Q?

G) t DISCONNECT 8-WAY CONNECTOR A TEBCM. REPLACE ABS MOTOR PACK.

• USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "G" OF
THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL "E" OF THE
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2!1 OR LESS?

0 t USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "H" OF

THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL "F" OF THE
REPAIR OPEN OR HIGH
RESISTANCE IN CKT 1282.
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2!1 OR LESS?

0 • INSPECT THE 6-WAY AQS MOTOR PACK AND 8-WAY EBCM

CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
REPAIR OPEN OR HIGH
RESISTANCE IN CKT 1283.
CORROSION. REFER TO SECTION 8A-4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 61 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED BY A POOR

CONNECTION. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.

AFTERALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
6-27-93
MS 12775
SE1-128 ANTILOCK BRAKE SYSTEM

EBCM

~
~~~~~~~~~~~~~~~~~1282PPL RF ABS MOTOR HIGH

:.~~~ M
F - - - - - - - - - 1283 BLK RF ABS MOTOR LOW
ABS MOTOR PACK
6WAYCONNECTOR

6-21-93
MS12768

DTC62
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO GND
Circuit Description:
This DTC identifies an ABS motor circuit that is shorted to ground. This malfunction will not allow the ABS
motor to be controlled at the commanded current rate or will cause the ABS motor driver circuit to allow current
directly to ground.

DTC Will Set When: DTC 62 can be set anytime. If the EBCM detects an out of range voltage on either of the
right front ABS motor circuits indicating a circuit shorted to ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to ground in the ABS motor
"HIGH" circuitry.
2. Checks for a short to ground in the ABS motor
"LOW" circuitry.
3. Checks for an ABS motor that is internally shorted
to ground.
4. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise ABS motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel anµ check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-129

DTC62
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO GND

DOES DTC 62 OCCUR INTERMITTENTLY?

CD • •
IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR
REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
AND THE 8-WA Y EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL "E" OF THE 6-WAY ABS
MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

<i) • MEASURE THE RESISTANCE BETWEEN GROUND AND REPAIR SHORT TO GROUND IN CKT 1282.
TERMINAL "F" OF THE 6-WAY ABS MOTOR PACK
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

G) • MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "E" OF THE ABS MOTOR PACK.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

INSPECT CKTs 1282 AND 1283 AND RELATED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHORT TO GROUND
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE
IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT
LEAST 16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 62 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN. 6-1 7 _93
MS 12776
SE1-130 ANTILOCK BRAKE SYSTEM

EBCM

~~~~~~~~~~~~~~~~-1282PPL

0®
RF ABS MOTOR HIGH

~~~~~ M - - - - - - -
F - 1283 BLK RF ABS MOTOR LOW
ABS MOTOR PACK
6 WAY CONNECTOR

6-21-93
MS12768

DTC63
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
Circuit Description:
This OTC identifies an ABS motor circuit that is shorted to battery or an ABS motor that has low or no
resistance. This malfunction will not allow the ABS motor to be controlled at the commanded current rate or will
cause the ABS motor to turn in the opposite direction or not at all.

OTC Will Set When: OTC 63 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out of range voltage on either of the right front ABS motor circuits indicating a circuit shorted to battery or an
ABS motor shorted, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to voltage in the ABS motor
"HIGH" circuitry.
2. Checks for a short to voltage in the ABS motor
"LOW" circuitry.
3. Checks for short circuit between ABS motor
"HIGH" and motor "LOW".
4. Checks for proper resistance of the ABS motor.
5. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the motor, an intermittent malfunction
may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the OTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-131

NOTICE: J 39200 TEST LEADS MUST BE "ZEROED"

PRIOR TO MAKING ANY RESISTANCE MEASUREMENTS.
DTC63
REFER TO J 39200 USER'S MANUAL.
RIGHT FRONT MOTOR CIRCUIT SHORTED
TO BATT

r."\ • IGNITION "OFF."

\..!.) • DISCONNECT THE 6-WAY ABS MOTOR PACK CONNECTOR
AND THE 8-WAY EBCM CONNECTOR.
• IGNITION "ON."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL 'T' OF THE 6-WAY ABS MOTOR
PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 • MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "F"

OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 • •
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINAL "E" AND TERMINAL "F" OF THE 6-WAY ABS
MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

(v • USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL 'T' REPAIR SHORT BETWEEN CKTs 1282 AND 1283.
AND TERMINAL "F" OF THE ABS MOTOR PACK.
IS RESISTANCE GREATER THAN 0.4Q?

0 • INSPECT CKTs 1282 AND 1283 AND RELATED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHORT TO
VOLTAGE WITH ALL CONNECTORS CONNECTED. REPAIR
ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE.ACHIEVING AT
LEAST 16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 63 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE; CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES 6-24-93
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN. MS 12777
5E1-132 ANTILOCK BRAKE SYSTEM

EBCM

- - - - - - - - - - - - - - - 1284 DK GRN - - - C REAR ABS MOTOR HIGH

J-----------------12850RN -----t F REAR ABS MOTOR LOW

ABS MOTOR PACK

6 WAY CONNECTOR

6-18-93
MS 12769

DTC64
REAR ABS MOTOR CIRCUIT OPEN
Circuit Description:
This DTC identifies an ABS motor that cannot be energized due to an open in its circuitry. This malfunction
will not allow proper rear ABS operation.

DTC Will Set When: DTC 64 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out of range voltage on either of the rear axle ABS motor circuits indicating an open circuit, a malfunction
exists.

Action Taken: An open motor will not activate when requested. A malfunction DTC is stored, ABS is disabled
and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. This checks for proper resistance of the ABS motor.
2. Checks for an open in the ABS motor "HIGH"
circuitry.
3. Checks for an open in the ABS motor "LOW"
circuitry.
4. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids: Using Tech 1, select .manual
control function, and exercise motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the motor, an intermittent malfunction
may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness. ·
 ANTILOCK BRAKE SYSTEM 5E1-133

DTC64
REAR ABS MOTOR CIRCUIT OPEN

DOES DTC 64 OCCUR INTERMITTENTLY?

Cv • •
IGNITION"OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.

• USING J 39200, MEASURE RESISTANCE ACROSS ABS

MOTOR PACK TERMINALS "C" AND "D".
IS RESISTANCE BELOW 20000?

DISCONNECT 8-WAY CONNECTOR AT EBCM.

• USING J 39200, MEASURE RESISTANCE BETWEEN
TERMINAL "C" OF THE 8-WAY EBCM HARNESS
CONNECTOR AND TERMINAL "C" OF THE 6-WAY
ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

G) • USINGJ 39200, MEASURE RESISTANCE BETWEEN REPAIR OPEN OR HIGH RESISTANCE IN CKT 1284.
TERMINAL "F" OF THE 8-WAY EBCM HARNESS
CONNECTOR AND TERMINAL "D" OF THE 6-WAY
ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

INSPECT THE 6-WAY ABS MOTOR PACK AND 8-WAY EBCM REPAIR OPEN OR HIGH RESISTANCE IN CKT 1285.
CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SECTION 8A-4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 64 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED BY A POOR

CONNECTION. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.6-24-93
MS 12778
5E1-134 ANTILOCK BRAKE SYSTEM

EBCM

C 1284DKGRN - - - C REARABSMOTORHIGH

·~~~~lj/<M -~~~~~~
D~ 1285 ORN - - - - - t F REAR ABS MOTOR LOW

ABS MOTOR PACK

6 WAY CONNECTOR

6-18-93
MS 12769

DTC65
REAR ABS MOTOR CIRCUIT SHORTED TO GROUND
Circuit Description:
This DTC identifies an ABS motor circuit that is shorted to ground. This malfunction will not allow the ABS
motor to be controlled at the commanded current rate or will cause the driver circuit to allow current directly to
ground.

OTC Will Set When: DTC 65 can be set anytime. If the EBCM detects an out of range voltage on either of the
rear axle ABS motor circuits indicating a circuit shorted to ground, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the '.'ABSJNOP" lamp is turned "ON."
. ,,

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to ground in the ABS motor
"HIGH" circuitry.
2. Checks for a short to ground in the ABS motor
"LOW" circuitry.
3. Checks for an ABS motor that is internally shorted
to ground.
4. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual
control function, and exercise ABS motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and.check if the. DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermitten~ complaint,. should be th<>roughly checked
for backed out terminals, improper. mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCKBRAKE SYSTEM 5E1-135

DTC65
REAR ABS MOTOR CIRCUIT SHORTED TO GROUND

DOES DTC 65 OCCUR INTERMITTENTLY?

G) • IGNITION "OFF."
• DISCONNECT THE 6-WAY ABS MOTOR PACK CONNECTOR
AND THE B-WAY EBCM CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL "C" OF THE 6-WAY ABS
MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

• MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "D" OF THE 6-WAY ABS MOTOR PACK
HARNESS CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "C" OF THE ABS MOTOR PACK.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

INSPECT CKTs 1284 AND 1285 AND RELATED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHQRT TO
GROUND WITH ALL CONNECTORS CONNECTED. REPAIR
ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "OFF."
• START ENGINE AND TEST DRIVE VEHICLE.ACHIEVING AT
LEAST 16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 65 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN. _ _
6 17 93
MS 12779
5E1-136 ANTILOCK BRAKE SYSTEM

EBCM

1--------------- 1284DKGRN - - - - C REARABSMOTORHIGH

1 - - - - - - - - - - - - - - - - 1285 ORN ------1 F REAR ABS MOTOR LOW

ABS MOTOR PACK

6WAYCONNECTOR

6-18-93
MS 12769

DTC66
REAR ABS MOTOR CIRCUIT SHORTED TO BATTERY
Circuit Description:
This DTC identifies an ABS motor circuit that is shorted to battery or an ABS motor that has low or zero
resistance. This malfunction will not allow the ABS motor to be controlled at the commanded current rate or will
cause the ABS motor to turn in the opposite direction or not turn at all.

OTC Will Set When: DTC 66 can be set only when the ABS motor is commanded "OFF." If the EBCM detects
an out of range voltage on either of the rear ABS axle motor circuits indicating a circuit shorted to battery or an
ABS motor shorted, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to voltage in the ABS motor
"HIGH" circuitry.
2. Checks for a short to voltage in the ABS motor
"LOW" circuitry.
3. Checks for a short circuit between motor "HIGH"
and motor "LOW".
4. Checks for proper resistance of the ABS motor.
5. Ensures malfunction was not due to physical
damage of the circuitry.
Diagnostic Aids: Using Tech 1, select manual,
control function, and exercise ABS motor movement of
affected channel in both directions while applying
light pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
An "Intermittent" malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-137

NOTICE: J 39200 TEST LEADS MUST BE "ZEROED"

PRIOR TO MAKING ANY RESISTANCE MEASUREMENTS.
DTC65
REFER TO J 39200 USER'S MANUAL. REAR ABS MOTOR CIRCUIT
SHORTED TO BATTERY
DOES OTC 66 OCCUR INTERMITTENTLY?

G) • IGNITION "OFF." REFER TO "DIAGNOSTIC

• DISCONNECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND THE AIDS .. ON FACING PAGE.
8-WAY EBCM CONNECTOR.
• IGNITION "ON.''
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "C" OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 . MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "D'.' ,

OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
RE:PAIR SHORT TO
VOLTAGE IN CKT 1284.
IS VOLTAGE 1 VOLTORLESS?

G). IGNITION "OFF."

• TERMINAL
USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" AND
"D.. OF THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS "OL" {INFINITE)?

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C"

AND TERMINAL .. D .. OF THE ABS MOTOR PACK.
IS RESISTANCE GREATER THAN 0.4Q.?

• INSPECT CKTs 1284 AND 1285 AND RELATED CONNECTORS FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS CONNECTED.
REPAIR ALL DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION .. OFF."
• START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST 16 km/h (10 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 66 SET IN THE LAST THREE DRIVE CYCLES?

MALFUNCTION WAS MOST LIKELY

CAUSED BY A POOR CONNECTION.
REFER TO "DIAGNOSTIC AIDS .. ON
FACING PAGE.

AFTER DIAGNOSIS IS COMPLETE, CLEAR ores AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN.
6-17-93
MS 12780
SE1-138 ANTILOCK BRAKE SYSTEM

EBCM

r- 5111
651 BLK/WHT - - - - - - - - - - - - - - - - - 651 BLKJWHT - - - 1 E GROUND

UFABS
G101 SOLENOID
651 BLK/WHT ~ 1288 DK GRN ---11 81 LF ABS SOLENOID
L!J U UU U L.=...J CONTROL

R/F ABS
SOLENOID
651BLK/WHT ~ 1289LTBLU ---1A9 RFABSSOLENOID
0 0 0 0 -i.:.r-
---i..:...,- CONTROL

6-24-93
NS 15727

DTC76
LEFT FRONT SOL CIRCUIT OPEN OR SHORTED TO BATT
Circuit Description:
This OTC identifies a solenoid that cannot be energized due to an open in its circuitry, or a solenoid that is
always energized due to a short to battery in its circuitry between the driver and the solenoid. An open will not
allow proper ABS operation, but the short to battery simply turns "ON" the solenoid. A path for base brakes is
still allowed once the motor re-homes and the check ball is lifted off its seat during key "ON" initialization.

DTC Will Set When: OTC 76 can be set only when the solenoid is commanded "OFF." If the EBCM detects an
excessive voltage in the left front solenoid control circuit, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to voltage in the control
circuitry of the solenoid.
2. Checks for an open in the control circuit of the
solenoid.
3. Checks the solenoid coil for proper resistance.
4. Checks for an open in the solenoid ground circuit.
5. Checks for a possible intermittent malfunction in
the solenoid circuitry due to poor terminal contact.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or· a wire that is broken inside the
insulation.
.The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
l, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly. formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-139

DTC76
G) • IGNITION "OFF."
LEFT FRONT SOL CIRCUIT OPEN
• DISCONNECT 32-WAY EBCM CONNECTOR. OR SHORTED TO BATT
• IGNITION "ON," ENGINE "OFF."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL "81" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

G) • IGNITION "OFF."
• DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINAL "81" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND TERMINAL" A" OF THE LEFT FRONT
SOLENOID HARNESS CONNECTOR.
IS RESISTANCE 20 OR LESS?

(!) • MEASURE TH~ RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE LEFT FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND Sil?

0 • MEASURE THE RESISTANCE BETWEEN

GROUND AND TERMINAL "B" OF THE
REPLACE LEFT FRONT
SOLENOID.
LEFT FRONT SOLENOID HARNESS
CONNECTOR,
IS RESISTANCE 20 OR LESS?

0 • INSPECT LEFT FRONT SOLENOID AND 32-WAY EBCM HARNESS

CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE
REPAIR OPEN OR HIGH
RESISTANCE IN CKT651.
OF CORROSION. REFER TO SECTION 8A-4, "CHECKING
TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT
SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
• INSPECT CKT 1288 FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO VOLTAGE WITH ALL CONNECTORS CONNECTED.
REPAIR DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
DOES DTC 76 SET AS A CURRENT DTC?

MALFUNCTION IS INTERMITTENT.
REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.

7-7-93
NS 15717
SE1-140 ANTILOCK BRAKE SYSTEM

EBCM

__r-- S111
651 BLK/WHT - - . . . . . - - ~ - - - - - - - - - - - - 651 BLK/WHT E GROUND

L/F ABS
G101 SOLENOID
651 BLK/WHT ~ 1288DKGRN ----181 LFABSSOLENOID
L!J O OOO L.:.J CONTROL

R/F ABS
SOLENOID
651 BLK/WHT ~
--i.:.,r QQQQ ~
1289LTBLU ----1 A9 RF ABS SOLENOID
CONTROL

6-24-93
NS 15727

DTC77
LEFT FRONT SOLENOID CIRCUIT SHORTED TO GND
Circuit Description:
This DTC identifies a solenoid that cannot be energized due to an open in its driver circuitry, or a short to
ground between the solenoid driver and the solenoid. These malfunctions can affect ABS operation since the flow
of brake fluid to the wheel cylinder cannot be stopped, making ABS operation for that channel impossible.

DTC Will Set When: DTC 77 can be set only when the solenoid is commanded "ON." If the EBCM detects the
left front solenoid control circuit voltage is out of specification, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a solenoid that is internally shorted to
ground.
2. Checks for a solenoid that is not within proper
resistance values.
3. Indicates if a short to ground exists in the solenoid
circuitry.
4. Checks for a possible intermittent malfunction in
the solenoid circuitry due to poor terminal contact.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation,.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1,.as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-141

DTC77
LEFT FRONT SOLENOID
CIRCUIT SHORTED TO GND

0 • •
IGNITION "OFF."
DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL" A" OF THE LEFT FRONT
SOLENOID.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

USING J 39200, MEASURE THE RESISTANCE BETWEEN

TERMINAL" A" AND TERMINAL "B" OF THE LEFT FRONT REPLACE LEFT FRONT SOLENOID.
SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5.0 Q?

0·• DISCONNECT 32-WAY EBCM CONNECTOR.

MEASURE THE RESISTANCE BETWEEN GROUND AND
REPLACE LEFT FRONT SOLENOID.

TERMINAL "81" OF THE 32-WAY EBCM HARNESS

CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?

©• INSPECT CKT 1288 AND THE LEFT FRONT SOLENOID AND

32-WAY EBCM HARNESS CONNECTORS FOR DAMAGE
REPAIR SHORT TO GROUND
INCKT1288.
WHICH MAY RESULT IN A SHORT TO GROUND WITH ALL
CONNECTORS CONNECTED. REPAIR DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• START ENGINE WITH FOOT OFF BRAKE.
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
DOES DTC 77 SET AS A CURRENT DTC?

MALFUNCTION IS INTERMITTENT.
REPLACE EBCM. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.

7-9-93
NS 15718
5E1-142 ANTILOCK BRAKE SYSTEM

EBCM

5111
~ 651 BLKIWHT - - - - - - - - - - - - - - - - - 651 BLKJWHT ---1 E GROUND

UFABS
G101 SOLENOID
651BLKIWHT ~ 1288DKGRN ---1181 LFABSSOLENOID
L!.J U UUU L.:J CONTROL

R/FABS
SOLENOID
651BLKIWHT ~ . A .- 1289LTBLU ---1A9 RFABSSOLENOID
-i.:_r Q Q Q Q· ~ CONTROL

6-24-93
NS 15727

DTC78
RIGHT FRONT SOL CIRCUIT OPEN OR SHORTED TO BATT
Circuit Description:
This OTC identifies a solenoid that cannot be energized due to an open in its circuitry, or a solenoid that is
always energized due to a short to battery in its circuitry between the driver and the solenoid. An open will not
allow proper ABS operation, but the short to battery simply turns "ON" the solenoid. A path for base brakes is
still allowed once the motor re-homes and the check ball is lifted off its seat during key "ON" initialization.

OTC Will Set When: OTC 78 can be set only when the solenoid is commanded "OFF." If the EBCM detects an
excessive voltage in the right front solenoid control circuit, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a short to voltage in the control
circuitry of the solenoid.
2. Checks for an open in the control circuit of the
solenoid.
3. Checks the solenoid coil for proper resistance.
4. Checks for an open in the solenoid ground circuit.
5. Checks for a possible intermittent malfunction in
the solenoid circuitry due to poor terminal contact.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-143

DTC78
RIGHT FRONT SOL CIRCUIT OPEN
8 • IGNITION "OFF."
OR SHORTED TO BATT
• DISCONNECT 32-WAY EBCM CONNECTOR.
• IGNITION "ON," ENGINE "OFF."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL" A9" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 •
•
IGNITION "OFF."
DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINAL "A9" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND TERMINAL" A" OF THE RIGHT FRONT
SOLENOID HARNESS CONNECTOR.
IS RESISTANCE 20 OR LESS?

MEASURE THE RESISTANCE BETWEEN TERMINAL "A" REPAIR OPEN OR HIGH

AND TERMINAL "B" OF THE RIGHT FRONT SOLENOID. RESISTANCE IN CKT
IS RESISTANCE BETWEEN 2.5 AND 50? 1289.

MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "B'' OF THE RIGHT FRONT SOLENOID HARNESS
CONNECTOR.
IS RESISTANCE 20 OR LESS?

INSPECT RIGHT FRONT SOLENOID AND 32-WAY EBCM

HARNESS CONNECTORS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REPLACE ALL TERMINALS THAT
EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
• INSPECT CKT 1289 FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO VOLTAGE WITH ALL CONNECTORS CONNECTED.
REPAIR DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
DOES OTC 78 SET AS A CURRENT OTC?

MALFUNCTION IS MOST LIKELY DUE TO

POOR TERMINAL CONTACT. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

7-8-93
NS 15719
5E1-144 ANTILOCK BRAKE SYSTEM

EBCM

_r- 651 BLK/WHT

S111
E GROUND

L/FABS
G101 SOLENOID
651 BLK/WHT ~ 1288DKGRN - - - t 8 1 LFABSSOLENOID
L!J U UUU L:.J CONTROL

R/FABS
SOLENOID
651 BLK/WHT ~ 1289 LT BLU - - - t A9 RF ABS SOLENOID
--....:..r QQQQ ~ CONTROL

6-24-93
NS 15727

DTC81
RIGHT FRONT SOLENOID CIRCUIT SHORTED TO GND
Circuit Description:
This DTC identifies a solenoid that cannot be energized due to an open in its driver circuitry, or a short to
ground between the solenoid driver and the solenoid. These malfunctions can affect ABS operation since the flow
of brake fluid to the wheel cylinder cannot be stopped, making ABS operation for that channel impossible.

OTC Will Set When: DTC 81 can be set only when the solenoid is commanded "ON." If the EBCM detects the
right front solenoid control circuit voltage is out of specification, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks for a solenoid that is internally shorted to
ground.
2. Checks for a solenoid that is not within proper
resistance values.
3. Indicates if a short to ground exists in the solenoid
circuitry.
4. Checks for a possible intermittent malfunction in
the solenoid circuitry due to poor terminal contact.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-145

DTC81
RIGHT FRONT SOLENOID
CIRCUIT SHORTED TO GND

0 •
•
IGNITION "OFF."
DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
• USING J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL" A" OF THE RIGHT FRONT
SOLENOID.
DOES J 39200 DISPLAY RESISTANCE AS "OL" {INFINITE)?

USING J 39200, MEASURE THE RESISTANCE BETWEEN

TERMINAL" A" AND TERMINAL "B" OF THE RIGHT
FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5.0 Q?

0·• DISCONNECT 32-WA Y EBCM CONNECTOR ..

MEASURE THE RESISTANCE BETWEEN GROUND AND
TERMINAL" A9" OF THE 32-WA Y EBCM HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" {INFINITE)?

©• INSPECT CKT 1289 AND THE RIGHT FRONT SOLENOID AND

32-WAY EBCM HARNESS CONNECTORS FOR DAMAGE
REPAIR SHORT TO GROUND
IN CKT 1289.
WHICH MAY RESULT IN A SHORT TO GROUND WITH ALL
CONNECTORS CONNECTED. REPAIR DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• START ENGINE WITH FOOT OFF BRAKE.
• ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
DOES OTC 81 SET AS A CURRENT OTC?

MALFUNCTION IS INTERMITTENT.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.

7-14-93
NS 15720
SE1-146 ANTILOCK BRAKE SYSTEM

MS 12781

DTC82
CALIBRATION MALFUNCTION
Circuit Description:
This OTC allows the EBCM to check for a calibration malfunction by comparing the calibration value to a
known value stored in the EEPROM.
This OTC is also used as a security measure to prevent improper use of calibrations or changes to these
calibrations that may alter the designed function of ABS.

OTC Will Set When: OTC 82 can be set at key-up. If the program identifier is incorrect or the memory
checksum is incorrect, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks to see if the malfunction is present during
diagnosis. If present, the EBCM is not functioning
correctly and must be replaced.
[I] Important
• At the time of printing, 1994 vehicles with ABS-VI
were not being field reprogrammed to correct this
failure. A service bulletin will be issued when
EEPROM reprogramming is authorized.
Diagnostic Aids: An intermittent OTC 82 may be
caused by a bad cell in the EEPROM that is sensitive
to temperature changes. If OTC 82 failed more than
once, but is intermittent, replace EBCM.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
 ANTILOCK BRAKE SYSTEM 5E1-147

DTC82
CALIBRATION MALFUNCTION

G) • IGNITION "ON."
IS DTC 82 SET AS A CURRENT DTC?

MALFUNCTION IS NOT PRESENT AT

THIS TIME. REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.

4.19.93
MS 8731·5E
SE1-148 ANTILOCK BRAKE SYSTEM

EBCM

SEE SA-11-4 BRAKE WARNING

LAMP CONTROL

IGN ABS ACTIVE

LAMP CONTROL

D6CHEV _lr;:;-t ABS WARNING

B17PONT 867LTGRN~867LTGRN
LAMP CONTROL
C200D
C200A

7-14-93
NS 15733

DTC86
EBCM TURNED "ON" THE RED "BRAKE" WARNING LAMP
Circuit Description:
This DTC is provided as an information only DTC, and reflects the status of the command issued by the ABS
EBCM to illuminate the red brake warning lamp. If another DTC issues a command to illuminate the red brake
warning lamp, DTC 86 will be stored in EEPROM as a history DTC at the conclusion of the ignition cycle.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Serves to identify if a DTC other than DTC 86
commanded the red brake warning lamp "ON."
Diagnostic Aids: Any ABS mechanical DTC that
issues a command to illuminate the red "BRAKE"
telltale will also result in DTC 86 being stored in
EEPROM during shut down. These DTCs are: 38, 41,
42, 46, and 51. If the motors are not in their home
position, certain electrical DTCs will also command
the red "BRAKE" telltale "ON." These DTCs are: 14,
16, 18, 55, 56, 57, 58, 61, 62, 63, 64, 65, and 66.
If any of these DTCs are indicated along with DTC
86, they must be corrected prior to addressing a DTC
86 malfunction.
 ANTILOCK BRAKE SYSTEM 5E1-149

DTC86
11
EBCM TURNED 0N" THE RED
11 11
BRAKE WARNING LAMP

ARE ANY DTCs CURRENTLY

SET WITH OTC 86?

OTC 86 SET DUE TO VEHICLE PROCEED TO uDIAGNOSTIC AIDS" ON

TRANSIENT VOLTAGES; CLEAR OTC. FACING PAGE OF THIS CHART.

4-19-93
MS 10093
SE1-150 ANTILOCK BRAKE SYSTEM

EBCM
BRAKE
INSTRUMENT BRAKE COMBO
CLUSTER WARNING SWITCH
r------,
_ ___.,_. _ ___, C10CHEV
A10PONT
33 TAN/ t fr ~ t
:;J 33 TAN/
WHT S ~ W H T
BRAKE WARNING
LAMP CONTROL
........~~- I I
D13CHEV 016 CH'EV 1537DKBLU~1537DKBLU ABS ACTIVE
IGN
AS PONT "LOW TRAC" A 16 PONT ~

a
LAMP CONTROL
I I
.____.:-,_ ____. :,6.,~iE:T 867 LT GRN 867 LT GRN ABS WARNING
LAMP CONTROL
C200D
C200A

7-14-93
NS 15733

DTC87
RED "BRAKE" WARNING LAMP CIRCUIT OPEN
Circuit Description:
This DTC is used to verify the EBCM has continuity to the red brake warning lamp in case the EBCM must
turn it "ON." This will only occur if an ABS malfunction is detected that may degrade base brake operation.
Because ABS is not the only device controlling the red brake warning lamp (parking brake and low fluid
sensor may also turn "ON" the lamp) a short to ground in this circuit cannot be detected.

OTC Will Set When: DTC 87 can be set after initializll.tion is completed. If the red brake warning lamp circuit
voltage is out of specification indicating an open circuit, a malfunction exists.

Action Taken: A malfunction DTC is stored, ABS is not disabled.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Identifies if the ground circuit to the red brake
warning lamp is completed by a source other than
theEBCM.
2. Checks for high resistance in park brake circuitry.
3. Checks for malfunctioning EBCM.
4. Checks for high resistance in fluid level switch
circuitry. ' parking brake handle may be lifted to verify proper
5. Checks for malfunctioning warning lamp bulb.
6. Checks for open or high resistance in CKT 33.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section. If a Tech 1 or T-100 are not available, the
lamp operation and continuity ofCKTs 3 and 39.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-151

DTC87
G) • IGNITION "OFF."
RED ''BRAKE" WARNING
• DISCONNECT 32-WAY EBCM CONNECTOR.
• USING A FUSED JUMPER SUCH AS J 36169 WITH A LAMP CIRCUIT OPEN
3 AMP FUSE, CONNECT 32-WAY EBCM HARNESS
CONNECTOR TERMINAL "84" TO GROUND.
• IGNITION "ON."
IS RED BRAKE WARNING LAMP "ON"?

'0 • •
ENSURE BRAKE FLUID IS AT THE PROPER LEVEL.
IGNITION "OFF."
0 • IGNITION "OFF."
• REMOVE 1/PCLUSTER.
• REMOVE JUMPER USED IN STEP 1. • REMOVE AND INSPECT RED BRAKE WARNING LAMP.
• APPLY PARK BRAKE. IS BULB OPEN?
• IGNITION "ON."
• USINGJ 39200, MEASURE VOLTAGE BETWEEN
GROUND AND 32-WAY EBCM HARNESS
CONNECTOR TERMINAL "84."
IS VOLTAGE LESS THAN 2 VOLTS? USING J 39200, MEASURE REPLACE
RESI.STANCE BETWE.EN 1/P BULB.
CLUSTER HARNESS
CONNECTOR TERMINAL "C1 O"
(CHEV)OR "A10" (PONT) AND
G) .....~R-E-L-EA_S_E_P_A_R_K_B_R_A_K_E_---------, r ;EF~; ~~ - - 1
32-WAY EBCM HARNESS
• IGNITION "OFF." SECTION SA CONNECTOR TERMINAL "84."
• DISCONNECT BRAKE COMBO VALVE SWITCH. TO REPAIR IS RESISTANCE LESS THAN 2Q?
• INSPECT 32-WAY EBCM HARNESS HIGH
CONNECTOR TERMINAL "84" FOR POOR RESISTANCE
TERMINAL CONTACT OR CORROSION. REFER IN PARK
TO SECTION BA-4, "CHECKING TERMINAL BRAKE r- - - - - - - - - - - - - - - - - ,
CONTACT." REPLACE TERMINALS THAT SWITCH : REFER TO SECTION BA TO : REPAIR OPEN OR
EXHIBIT POOR CONTACT OR CORROSION. CIRCUITRY. I DIAGNOSE CLUSTER AND/OR I HIGH RESISTANCE
• RECONNECT 32-WAY EBCM CONNECTOR. J : CIRCUITRY TO CLUSTER. : INCKT33 ..
• START ENGINE.
L- - - - - - - -
L------------------~
• WAIT 10 SECONDS.
DOES OTC 87 SET AS A CURRENT DTC?

(!) • IGNITION "OFF."

• INSPECT BRAKE COMBO VALVE SWITCH HARNESS CONNECTOR FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SECTION BA-4, "CHECKING TERMINAL CONTACT."
REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF TERMINAL CONTACT OR CORROSION.
• RECONNECT BRAKE COMBO VALVE SWITCH CONNECTOR.
• START ENGINE.
• WAIT 10 SECONDS.
DOES OTC 87 SET AS A CURRENT OTC?

r- -----------------------,
: CHECK BRAKE FLUID LEVEL AND REFER : MALFUNCTION IS MOST LIKELY DUE
I TO SECTION BA TO REPAIR HIGH I TO A POOR CONNECTION. REFER TO
: RESISTANCE IN BRAKE PRESSURE : "DIAGNOSTIC AIDS" ON FACING PAGE.
[ DIFFERENTIAL SWITCH CIRCUITRY. ___ ]

7-9-93
NS 15721
5E1-152 ANTILOCK BRAKE SYSTEM

EBCM
BRAKE
INSTRUMENT BRAKE COMBO
.-----,
CLUSTER WARNING SWITCH

SEESA-11-4
I _ ____..._._ _____. C10 CHEV
I "BRAKE" A10PONT
t
33 TAN/ rr-~-i)
WHT s ~ W H T
t
33 TAN/ BRAKE WARNING
LAMP CONTROL

013 CHEV
t=====~
016 CHEV
I I
£::li ABS ACTIVE
IGN AS PONT ._._"L-O~W•-TR~IA>-C-..-1 A 16 PONT 1 537 DK BLU ~ 1537 DK BLU
LAMP CONTROL
--~~~ I I
D6CHEV ~ ABS WARNING
817 PONT 867L T GRN ~ 867L T GRN
LAMP CONTROL
C200D
C200A

7-14-93
NS 15733

DTC88
RED "BRAKE" WARNING LAMP CKT SHORTED TO BATT
Circuit Description:
This OTC identifies a short to battery between the EBCM and the red brake warning lamp, or an open driver
that does not allow the red brake warning lamp to be illuminated by the EBCM. This will only occur if an ABS
fault is detected that may degrade base brake operation.

DTC Will Set When: OTC 88 can be set only at the beginning of the three second bulb check. If the EBCM
detects battery voltage on the red brake warning lamp control circuit, a malfunction exists.

Action Taken: A malfunction OTC is stored. A.BS is not disabled; however, the "ABS INOP" lamp will flash to
indicate a malfunction exists.

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Identifies if the ground circuit to the red brake
warning lamp is being completed by a source other
than the EBCM.
2. Identifies if the malfunction is currently present.
3. By removing the 10 amp "GAGES" Fuse 9, the
voltage source is eliminated. This test indicates if
voltage is being supplied from a source other than
the gauge fuse.
4. Ensures malfunction was not due to physical
damage of the circuitry.
5. Checks for OTC 86 also being set.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-153

DTC88
RED ''BRAKE" WARNING
LAMP CKT SHORTED TO BATT

8 ••
IGNITION "ON."
OBSERVE RED "BRAKE" WARNING LAMP.
IS LAMP "OFF"?

0 • USING TECH 1 LAMP FUNCTION,

COMMAND RED "BRAKE" LAMP ON.
IS LAMP ILLUMINATED?

G) • IGNITION "OFF." MALFUNCTION IS CHECK FOR LOW FLUID LEVEL PROCEED TO DTC
• REMOVE 10 AMP GAUGES FUSE 9. NOT PRESENT AT OR 86 DIAGNOSTIC
• DISCONNECT32-WAY EBCM THIS TIME. REFER TO PARKING BRAKE SWITCH CHART.
CONNECTOR. "DIAGNOSTIC AIDS" CLOSED AND CORRECT AS
• IGNITION "ON." ON FACING PAGE. NECESSARY.
• USING J 39200, MEASURE THE
VOLTAGE BETWEEN GROUND AND
TERMINAL "84" OF THE 32-WAY
EBCM HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?

0 • •
IGNITION "OFF."
INSPECT CKT 33 AND 32-WA Y EBCM HARNESS
CONNECTOR FOR DAMAGE WHICH MAY RESULT
IN A SHORTTO VOLTAGE WITH ALL CONNECTORS
CONNECTED. REPAIR DAMAGE IF EVIDENT.
• RECONNECT ALL CONNECTORS.
• IGNITION "ON."
• IS OTC 88 SET AS A CURRENT DTC?

MALFUNCTION IS MOST LIKELY DUE TO

A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

7-16-93
NS 15722
SE1-154 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE C200D
LINK "F"
~2J-
STO~U~~ZlRD
~~~ ~ 1400RN
1 ~~ B C
~
820YEL
C200A 5271
A4 820YEL
5243
C200A 20AMP • - - •
C200D BRAKE SWITCH

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC91
OPEN BRAKE SWITCH DURING DECELERATION
Circuit Description:
This DTC is used to detect an open brake switch in the non-ABS mode. The EBCM looks for deceleration
rates that would indicate braking action and verifies this assumption by requiring several repeats of this
detection method. In each case, ABS will not be available since no brake switch is seen.

DTC Will Set When: DTC 91 can be set if three deceleration cycles occur with the brake switch "OFF."

Action Taken: A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Indicates if the brake switch signal is being
received by the EBCM.
2. Indicates if an open circuit exists in the brake
switch or brake lamp circuitry.
3. Isolates the open circuit to either the brake switch
input circuitry, or the EBCM.
4. Ensures malfunction was not due to poor terminal
contact.
5. Verifies that voltage is available at the brake
switch.
6. Verifies that the brake switch is functioning
properly.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
· locks, improperly formed or damaged terminals, poOr
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-155

DTC91
OPEN BRAKE SWITCH
DURING DECELERATION

G) • IGNITION "ON."
• USING TECH 1,SELECT "F0: DATA LIST."
• APPLY LIGHT PRESSURE ON BRAKE PEDAL,
WHILE MONITORING BRAKE SWITCH STATUS ON
TECH 1.
DOES TECH 1 INDICATE BRAKE SWITCH "ON"
WITHIN 1 INCH OF TRAVEL,?

WITH PRESSURE STILL APPLIED TO BRAKE MALFUNCTION IS NOT PRESENT AT

PEDAL, OBSERVE REAR BRAKE LAMPS. THIS TIM.E. REFER TO "DIAGNOSTIC
ARE BRAKE LAMPS "ON"? AIDS" ON FACING PAGE.

G) • IGNITION "OFF." G) • USINGJ 39200, MEASURE THE VOLTAGE

• DISCONNECT 32-WAY EBCM CONNECTOR. BETWEEN GROUND AND TERMINAL "B" OF
• IGNITION "ON." THE BRAKE SWITCH.
• USINGJ39200,MEASURETHE VOLTAGE IS VOLTAGE 10VOLTS OR GREATER?
BETWEEN GROUND AND TERMINAL "812"
OF THE 32-WAY EBCM HARNESS
CONNECTOR WHILE APPLYING FIRM
PRESSURE ON BRAKE PEDAL.
IS VOLTAGE 10 VOLTS OR GREATER?
G) • MEASURE THE VOLTAGE BETWEEN REPAIR OPEN OR
GRO.UND AND TERMINAL "C" OF SHORTEDCKT 140
THE BRAKE SWITCH WHILE AND REPLACE 20
APPL YING FIRM PRESSURE ON AMP STOP

0 • INSPECT 32-WAY EBCM HARNESS

CONNECTOR TERMINAL "812" FOR
REPAIR
BRAKE PEDAL.
IS VOLTAGE 10 VOLTS OR GREATER?
HAZARD FUSE 6.

SHORTED
POOR TERMINAL CONTACT AND QR OPEN
EVIDENCE OF CORROSION. REFER CKT820.
TO SECTION 8A·4, "CHECKING
TERMINAL CONTACT." REPLACE
ALL TERMI.NALS THAT EXHIBIT MISADJUSTED OR FAULTY BRAKE
SIGNS OF TERMINAL CONTACT OR SWITCH. ADJUST OR REPLACE
CORROSION. SWITCH AS NECESSARY.
• RECONNECT ALL CONNECTORS ..
• DRIVE VEHICLE AND PERFORM A
MODERATELY HARD ABS STOP.
DOESDTC910R92SETASA
CURRENT OTC?

MALFUNCTION IS MOST LIKELY DUE

TO A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

7-8·93
NS 15723
5E1-156 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE
LINK "F" STOP HAZARD
FUSE6
Jc 2• _ 1002
L: :..J RED
~ 140 ORN
C200A 20AMP
C200D

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC92
OPEN BRAKE SWITCH WHEN ABS WAS REQUIRED
Circuit Description:
This OTC is run to determine the proper operation of the brake switch. This is important because ABS is
activated when the brake switch is "ON." If the brake switch is "OFF," ABS will never be activated. Since this
malfunction is difficult to detect under normal braking conditions, this malfunction is only detected when ABS is
required.

OTC Will Set When: OTC 92 can be set if the vehicle's speed is greater than 8 km/h (5 mph). If the brake was
not "ON" and a release was required on two charinelsfor 0.5 seconds, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

OTC Chart Test Description: Number(s) below
refer to circled num~er(s) on the diagnostic chart ..
1. Indicates if the brake switch signal is being
received by the EBCM.
2. Indicates if an open circuit exists in the brake
switch or brake lamp circuitry.
3. Isolates the open circuit to either the brake switch
input circuitry, or the EBCM.
4. Ensures malfunction was not due to poor terminal
contact.
5. Verifies the voltage is available at the brake
switch.
6. Verifies that the brake switch is functioning
properly.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM 5E1-157

IS OTC 95 CURRENTLY SET?

DTC92
OPEN BRAKE SWITCH WHEN
ABS WAS REQUIRED

G) • IGNITION "ON."
• USING TECH 1, SELECT "F0: DATA LIST."
• APPLY LIGHT PRESSURE ON BRAKE PEDAL,
WHILE MONITORING BRAKE SWITCH STATUS ON
TECH 1.
DOES TECH 1 INDICATE BRAKE SWITCH "ON"
WITHIN 1 INCH OF TRAVEL?

WITH PRESSURE STILL APPLIED TO BRAKE MALFUNCTION IS NOT PRESENT AT

PEDAL, OBSERVE REAR BRAKE LAMPS. THIS TIME. REFER TO "DIAGNOSTIC
ARE BRAKE LAMPS "ON"? AIDS" ON FACING PAGE.

0 ••
IGNITION "OFF."
DISCONNECT 32-WAY EBCM CONNECTOR.
0 • USING J 39200, MEASURE THE VOLTAGE
BETWEEN GROUND AND TERMINAL "B" OF
• IGNITION "ON." THE BRAKE SWITCH.
• USING J 39200, MEASURE THE VOLTAGE IS VOLTAGE 10 VOLTS OR GREATER?
BETWEEN GROUND ANO TERMINAL "812"
OF THE 32-WAY EBCM HARNESS
CONNECTOR WHILE APPLYING FIRM
PRESSURE ON BRAKE PEDAL.
IS VOLTAGE 10 VOL TS OR GREATER?
0 • MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "C" OF
REPAIR OPEN OR
SHORTED CKT 140
THE BRAKE SWITCH WHILE AND REPLACE 20
APPLYING FIRM PRESSURE ON AMP STOP

0 • INSPECT 32-WAY EBCM HARNESS

CONNECTOR TERMINAL "812" FOR
REPAIR
SHORTED
BRAKE PEDAL.
IS VOLTAGE 10 VOL TS OR GREATER?
HAZARD FUSE 6.

POOR TERMINAL CONTACT AND OR OPEN

EVIDENCE OF CORROSION. REFER CKT820.
TO SECTION SA-4, "CHECKING
TERMINALCONTACT." REPLACE
ALL TERMINALS THAT EXHIBIT MISADJUSTED OR FAULTY BRAKE
SIGNS OF TERMINAL CONTACT OR SWITCH. ADJUST OR REPLACE
CORROSION. SWITCH AS NECESSARY.
• RECONNECT ALL CONNECTORS.
• DRIVE VEHICLE AND PERFORM A
MODERATELY HARD ABS STOP.
DOES OTC 91 OR 92 SET AS A
CURRENT OTC?

MALFUNCTION IS MOST LIKELY DUE

TO A POOR CONNECTION. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.

7-8-93
NS 15723
SE1-158 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE
LINK UFU
~i]-- ~~°;
sTOrJs~~ARD
~ 1400RN
1 ~~ B C
~
820YELS
C200D
C200A 5271
A4 820YEL
243
C200A 20AMP • - - •
C200D BRAKE SWITCH

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC93
OTC 91 OR 92 SET IN CURRENT OR PREV. IGN CYCLE
Circuit Description:
This DTC is the second portion of DTCs 91 and 92. If DTCs 91 or 92 failed during the last ignition cycle, DTC
93 becomes a current failure during the next ignition cycle, keeping ABS disabled until a brake switch "ON"
state is seen. When a change is seen during an ignition cycle in which DTC 93 is a current malfunction, DTC 91
or 92 will clear itself at the end of the current ignition cycle, and ABS will enable itself at the start of the next
ignition cycle. DTC 93 alone indicates 91 or 92 failed previously, but is intermittent, or has been corrected.

OTC Chart Test Description: Number(s) below.·
refer to circled number(s) on the diagnostic chart.
1. Indicates which DTC (either 91 or 92) caused DTC
93 to set.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
Also, verify proper brake switch operation using
the data list of the Tech 1. As the brake is applied, the
data list should display the brake switch "ON" within
1 inch of travel.
 ANTILOCK BRAKE SYSTEM SE1-15.9

DTC93
OTC 91 OR 92 SET IN CURRENT
OR PREV. IGN CYCLE

G) • IGNITION "ON."
• USING TECH 1, READ DTCs •
IS DTC 91 OR 92 SET AS A HISTORY OR
CURRENT DTC?

.USING TECH 1, SELECT "F1: DTC HISTORY,"

VERIFY MALFUNCTION FREQUENCY WAS
LOW AND CLEAR DTCs.

4-21-93
MS8721-5E
SE1-160 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE
LINK "FN

-3:2}--
C200A
C200D
STOP HAZARD

~~°; _.;z,:_
20AMP
1400RN J
'
B ~-=-c
L.:_-_J '
BRAKE SWITCH
La2ovELs
C200D
C200A

243
A4
527
~2oveL

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC94
BRAKE SWITCH CONTACTS ALWAYS CLOSED
Circuit Description:
This OTC is run to determine the proper operation of the brake switch. This is important because ABS is
activated when the brake switch is "ON" and turned "OFF" when the brake is "OFF." If the brake switch is
always "ON," ABS operation will always be requested resulting in potential modulator cycling on rough roads.
Additionally, this malfunction will most likely result in a dead battery (due to the brake lights staying "ON") if
the driver is not informed of this malfunction.

OTC Will Set When: OTC 94 can be set when the vehicle reaches at least 40 km/h (25 mph). If the brake was
never "OFF" during two consecutive drive cycles, a malfunction exists.

Action Taken: A malfunction OTC is stored. ABS is not disabled; however.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Checks if the malfunction is currently present.
2. Isolates the cause of the malfunction to either a
malfunctioning or misadjusted brake switch, or a
short to voltage in the brake switch circuitry.
3. Checks for unwanted voltage on the brake switch
input circuit.
4. Checks for a possible intermittent malfunction.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-161

DTC94
BRAKE SWITCH CONTACTS
ALWAYS CLOSED

G). IGNITION "OFF."

• ARE
OBSERVE REAR CENTER HIGH MOUNTED STOP LAMP (CHMSL) •
THE CHMSL LAMPS "OFF"?

G) • UNPLUG BRAKE LAMP '3' • DISCONNECT 32-WAY EBCM HARNESS CONNECTOR.

SWITCH CONNECTOR.
ARE BRAKE LAMPS "ON"?
"V • IGNITION "ON."
• USINGJ39200 MEASURE VOLTAGE BETWEEN
TERMINAL "812" OF 32-WAY EBCM HARNESS
CONNECTOR AND GROUND.
IS VOLTAGE 2 VOLTS OR LESS?

REPAIR SHORT MISADJUSTED OR 0 ••

IGNITION "OFF."
INSPECT 32-WAY EBCM HARNESS CONNECTOR
REPAIR SHORT
TO VOLTAGE
TO VOLTAGE MALFUNCTIONING
ONCKT820. BRAKE SWITCH. TERMINAL "812" FOR POOR CONTACT. INCKT820.
ADJUST OR REPLACE • RECONNECT ALL CONNECTORS.
SWITCH AS • IGNITION "OFF."
NECESSARY. • START ENGINE AND TEST DRIVE VEHICLE,
ACHIEVING AT LEAST 40 km/h (25 MPH).
• REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO
MORE TIMES.
DID OTC 94 SET IN THE LAST THREE DRIVE
CYCLES?

REPLACE EBCM. MALFUNCTION IS NOT

PRESENT AT THIS
TIME, REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.

7-6-93
NS 15724
SE1-162 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE C200D
LINK "F" STO~Jis~ZlRD ~ ~~ ~ C200A 5271
. ~2]- ~~~ ~ 1400RN B C 820YEL
5243
820YEL
C200A 20AMP • - - -
C200D BRAKE SWITCH

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC95
BRAKE SWITCH CIRCUIT OPEN
Circuit Description:
This DTC is used to identify open brake switch circuitry that prevents the brake switch input to the EBCM
from changing states ,when the brake is applied. This DTC is used in conjunction with DTCs 91 and 92 to
determine the cause of an open brake switch malfunction.

DTC Will Set When: DTC 95 can be set after initialization is completed. If the brake switch input voltage is
out of specification for one second indicating an open circuit, a malfunction exists.

Action Taken: A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

DTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. Is used to confirm that an open in the brake switch
circuitry currently exists.
2. Indicates if the brake switch signal is being
received by the EBCM.
3. Indicates if an open circuit exists in the brake
switch or brake lamp circuitry.
4. Isolates the open circuit to either the brake switch
input circuitry, or the EBCM.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness. "
 ANTILOCK BRAKE SYSTEM SE1-163

DTC95
BRAKE SWITCH CIRCUIT OPEN

IS OTC 96 CURRENTLY SET?

G) • IGNITION "ON." f PROCEED TO OTC 96 DIAGNOSTIC CHART. :

• USING TECH 1, SELECT "FO: DATA LIST" AND MONITOR ~---------------------------~
BRAKE SWITCH STATUS.
DOES TECH 1 INDICATE THAT BRAKE SWITCH IS OPEN?

G) • APPLY LIGHT PRESSURE ON BRAKE PEDAL WHILE MALFUNCTION IS NOT PRESENT AT THIS
MONITORING BRAKE SWITCH STATUS ON TECH 1. TIME. REFER TO "DIAGNOSTIC AIDS" ON
DOES TECH 1 INDICATE BRAKE SWITCH "ON" WITHIN 1 FACING PAGE.
INCH OF TRAVEL?

G) • APPLY FIRM PRESSURE TO BRAKE PEDAL rPROCEED TO OTC 96 DIAGNOSTIC CHART. 1

AND OBSERVE CHMSL LAMPS. ~---------------------------~
ARE ALL CHMSL LAMPS "ON"?

0 ••
IGNITION"OFF."
DISCONNECT32-WAY EBCMCONNECTOR.
REPAIR OPEN CHMSL LAMP CIRCUIT AS
DIRECTED IN SECTION SA - 110.
• IGNITION "ON."
• USING J 39200, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "812" OF THE 32-WAY EBCM
HARNESS CONNECTOR WHILE APPL YING FIRM PRESSURE
ON BRAKE PEDAL.
IS VOLTAGE 10 VOL TS OR GREATER?

CHECK FOR POOR TERMINAL

CONTACT AT EBCM.
IF OK, REPLACE EBCM.

7-8-93
NS 15725
SE1-164 ANTILOCK BRAKE SYSTEM

EBCM

B+
FUSIBLE
LINK "F" STOP HAZARD
FUSE 6
Jc 2' - 1002
L,;; :..J RED
...rv,-. 140 ORN
C200A 20AMP
C200D

CRUISE CONTROL
MODULE

6-28-93
NS 15734

DTC96
REAR BRAKE LAMP CIRCUIT OPEN
Circuit Description:
This DTC is designed to isolate the cause of a DTC 95 malfunction and indicate to the driver ABS is still
available. If DTC 95 fails with DTC 96, the Center High Mounted Stop Lamp (CHMSL) circuit is open. The
presence of battery voltage at the brake switch input indicates a valid brake switch input is still available.

OTC Will Set When: DTC 96 can be set only after DTC 95 has been set. If the EBCM detects battery voltage
on the brake switch input circuit for 0.5 seconds, a malfunction exists.

Action Taken: A malfunction DTC is stored. ABS is not disabled; however.

OTC Chart Test Description: Number(s) below
refer to circled number(s) on the diagnostic chart.
1. As a result of a malfunction of an additional brake
switch circuit DTC, this DTC may be set. To
insure proper diagnosis, any additional brake
switch DTCs must be repaired first.
2. Identifies if the malfunction is currently present in
the brake circuit.
Diagnostic Aids: An "Intermittent" malfunction
may be caused by a poor connection, rubbed through
wire insulation, or a wire that is broken inside the
insulation.
The frequency of the malfunction can be checked
by using the enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
 ANTILOCK BRAKE SYSTEM SE1-165

DTC96
REAR BRAKE LAMP CIRCUIT OPEN

G) ARE ANY OTHER BRAKE SWITCH DTCs

(EXCEPT 95) CURRENTLY SET?

G) • APPLY FIRM PRESSURE TO BRAKE PEDAL AND

OBSERVE REAR CHMSL LAMPS.
ARE ALL CHMSL LAMPS "ON"7

MALFUNCTION IS NOT PRESENT AT THIS TIME. REFER TO REPAIR OPEN CHMSL LAMP CIRCUIT
"DIAGNOSTIC AIDS" ON FACING PAGE. AS DIRECTED IN SECTION BA.

6-24-93
NS 15726
5E1-166 ANTILOCK BRAKE SYSTEM
DIAGNOSIS/MISC. TEST (F4)
MANUAL CONTROL (FO)
This function can be used to manually control the
ABS VI motors and solenoids.
Motor Test (Apply/Release)
Each motor can be manually turned "ON" for up to
5 seconds, at a current of 10 amps applied (forward) or
6 amps released (reverse). After running the motors,
the command and feedback currents will be stored in a
snapshot buffer. This information can be reviewed,
when instructed to do so by the trouble tree, to
determine if the motors are operating properly.
The test below describes how the front motors will
normally operate, the rear motor can be tested in a
similar manner, except there will be only a slight
pedal drop (bump) and rise during the test.
1. Ignition "OFF."
2. Install Tech 1 with MSC.
3. Ignition "ON," engine "OFF."
4. Pump brake pedal until firm to deplete vacuum
from power booster.
5. Depress and hold brake pedal.
6. Using the Tech 1, "Release" one of the motors. The
brake pedal should move smoothly toward the
floor. As the pedal drops, the feedback current
should momentarily drop to only a few amps
(indicating motor movement) and then become
equal to command current (6 amps). This indicates
the motor is no longer moving since the piston has
reached the bottom of the bore.
7. With the brake pedal still depressed and at the
floor, "Apply" the same motor. The brake pedal
should now smoothly rise back to the top of its
travel. The feedback current should momentarily
drop to a few amps, then quickly increase to the
command current (10 amps). This indicates the
motor is no longer moving since the piston has
reached the top of the bore ("home" position).
Solenoid Test ("ON/OFF")
Only use this test when no DTCs are stored and
you suspect a leaky solenoid or check valve.
1. Ignition "OFF."
2. Install Tech 1 with MSC.
3. Ignition "ON," engine "OFF."
4. Pump brake pedal and deplete vacuum from power
booster.
5. Select manual control (FO).
6. Select left front or right front motor release.
7. "Release" the motor for the channel being tested.
Review the motor command and feedback currents
to be sure the motor released properly. Refer to
"Motor (Apply/Release)" in this section.
8. Select the solenoid for the same channel as that
being tested.
9. With no brake pedal pressure applied, turn the
solenoid "ON."
10. Depress the brake pedal. It should be very high
and firm.
• If the pedal goes nearly to the floor, the
solenoid is leaking or not closing and/or the
check valve is leaking, proceed to Step 12.
11. With brake pressure still applied, turn the
solenoid "OFF." The brake pedal should move
toward the floor. This verifies normal solenoid
operation. END OF TEST.
• If the pedal does not, the solenoid is stuck
"ON," proceed to Step 12.
12. Verify that the solenoid connectors are connected
to the proper solenoids, (the right front solenoid is
the one on the rear of the modulator, closest to the
brake booster). If the wiring is incorrect, move th~
connectors to the proper solenoid and repeat this
entire test starting with Step 1.
A. Physically switch the two solenoids.
B. Repeat the entire test starting at Step 1 for the
channel in question.
• If the test now works properly, test the other
channel. If the test fails for this channel,
replace the solenoid currently installed in this
channel. Refer to "Hydraulic Modulator
Solenoid" under "On-Vehicle Service" in this
section.
• If the test fails for the same channel, the check
valve is leaking. Replace hydraulic modulator.
Refer to "Hydraulic Modulator" under "Unit
Repair" in this section.
rn
•
Important
After performing Step 12, it is necessary to bleed
the brake system. Refer to "Bleeding Procedure"
in this section.
HYDRAULIC CONTROL TEST (F2)
This test is used to verify base brake apply and
ABS release, hold, and apply function.
1. Ignition "OFF."
2. Raise the vehicle such that all wheels to be tested
are off the ground.
3. Install Tech 1 with MSC.
4. Ignition "ON," vehicle transmission in neutral.
5. Select a channel to test; left front, right front, or
rear. When testing the rear brakes, both rear
wheels should rotate and not rotate together at
various points in the test; this is true because both
rear brake pressures are controlled together.
6. Firmly depress brake pedal. Pedal should remain
high and firm.

7. Have an assistant attempt to rotate the wheel
being tested. If the wheel does not rotate, base
brake apply is working properly.
8. With the brake pedal still depressed, press the
t key on the Tech 1 to start the test. The Tech 1
will display "Release" on the screen. Your
assistant should be able to rotate the wheel being
tested during the release portion of the test
(approximately 2 seconds long). This verifies ABS
pressure release. The brake pedal should remain
high and firm. (If the brake pedal moves toward
the floor, verify the solenoid electrical connectors
are connected to the correct solenoids.)
9. The Tech 1 will switch to the "Hold" mode and
display the word "Hold" on the screen along with
an 18 second decrement counter. With the brake
pedal still depressed, have your assistant attempt
to rotate the wheel. The wheel should rotate for
the full 18 seconds of the test. This verifies ABS
pressure hold.
10. When the hold portion of the test is complete,
brake pressure will be applied and a slight bump
may be felt in the pedal. This is normal. The
assistant should not be able to rotate the wheel at
the point. This verifies ABS apply.
MOTOR TEST (F4)
Once the motor pack has been separated from the
hydraulic modulator, this test will help determine if
the motor pack is operating properly.
The Tech 1 will rotate the motors in one direction,
than the other.
• If any motor does not turn in both directions, the
motor pack is malfunctioning and must be
replaced. The motor pack is not serviceable and
must be replaced as an assembly. Refer to "Motor
Pack" under "Unit Repair" in this section.
• If all three motors rotate, try to rotate each gear on
the hydraulic modulator, refer to "No Gear
Movement" in this section.
NO GEAR MOVEMENT
After the motor pack has been removed, rotate
each gear by hand on the hydraulic modulator (unit
with large gears). The front gears (non-center gears)
should be able to be rotated approximately 12.25 full
turns lock to lock. If the gear does not turn freely or at
least 12 turns are not possible, replace the hydraulic
modulator.
The rear gear (center gear) should rotate
approximately 7.25 turns. If the gear does not turn
freely or at least 7 turns are not possible, replace the
hydraulic modulator.
Refer to "Hydraulic Modulator" under "Unit
Repair" in this section if replacement of the modulator
is indicated above.
ANTILOCK BRAKE SYSTEM SE1-167
GEAR TENSION RELIEF (FS)
When the displacement cylinder pistons are in the
"home" position, each motor has prevailing torque.
This torque results in "gear tension," or force on each
gear that makes motor pack separation difficult. To
avoid injury, or damage to the gears, the "Gear
Tension Relief Function" briefly reverses each motor
to eliminate the prevailing torque.
Always perform the "Gear Tension Relief
Function" prior to removing the hydraulic
modulator/motor pack assembly from the vehicle.
RELAY TEST (F6)
This test allows the user to turn the relay "ON"
and "OFF" using the t and ! arrow keys on the Tech
1. The battery voltage supplied to the EBCM through
the relay contacts is displayed on the screen during the
test.
When the relay is commanded "ON," the voltage
should be equal to the battery voltage. When the relay
is "OFF," the voltage should drop below 2 volts.
NOTICE: Voltage will not drop to zero when the
relay contacts are open due to capacitors in the
EBCM. If voltage drops below 2 volts, the relay is
operating properly.
VOLTAGE LOAD TEST (F7)
The ABS VI system can draw significant amounts
of current when operating. This test turns "ON" many
of the system components to load-test the vehicle's
electrical system.
If low voltage malfunctions or intermittent ABS
operations are occurring, this test will allow you to
monitor the ignition and switched battery inputs to
the EBCM. If only one of these two inputs drops below
10 volts during testing, a high resistance may be
present in that power feed circuit. If both inputs drop
below 10 volts the vehicle's electrical system needs to
be diagnosed. In either case, the Tech 1 will display
that the "Voltage Load Test" failed.
LAMP TEST (F8)
This test allows the user to control the
warning/indicator lamps associated with ABS. It can
be used to check the lamp circuit including the lamp
driver module. The amber "ABS INOP" lamp can be
turned "ON" or flashed. The red "BRAKE" warning
lamp and the "LOW TRAC" lamp can be turned "ON"
and "OFF."
5E1-168 ANTILOCK BRAKE SYSTEM
SYSTEM ID (F9)
This feature is used to determine the ABS VI
version and whether the system includes Traction
Control (TCS).
MOTOR REHOME (FS)
The motor rehome function is initiated by pressing
the F5 key from the Tech 1 "Select Mode" menu. The
motor rehome function must ALWAYS be used prior to
bleeding the brake system. This function will return
all of the hydraulic modulator pistons to their upmost
or "home" position. This allows all fluid paths within
the modulator to be open so that the modulator can be
properly bled.
rn
•
Important
The motor rehome function cannot be performed if
any current DTCs are present. If current DTCs are
present, the vehicle must be repaired and DTCs
cleared before performing the motor rehome
function.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
CAUTION: Brake fluid may irritate eyes
and skin. In case of contact, take the
following actions:
• Eye contact - rinse thoroughly with
water.
• Skin contact - wash with soap and
water.
• If ingested - consult a physician
immediately.
CAUTION: To help avoid personal injury
due to poor braking, DO NOT tap into the
vehicle s brake system to operate a trailer
brake system.
NOTICE: When fasteners are removed, always
install them at the same location from which they
were removed. If a fastener needs to be replaced,
use the correct part number fastener for that
application. If the correct part number fastener is
not available, a fastener of equal size and strength
(or stronger) may be used. Fasteners that are not
reused, and those requiring thread-locking
compound, will be called out. The correct fastener
tightening specification must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system could
be damaged.
NOTICE: The use of rubber hoses or parts other
than those specified for the Antilock Brake System
(ABS) may lead to functional problems requiring
replacement of the hydraulic parts. Replace all
components included in repair kits used to service
this system. Lubricate rubber parts with clean,
fresh brake fluid to ease assembly. Do not use
lubricated shop air on brake parts as damage to
rubber components may result. If any hydraulic
component is removed or brake line disconnected,
it is necessary to bleed all or part of the brake
system. The fastener tightening specifications
listed are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11 (GM 1052542) or
equivalent DOT 3 brake fluid. The use of DOT 5
(silicone) brake fluid is not recommended.
Reduced braking performance or durability may
result.
NOTICE: Avoid spilling brake fluid on any of the
vehicle's painted surfaces, wiring, cables or
electrical connectors. Brake fluid will damage
paint and electrical connections. If any fluid is
spilled on the vehicle, flush the area with water to
lessen the damage.
CHECKING AND ADDING FLUID
Refer to SECTION 5A.
FLUSHING PROCEDURE
rn
•
Important
If evidence of contamination is present in the
vehicle's brake fluid, the entire brake system must
be flushed following one of the procedures outlined
below.
• After flushing the entire brake system, all rubber
components must be replaced. Components which
must be replaced include: brake hose assemblies,
master cylinder rubber parts, brake caliper and
wheel cylinder boots and seals, combination valve
assembly, hydraulic modulator, and ABS
solenoids. Refer to the proper "On-Vehicle
Service" for replacement procedures.
• After all rubber components have been replaced,
the entire brake system must be re-flushed
following one of the procedures outlined below.
• Once the second flushing procedure has been
performed, a complete system bleed must be
performed, refer to "Bleeding Procedure" in this
section.
 ANTILOCK BRAKE SYSTEM SE1-169

HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY 3 UNDERHOOD ELECTRICAL CENTER

2 LEFT HAND WHEELHOUSE

NS 16308
Figure 10-ABS Hydraulic Modulator/Motor Pack Assembly

MS 12383 MS 12384
Figure 11 - Gear Removal Figure 12 - Gear Positioning
5E1-170 ANTILOCK BRAKE SYSTEM
NOTICE: Use only DOT 3 brake fluid from a
clean, sealed container. Do not use any fluid from
a container which is wet with water. Do not use
DOT 5 silicone brake fluid. Improper brake fluid,
mineral oil (from such things as engine oil,
transmission fluid, etc.), or water in the fluid may
cause the brake fluid to boil or the rubber
components to deteriorate. Keep all fluid
containers capped to prevent contamination.
• The system must be flushed if there is any doubt
about the condition of fluid in the system or if fluid
has been used which contains the slightest trace of
mineral oil (from such things as engine oil,
transmission fluid, etc.).
Pressure Flush
Tools Required:
J 35589, Bleeding Adapter
NOTICE: Pressure bleeding equipment can be
used to perform the flush procedure. The pressure
bleeding equipment used for flushing must be of
the diaphragm type. It must have a rubber
diaphragm between the air supply and the brake
fluid to prevent air, moisture, and other
contaminants from entering the hydraulic system.
~ Clean
1. Fluid reservoir cover and surrounding area.
l++I Remove or Disconnect
2. Fluid reservoir cover.
3. Any remaining brake fluid in reservoir.
IL•I Inspect
4. Refill reservoir with clean DOT 3 brake fluid to
proper level.
l++I Install or Connect
5. Bleeder adaptor J 35589 to brake fluid reservoir.
6. Bleeder adaptor to pressure bleeding equipment.
llJ Adjust
7. Pressure bleeding equipment to 35-70 kPa (5-10
psi) and wait for approximately 30 seconds to
insure there is no leakage.
8. Pressure bleed equipment to 205-240 kPa (30-35
psi).
Hydraulic Modulator
9. Proceed as follows with pressure bleeding
equipment connected and pressurized:
A. Attach a clear plastic hose to the rearward
bleeder valve on the hydraulic modulator.
Place the other end of the hose in a container to
collect draining brake fluid. Do not submerge
hose end into fluid.
B. Slowly open bleeder valve and allow fluid to
flow until clean brake fluid flows or until at
least 118 ml (4 ounces) of fluid is accumulated.
C. Close valve.
D. Repeat above procedure for the forward
bleeder valve until clean brake fluid flows or
until at least 11.8 ml (4 ounces) of fluid is
accumulated.
l~I Tighten
• Hydraulic modulator bleeder valve to 9 N·m
(80 lb. in.).
10. Raise vehicle and suitably support.
m
•
Important
Flush sequence:
Right rear.
Left rear.
Right front.
Left front.
11. Flush wheel brakes in sequence shown above.
A. Attach bleeder hose to bleeder valve at each
wheel and place the other end into a container
to collect draining brake fluid. Do not
submerge hose end in fluid.
B. Slowly open bleeder valve and allow fluid to
flow.
C. Close valve when clean brake fluid begins to
flow or at least 235 ml (8 ounces) of fluid is
accumulated.
12. Repeat Step 11 on left rear wheel brake.
13. Repeat Step 11 on right front wheel brake.
14. Repeat Step 11 on left front wheel brake.
15. Lower vehicle.
16. Remove bleeder adapter.
17. Replace all rubber components listed under
"Flushing Procedure," refer to the appropriate
"On-Vehicle Service" section.
18. Repeat flushing procedure one more time.
IL1'1 Inspect
19. Fluid level in reservoir and fill to correct level if
necessary.
l++I Install or Connect
20. Fluid reservoir cap.
21. Bleed the entire brake hydraulic system; refer to
"Bleeding Procedure" in this section.
 ANTILOCK BRAKE SYSTEM 5E1-171

Manual Flush
[I] Important
[I] Important • Flush sequence:
• In the following steps, use a suitable container Right rear.
and/or shop rags to catch fluid and prevent it from Left rear.
contacting any painted surfaces. Right front.
Left front.
~ Clean
1. Fluid reservoir cover and surrounding area. 11. Flush wheel brakes in sequence shown above.
A. Attach bleeder hose to bleeder valve at each
l++f Remove or Disconnect wheel and place the other end into a container
to collect draining brake fluid. Do not
2. Fluid reservoir cover. submerge hose end in fluid.
3. Any remaining brake fluid in reservoir. B. Open bleeder valve.

IL•f inspect C. Slowly depress brake pedal.

D. Close valve and slowly release brake pedal.
4. Refill reservoir with clean DOT 3 brake fluid to E. Repeat above procedure until clean brake fluid
proper level. flows or at least 235 ml (8 ounces) of fluid is
accumulated.
l++f Install or Connect 12. Repeat Step ll on left rear brake.
5. Fluid reservoir cover. 13. Repeat Step 11 on right front brake.
14. Repeat Step 11 on left front brake.
Hydraulic Modulator 15. Lower vehicle.
16. Replace all rubber components listed under
6. Flush hydraulic modulator as follows: "Flushing Procedure," refer to the appropriate
A. Attach a clear plastic bleeder hose to rearward "On-Vehicle Service" section.
bleeder valve on the hydraulic modulator and 17. Repeat flushing procedure one more time.
place the other end of hose in a container to
collect draining brake fluid. Do not submerge IL•I Inspect
hose end into fluid. 18. Fluid level in reservoir and fill to correct level if
B. Slowly open rearward bleeder valve 1/2 to 3/4 necessary.
turns.
C. Depress brake pedal until fluid begins .to flow. f++f Install or Connect
D. Close valve and release brake pedal. Repeat 19. Fluid reservoir cap.
above steps until clean brake fluid flows or at 20. Bleed the entire brake hydraulic system; refer to
least ll8 ml (4 ounces) of fluid is accumulated. "Bleeding Procedure" in this section.
E. Repeat above procedure for the forward
bleeder valve until clean brake fluid flows orat BLE.EDING PROCEDURE
least 118 ml (4 ounces) of brake fluid is
accumulated. NOTICE: If any brake component is repaired or
l~I Tighten replaced such that air is allowed to enter the brake
system, the entire bleeding procedure MUST be
• Hydraulic modulator bleeder valves to 9 N·m followed.
(80 lb. in.).
NOTICE: Use only SUPREME 11 (GM 1052542)
l++f Remove or Disconnect or equivalent DOT 3 brake fluid from a clean,
7. Fluid reservoir cover. sealed container. Do not use fluid from an open
container that may be contaminated with water.
IL•f inspect The use of DOT 5 (silicone) brake fluid is not
recommended. Reduced braking performance or
8. Fluid level in reservoir and fill to correct level if durability may result.
necessary.
NOTICE: Avoid spilling brake fluid on any of the
l++f Install or Connect vehicle's painted surfaces, wiring, cables or
9. Fluid reservoir cover. electrical connectors. Brake fluid will damage
10. Raise vehicle and suitably support. paint and electrical connections.
5E1-172 ANTILOCK BRAKE SYSTEM
If any fluid is spilled on the vehicle, flush the area
with water to lessen the damage.
NOTICE: Prior to bleeding the brakes, the front
and rear displacement cylinder pistons must be
returned to the topmost position. The preferred
method uses a Tech 1 to perform the rehoming
procedure. If a Tech 1 is not available, the second
procedure may be used, but it is extremely
important that the procedure be followed exactly
as outlined.
With Tech 1 (Preferred Method)
1. Using a Tech 1 or T-100 (CAMS), select "F5: Motor
Rehome." The motor re home function cannot be
performed if current DTCs are present. If DTCs
are present, the vehide must be repaired and
DTCs cleared before performing the motor rehome
function.
2. The entire brake system should now be bled
following either "Pressure Bleeding" or ''Manual
Bleeding" outlined below.
Without Tech 1
NOTICE: This method can only be used if the
"ABS INOP" lamp is not illuminated and no DTCs
are present.
rn Important
• · Do not place your foot on the brake pedal through
this entire procedure unless specifically directed to
doso.
1. Remove foot from brake pedal.
2. Start engine and allow it to run for at least 10
seconds while observing the "ABS INOP" lamp.
3. If the "ABS INOP" lamp turned "ON" and stayed
"ON" after about 10 seconds, the bleeding
procedure must be stopped and a Tech 1 must be
used to diagnose the ABS malfunction.
4. If the "ABS INOP" lamp turned "ON" for
approximately 3 seconds, then turned "OFF" and
stayed "OFF," turn the ignition "OFF."
5. Repeat Steps 1 through 4 one more time.
6. The entire brake system should now be bled
following either "Pressure Ble.eding" or "Manual
Bleeding" outlined below.
REHOME PROCEDURE
1. Using a Tech 1 or T-100 (CAMS), select F5: Motor
Rehome. The motor rehome function cannot be
performed if current DTCs are present. If DTCs
are present, the vehicle must be repaired and
DTCs cleared before performing the motor rehome
function.
2. The entire brake system should now be bled
following either "Pressure Bleeding" or "Manual
Bleeding" outlined below.
Pressure Bleeding
Tools Required:
J 35589, Bleeding Adaptor
NOTICE: Use only DOT 3 brake fluid from a
clean, sealed container. Do not use fluid from an
open container that may be contaminated with
water. Do not use DOT 5 brake fluid.
NOTICE: Pressure bleeding equipment must be
of the diaphragm type. It must have a rupber
diaphragm between the air supply and the brake
fluid to prevent air, moisture and other
contaminants from entering the hydraulic system.
~ Clean
1. Fluid reservoir cover and surrounding area.
l++I Remove or Disconnect
2. Fluid reservoir cover.
IL•I Inspect
3. Fluid to be at proper level. Refer to SECTION 5A.
Add clean brake fluid as required.
l++I Install or Connect
4. Bleeder adaptor J 35589 to brake fluid reservoir.
5. Bleeder adaptor to pressure bleeding equipment.
~ Adjust
6. Pressure bleed equipment to 35-70 kPa (5-10 psi)
and wait for approximately 30 seconds to insure
there is no leakage.
7. Pressure bleed equipment to 205-240 kPa (30-35
psi).
Hydraulic Modulator
8. Proceed as follows with pressure bleeding
equipment connected and pressurized:
A. Attach a clear plastic bleeder hose to the
rearward bleeder valve on the hydraulic
modulator. Submerge opposite hose end in a
clean container partially filled with clean
brake fluid.
B. Slowly open bleeder valve and allow fluid to
flow until no air is seen in fluid.
C. Close valve when fluid flows without any air
bubbles.

D. Repeat Steps 8B and 8C until no air bubbles
are present.
E. Relocate the bleeder hose on the forward
hydraulic modulator bleeder valve and repeat
Steps 8A through SD.
!~I Tighten
• Hydraulic modulator bleeder valves to 9 N·m
(80 lb. in.).
Brake Pipe Connections
[I] Important
• Use a shop cloth to catch escaping brake fluid.
Take care to prevent fluid from running down
motor pack and entering the motor pack base or
into the electrical connector. Also, do not allow
brake fluid to contact any painted surfaces as
surface damage will occur. If brake fluid does
contact any surface, flush surface with water to
lessen damage.
9. Proceed to bleed the master cylinder brake
connections as follows with pressure bleeding
equipment connected and pressurized:
A. Crack (slightly open) the forward brake pipe
tube nut on the master cylinder and check for
air in escaping fluid.
B. When air flow ceases, immediately tighten
tube nut.
l~I Tighten
• Master cylinder tube nut to 32 N ·m (24
lb. ft.).
C. Repeat Steps 9A and 9B for the rearward
master cylinder brake pipe connection.
10. Proceed to bleed the brake combination valve
connections as follows with pressure bleeding
equipment connected and pressurized:
A. Crack (slightly open) the forward brake pipe
tube nut on the brake combination valve and
check for air in escaping fluid.
B. When air flow ceases, immediately tighten
tube nut.
l~I Tighten
• Brake combination valve tube nut to 18
N·m (13 lb. ft.).
C. Repeat Steps IOA and lOB for the rearward
brake combination valve pipe connection.
11. Proceed to bleed the hydraulic modulator brake
connections as follows with pressure bleeding
equipment connected and pressurized:
A. Crack (slightly open) the forward brake pipe
tube nut on the hydraulic modulator and check
for air in escaping fluid.
ANTILOCK BRAKE SYSTEM 5E1-173
B. When air flow ceases, immediately tighten
tube nut.
l~I Tighten
Hydraulic modulator tube nut to 32 N ·m
•
(24 lb. ft.).
C. Repeat Steps llA and llB for the remaining
hydraulic modulator brake pipe connections,
moving from front to rear.
Wheel Brakes
12. Raise vehicle and suitably support.
13. Proceed as follows to bleed the rear wheel brakes:
A. Attach a clear plastic bleeder hose to the right
rear wheel bleeder valve and submerge
opposite hose end in a clean container partially
filled with clean brake fluid.
B. Slowly open bleeder valve and allow fluid to
flow.
C. Close valve when fluid begins to flow without
any air bubbles. Tap lightly on the caliper or
backing plate to dislodge any trapped air
bubbles.
D. Relocate bleeder hose to the left rear wheel
bleeder valve and repeat Steps 13A through
13C.
14. Remove pressure to the pressure bleeding
equipment.
15. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve and submerge opposite
hose end in a clean container partially filled with
clean brake fluid.
16. Turn the ignition "ON."
17. Open the bleeder valve and apply the brake until
the red "BRAKE" warning lamp turns "ON." This
shuttles the brake pressure differential warning
valve.
18. Close bleeder valve.
19. Reapply pressure to pressure bleeding equipment.
20. Turn the ignition "OFF."
[I] Important
• Do not reapply the brakes after closing the
bleeder valve.
21. Lower vehicle.
22. Repeat the entire Step 8.
23. Raise vehicle and suitably support.
24. Repeat the entire Step 13.
25. Proceed as follows to bleed the front wheel brakes:
A. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve and submerge
opposite hose end in a clean container partially
filled with clean brake fluid.
B. Slowly open bleeder valve and allow fluid to
flow.
5E1-174 ANTILOCK BRAKE SYSTEM
C. Close valve when fluid begins to flow without
any air bubbles. Tap lightly on the caliper to
dislodge any trapped air bubbles.
D. Relocate bleeder hose to the left front wheel
bleeder valve and repeat Steps 25A through
25C.
26. Lower vehicle.
27. Remove pressure bleeding equipment, including
bleeder adapter J 35589.
IL•I Inspect
28. Fluid level in reservoir and fill to proper level if
necessary.
l++I Install or Connect
29. Fluid reservoir cap.
IL•I Inspect
30. With ignition "ON," apply brake pedal with
moderate force and hold. Note pedal travel and
feel.
If pedal feels firm and constant and pedal
travel is not excessive, start the engine. With
the engine running, recheck the pedal travel.
If it's still firm and constant and pedal travel is
not excessive, go to Step 31.
If pedal feels soft or has excessive travel either
initially or after engine start, the following
procedure may be used. With the Tech 1,
"Release" then "Apply" each motor 2 to 3 times
and cycle each solenoid 5 to 10 times. When
finished, be sure to "Apply" the front and rear
motors to ensure the pistons are in the upmost
position. DO NOT DRIVE THE VEHICLE. If
a Tech 1 is not available, remove foot from
brake pedal, start the engine and allow it to
run for at least 10 seconds to initialize the
ABS. DO NOT DRIVE THE VEHICLE. After
10 seconds, turn the ignition "OFF." This
initialization procedure MUST be repeated 5
times to ensure any trapped air has been
dislodged. ·Now repeat bleeding procedure
starting at Step 1.
31. Road test the vehicle.
• Make several normal (non ABS) stops from a
moderate speed to ensure proper brake system
function. Allow adequate cooling time
between stops.
Manual Bleeding
NOTICE: Use only DOT 3 brake fluid from a
clean, sealed container. Do not use brake fluid
from an open container that may be contaminated
with water. Do not use DOT 5 brake fluid.
rn
•
Important
In the following steps, use a suitable container
and/or shop cloths to catch fluid and prevent it
from contacting any painted surfaces.
~ Clean
1. Fluid reservoir cover and surrounding area.
l++I Remove or Disconnect
2. Fluid reservoir cover.
IL•I Inspect
3. Fluid level in reservoir and fill to the correct level
if necessary.
l++I Install or Connect
4. Fluid reservoir cover.
Hydraulic Modulator
5. Prime hydraulic modulator as follows:
A. Attach clear plastic bleeder hose to the
rearward bleeder valve on the hydraulic
modulator. Submerge opposite hose end in a
clean container partially filled with clean
brake fluid.
B. Slowly open rearward bleeder valve 1/2 to 3/4
turns.
C. Depress brake pedal and hold until fluid
begins to flow.
D. Close valve and release brake pedal.
E. Repeat Steps 58 and 50 until no air bubbles
are present.
F. Relocate the bleeder hose on the forward
hydraulic modulator bleeder valve and repeat
Steps 5A through 5E.
[I] Important
• Once fluid is seen to flow from both modulator
bleeder valves, the hydraulic modulator is
sufficiently full of fluid. However, it may not
be completely purged of air. At this point move
to the wheel brakes and bleed them. This
ensures that the lowest points in the system
are completely free of air and then the
hydraulic modulator can be purged of any
remaining air.
l++I Remove or Disconnect
6. Fluid reservoir cover.
IL1tl 1nspect
7. Fluid level in reservoir and fill to the correct level
if necessary.

f++f Install or Connect
8. Fluid reservoir cover.
Wheel Brakes
9. Raise vehicle and suitable support.
rn
•
Important
Bleed sequence:
Right rear.
Left rear.
Right front.
Left front.
10. Bleed wheel brakes in sequence shown above.
A. Attach a clear plastic bleeder hose to the
bleeder valve at each wheel and submerge
opposite hose end in a clean container partially
filled with clean brake fluid.
B. Open bleeder valve.
C. Slowly depress brake pedal.
D. Close valve and slowly release brake pedal.
E. Wait 5 seconds.
F. Repeat Steps lOB through lOE until the brake
pedal feels firm and no air bubbles are
observed in the bleeder hose.
• To assist in freeing entrapped air, tap
lightly on caliper or backing plate with a
rubber mallet.
11. Repeat Step 10 on left rear wheel brake.
12. Repeat Step 10 on right front wheel brake.
13. Repeat Step 10 on left front wheel brake.
14. Lower vehicle.
f++I Remove or Disconnect
15. Fluid reservoir cover.
IL•I Inspect
16. Fluid level in reservoir and fill to the correct level
if necessary.
E3 Install or Connect
17. Fluid reservoir cover.
18. Bleed the hydraulic modulator.
A. Attach a clear plastic bleeder hose to the
rearward bleeder valve on the hydraulic
modulator. Submerge opposite hose end in a
clean container partially filled with clean
brake fluid.
B. Depress brake pedal with moderate force.
C. Slowly open rearward bleeder valve 1/2 to 3/4
turns and allow fluid to flow.
ANTILOCK BRAKE SYSTEM 5E1-175
D. Close valve and slowly release brake pedal.
E. Wait 5 seconds.
F. Repeat Steps 18B through 18E until the no air
bubbles are observed in the bleeder hose.
G. Relocate the bleeder hose on the forward
hydraulic modulator bleeder valve and repeat
Steps 18A through 18F.
l~I Tighten
• Hydraulic modulator bleeder valves to 9
N·m (80 lb. in.).
f++I Remove or Disconnect
19. Fluid reservoir cover.
IL•I Inspect
20. Fluid level in reservoir and fill to the correct level
if necessary.
l++I Install or Connect
21. Fluid reservoir cover.
L'l'I Inspect
f
22. With ignition "ON" apply brake pedal with
moderate force and hold. Note pedal travel and
feel.
If pedal feels firm and constant and pedal
travel is not excessive, start the engine. With
the engine running, recheck the pedal travel.
If it's still firm and constant and pedal travel is
not excessive, go to Step 23.
If pedal feels soft or has excessive travel either
initially or after engine start, the following
procedure may be used. With the Tech 1,
"Release" then "Apply" each motor 2 to 3 times
and cycle each solenoid 5 to 10 times. When
finished, be sure to "Apply" the front and rear
motors to ensure the pistons are in the upmost
position. DO NOT DRIVE THE VEHICLE. If
a Tech 1 is not available, remove foot from
brake pedal, start the engine and allow it to
run for at least 10 seconds to initialize the
ABS. DO NOT DRIVE THE VEHICLE. After
10 seconds, turn the ignition "OFF." This
initialization procedure MUST be repeated 5
times to ensure any trapped air has been
dislodged. Now repeat bleeding procedure
starting at Step 1.
23. Road test the vehicle.
• Make several normal (non-ABS) stops from a
moderate speed to ensure proper brake system
function. Allow adequate cooling time
between stops.
5E1-176 ANTILOCK BRAKE SYSTEM

l++I Install or Connect

1. New solenoid.
• Verify that the solenoid lip seal is properly
positioned before solenoid is installed in
hydraulic modulator (refer to Figure 14).
• Position solenoid so that its electrical
connector will face the same direction as the
solenoid that was removed.
• By hand, press down firmly on solenoid until
its flange seats on ABS hydraulic modulator.
2. Torx® head bolts.

l~I Tighten
• Bolts to 4.5 N·m (40 lb. in.).
3. Solenoid electrical connector to solenoid.

rn
•
Important
Make sure the solenoid connectors are installed on
correct solenoids.
• It is necessary to bleed the entire system. Refer to
"Bleeding System" in this section.
REARWARD BLEEDER VALVE

2 FORWARD BLEEDER VALVE HYDRAULIC MODULATOR/MOTOR PACK

NS 16304
ASSEMBLY
Figure 10
Figure 13 • ABS Hydraulic Modulator Bleeder
Locations CAUTION: To help avoid personal injury,
HYDRAULIC MODULATOR BLEEDER VALVES due to a retained load on the hydraulic
Figure 13 modulator, the gear tension relief
function of the Tech 1 must be performed
l++I Remove or Disconnect prior to the removal of the ABS hydraulic
• Damaged bleeder valve or valves. modulator.

l++I Install or Connect l++I Remove or Disconnect

• New bleeder valve or valves. l. Using Tech 1, perform "Gear Tension Relief
Sequence," as outlined in this section.
l~I Tighten 2. Air cleaner duct assembly.
3. Two solenoid electrical connectors.
• Bleeder valve to 9 N·m (80 lb. in.).
4. Brake pressure differential warning switch
electrical connector.
HYDRAULIC MODULATOR SOLENOID
5. 6-pin motor pack electrical connector.
Figure 14
6. Five brake pipes (two to master cylinder, three to
l++I Remove or Disconnect wheel brakes).
• Place shop cloth on top of motor pack to catch
1. Solenoid electrical connector. any dripping fluid. Take care not to allow any
2. Torx® head bolts. brake fluid to enter the bottom of the motor
3. Solenoid. pack or the electrical connectors. Plug open

rn
•
Important
Be sure the seal is still attached to the solenoid
brake pipes to prevent fluid loss and
contamination.
7. Bolt attaching front of hydraulic modulator/motor
when it is removed. If not, check solenoid bore in pack assembly to frame rail.
modulator. 8. Hydraulic modulator/motor pack assembly from
• Do not attempt to disassemble solenoid, it is vehicle.
serviceable only as an assembly.
• Lubricate seal on new solenoid with clean brake
fluid.
 ANTILOCK BRAKE SYSTEM 5E1-177

SOLENOID LIP SEAL 3 TORX® HEAD BOLT

2 SOLENOID 4 HYDRAULIC MODULATOR/MOTOR
PACK ASSEMBLY
NS 16309

Figure 14- Hydraulic Modulator Solenoid Removal

I++! Install or Connect l~I Tighten

1. Hydraulic modulator/motor pack assembly in • Two brake combination valve tube nuts to 18
vehicle. N·m (13 lb. ft.).
2. Bolt attaching hydraulic modulator/motor pack • Three hydraulic modulator tube nuts to 32 N ·m
assembly to frame rail. (24 lb. ft.).

l~I Tighten ELECTRONIC BRAKE CONTROL MODULE

• Bolt to 9.0 N ·m (80 lb. in.).
3. Five brake pipes to hydraulic modulator/motor
pack assembly.
4. 6 pin motor pack electrical connector.
5. Brake pressure differential warning switch
electrical connector.
6. Two solenoid electrical connectors.
II] Important
• Bleed entire brake system as outlines in "Bleeding
System" in this section.
(EBCM)
Figure 15
l++I Remove or Disconnect
1. Fasteners on lower sound insulator panel under
steer~ng column.
2. Lower sound insulator panel from vehicle.
3. Manual transmission only: left side kick panel.
4. Nut attaching EBCM bracket to upper I/P.
5. Push in retainer ("Christmas Tree") attaching
EBCM bracket to sidewall.
5E1-178 ANTILOCK BRAKE SYSTEM

LEFT SIDE SHOWN

RIGHT SIDE SIMILAR

EBCM AND BRACKET

2 EBCM HARNESS
FRONT WHEEL SPEED SENSOR
3 LEFT HAND KICK PANEL
2 FRONT WHEEL SPEED SENSOR JUMPER HARNESS
4 PUSH-IN RETAINER

5 MOUNTING STUD AND NUT 3 LOWER CONTROL ARM

NS 16187 NS 16186

Figure 15 - EBCM Location Figure 16 - Front Wheel Bearing and Speed Sensor

rn
•
Important . .
It will be necessary to cut the push m retamer
ASSEMBLY
Figure 16
Assembly
FRONT WHEEL BEARING AND SPEED SENSOR

head off to remove EBCM bracket. Do not

attempt to pry fastener out as damage to the
EBCM bracket may result.
rn
•
Important
The front wheel speed sensors and rings are
6. EBCM and EBCM bracket from mounting place. integral with the hub and bearing assemblies.
7. EBCM electrical connectors. Should a speed sensor or ring require replacement,
8. EBCM from vehicle. the entire hub and bearing assembly must be
9. Remaining portion of push in retainer. replaced. Refer to SECTION 3C.

rn
•
Important
It is necessary to remove the destroyed
FRONT WHEEL SPEED SENSOR JUMPER
HARNESS
Figure 17
retainer to insure proper retaining force when
installing the new push in retainer. Raise and support vehicle on a suitable hoist as

l++I Install or Connect indicated in SECTION OA.

1. EBCM electrical connectors.

2. EBCM and EBCM bracket into mounting location.
3. New push in retainer ("Christmas Tree")
attaching EBCM bracket to sidewall.
4. Nut attaching EBCM bracket to upper 1/P.
I++! Remove or Disconnect
1. Connector from wheel speed sensor.
2. Harness from retaining clips.
3. Harness grommets from retainers.
4. Upper jumper harness connector attached to inside

l~I Tighten of frame rail.

• Nut to 25.0 N·m (18.5 lb. ft.).

5. Manual transmission only: left side kick panel.
l++I Install or Connect
1. Upper jumper harness connector attached to inside
6. Lower sound insulator panel and fasteners. of frame rail.
 ANTILOCK BRAKE SYSTEM 5E1-179

LH SHOWN
RH SIMILAR 6

FRONT WHEEL SPEED SENSOR JUMPER HARNESS 4 BRAKE LINE

2 HARNESS ROSEBUD RETAINER (PUSH INTO CRADLE HOLE) 5 WHEEL

3 HARNESS GROMMET (PUSH INTO GROMMET RETAINER) 6 CRADLE

NS 16303

Figure 17 - Front Wheel Speed Sensor Jumper Harness

2. Harness to retaining clips, 3. Connector to wheel speed sensor.
3. Harness rubber grommets into retainers. 4. Jumper harness grommet into retainer.
4. Connector to wheel speed sensor.
REAR WHEEL SPEED SENSOR TOOTHED RING
REAR WHEEL SPEED SENSOR
Figure 18 rn
•
Important
The rear wheel speed sensor toothed ring is an
Raise and support vehicle on a suitable hoist as integral part of the rear differential case. If it has
indicated in SECTION OA. been determined that the toothed ring must be

l++I Remove or Disconnect replaced, refer to SECTION 4B for removal and

installation procedures.
1. Connector from wheel speed sensor.
2. Jumper harness grommet from retainer. REAR WHEEL SPEED SENSOR JUMPER
3. Bolt attaching sensor to differential housing. HARNESS
4. Sensor from differential housing.

l++I Install or Connect I++! Remove or Disconnect

1. Sensor into differential housing.
[I] Important
• Be sure to lubricate sensor 0-ring with
differential oil before installing sensor into
differential housing.
2. Bolt attaching sensor to differential housing.
I~! Tighten
• Bolt to 10 N·m (89 lb. in.).
1. Connector from wheel speed sensor.
2. Jumper harness grommet from retainer.
3. Upper jumper harness connector from rear body
pass-thru connector.
l++I Install or Connect
1. Upper jumper harness connector to rear body pass-
thru connector.
2. Connector to wheel speed sensor.
3. Jumper harness grommet into retainer.
5E1-180 ANTILOCK BRAKE SYSTEM

[I] Important
• Remove the lock before separating the electrical
connectors.
• Take care not to damage the locking pin during
removal.
• Make sure that the rubber connector seal is in
place on the connector before and after connection.
• Always install the lock after the connection is
made.

FUSE AND FUSIBLE LINKS

Refer to SECTION SA-11 for repair or replacement

information.

UNIT REPAIR

1 REAR WHEEL SPEED SENSOR

2 REAR WHEEL SPEED SENSOR JUMPER HARNESS
3 REARAXUHOU~NG
4 REAR WHEEL SPEED SENSOR MOUNTING BOLT
NS 16185
CAUTION: To help avoid personal injury,
due to a retained load on the ABS
hydraulic modulator/motor pack
assembly, the gear tension relief function
of the Tech 1 must be performed prior to
removal of the ABS hydraulic
modulator/motor pack assembly.

Figure 18 - Rear Wheel Speed Sensor NOTICE: The following service procedures shall
be performed only after the hydraulic
ENABLE RELAY modulator/motor pack assembly has been removed
Figure 19 from the vehicle. Do not perform these procedures
l++I Remove or Disconnect with the unit installed on -the vehicle. Complete
overhaul of the hydraulic modulator/motor pack
1. Enable relay cover. assembly is not authorized - only the following
2. Relay from connector. steps. These steps will break the unit down into
major components for replacement purposes.
l++I Install or Connect GEAR COVER
1. Relay to connector.
2. Enable relay cover. Figure 21

BRAKE COMBINATION VALVE l+:+I

Disassemble
1. Torx® head screws attaching gear cover.
Refer to SECTION 5A. 2. Remove gear cover.

WARNING/INDICATOR LAMPS l+++I Assemble

1. Gear cover to hydraulic modulator/motor pack
Refer to SECTION SC for replacement procedures assembly.
and detailed information. 2. Torx® head screws.
ELECTRICAL CONNECTORS
Figure20 l~I Tighten
• Torx® bolts to 4 N ·m (35 lb. in.).
Some ABS VI components are equipped with
electrical connectors using a Connector Position MOTOR PACK
Assurance (CPA) lock. This feature insures that when Figure 21
the connectors are installed they are aligned properly
and connected securely. l+!+I
Disassemble
1. Remove gear cover.
 ANTILOCK BRAKE SYSTEM 5E1-181

UNDERHOOD ELECTRICAL CENTER

(ABS ENABLE RELAY LOCATED INSIDE}
NS 16307

Figure 19 • Enable Relay Location

LOCKING PIN

CONNECTOR
CONNECTOR
LOCKING PIN ~NG~N

SEAL*
~ CONN~

LOCKING PIN

CONNECTOR

CONNECTOR

CONNECTOR

CONNECTOR POSITION ASSURANCE (CPA) TYPICAL * MAKE SURE SEAL IS IN PLACE ON CONNECTOR NS
16190

Figure 20 • ABS VI Electrical Connectors (Typical)

SE1-182 ANTILOCK BRAKE SYSTEM
2. Four Torx® head screws attaching motor pack.
rn
•
Important
Use care when handling motor pack to ensure
motor pack connector is not damaged, or
accidental intrusion of brake fluid into the
motor pack does not occur. This may result in
a premature failure of the motor pack.
• Take care in handling the motor pack. If
dropped or damaged during handling, the
motor pack must be replaced.
3. Remove motor pack.
rn
•
Important
If disassembly of the hydraulic modulator/motor
pack assembly was due to a ABS hydraulic
functional test that did not pass, the "Automated
Motor Pack Diagnosis Test" described in this
section should be performed at this time to isolate
the motor pack or hydraulic modulator.
• No repair of the motor pack is authorized. Replace
as an assembly.
1-+t+I Assemble
1. With the hydraulic modulator upside down, and
the gears facing you, rotate each hydraulic
modulator gear counterclockwise until movement
stops. This procedure will position the pistons very
close to the top of the modulator bore, simplifying
the brake bleeding procedure (refer to Figure 12).
2. Motor pack to hydraulic modulator.
rn
•
Important
Take care in handling the motor pack. If
dropped or damaged during handling the
motor pack must be replaced.
• Align each of the three motor pack pinions
with the hydraulic modulator gears.
3. Four Torx® head screws.
l~I Tighten
• Torx® head screws to 4.5 N ·m (40 lb. in.).
4. Gear cover to hydraulic modulator/motor pack
assembly.
GEAR REPLACEMENT
Figures 11 and 12
rn
•
Important
Do not attempt to repair damaged motor packs or
hydraulic modulators. Other than modulator
drive gear replacement, repair of these assemblies
is not authorized. Do not lubricate or oil gears on
motor pack.
CAUTION: The modulator drive gears are
under spring load and will turn during
disassembly. After removing hydraulic
modulator drive gear cover, exercise
extreme care not to place fingers into the
gear set, since fingers can be pinched by
rotating gears.
l+l+I Disassemble
1. Hydraulic modulator. Refer to "Hydraulic
Modulator" in this section.
2. Torx® head screws attaching gear cover.
3. Four motor pack to hydraulic modulator Torx®
head screws.
rn Important
• Take care in handling the motor pack. If
dropped or damaged in the handling, the motor
pack must be replaced.
4. Separate motor pack from hydraulic modulator.
NOTICE: Do not allow gear to turn while
removing the retaining nut, since the modulator
piston can hit the top of the modulator bore,
damaging the piston. Turn the modulator gear to
position the piston in the center of its travel. Place
a screwdriver through the holes in the gears (not
between the gears) into the recessed hole in the
modulator base. This will prevent the gear from
turning, aiding in gear removal.
5. Three modulator drive gear to modulator drive
shaft retaining nuts.
6. Gears from modulator (refer to Figure 11).
1-+*+I Assemble
NOTICE: Do not allow gear to turn while
tightening the retaining nut, since the modulator
piston can bottom out in the modulator bore
damaging the piston. Turn the modulator gear to
position the piston in the center of its travel. Place
a screwdriver through the holes in the gears (not
between the gears) into the recessed hole in the
modulator base. This will prevent the gear from
turning, aiding in gear installation (refer to Figure
11).
1. Position hydraulic modulator drive gears onto
hydraulic modulator drive shaft.
2. Three gear retaining nuts.
!~I Tighten
• Nuts to 8.5 N·m (76 lb. in.).
 ANTILOCK BRAKE SYSTEM SE1-183

i
I
I

NS 16306
Figure 21 -ABS Hydraulic Modulator Components
3. With the hydraulic modulator upside down, and 6. Gear cover onto hydraulic modulator with Torx®
the gears facing you, rotate each hydraulic head screws.
modulator gear counterclockwise until movement
stops. This procedure will position the pistons very
close to the top of the hydraulic modulator bore,
I~! Tighten .
• Torx® head screws to 4 N·m (35 lb. in.).
simplifying the brake bleeding procedure (refer to 7. Hydraulic modulator. Refer to "Hydraulic
Figure 12). Modulator" in this section.
4. Position motor pack onto hydraulic modulator,
aligning the three motor pack gears with the HYDRAULIC MODULATOR
modulator gears. Figure 21
rn
•
Important
Take care in handling the motor pack. If
I+!+! Disassemble
1. Remove gear cover. Refer to "Gear Cover" in this
dropped or damaged during handling, the section.
motor pack must be replaced. 2. Remove motor pack. Refer to "Motor Pack" in this
section.
5. Four motor pack to hydraulic modulator Torx® 3. Two hydraulic modulator to brake combo valve
head screws. banjo bolts; separate hydraulic modulator from

I~! Tighten brake combo valve.

4. Two transfer tubes with 0-rings from brake combo
• Torx® head screws 4.5 N·m (40 lb. in.). valve or hydraulic modulator.
SE1-184 ANTILOCK BRAKE SYSTEM

5. Banjo bolt 0-rings from brake combo valve and MASTER CYLINDER
hydraulic modulator.

rn
•
Important
If hydraulic modulator is to be replaced, install the
Refer to SECTION 5A for repair of master
cylinder.

three gears in the same location on replacement SPECIFICATIONS

hydraulic modulator. Refer to "Gear
Replacement" in this section. FASTENER TIGHTENING SPECIFICATIONS
• No repair of the hydraulic modulator is authorized.
Replace as an assembly. ABS Hydraulic Modulator
• Refer to SECTION 5A for repair of brake combo Bleeder Valves ••••••• 9.0 N·m (80 lb. in.)
valve. ABS Hydraulic Modulator
• Use new transfer tube assemblies when Solenoid Torx® Head
assembling the hydraulic modulator/brake combo Bolt •••••••••••••• 4.5 N·m (40 lb. in.)
valve assembly. Make sure two 0-rings are Electronic Brake Control
properly installed on each transfer tube. Module (EBCM) Nut 25 N·m (18.5 lb. ft.)
ABS Hydraulic Modulator
1-+*+I Assemble Mounting Bolt ••••••• 9.0 N·m (80 lb. in.)
1. Two transfer assemblies. Three Hydraulic Modulator
• Lubricate transfer tube assembly 0-rings with Brake Pipe Tube Nuts 32 N·m (24 lb. ft.)
clean brake fluid. Two Brake Combination Valve
• Install transfer tube assemblies in ports in Brake Pipe Tube Nuts 18 N·m (13 lb. ft.)
hydraulic modulator and push in by hand to Two Master Cylinder Brake
bottom. Pipe Tube Nuts ••••••• 32 N·m (24 lb. ft.)
2. Lubricate new banjo bolt 0-ring with clean brake Modulator Drive Gear Nuts • 8.5 N·m (75 lb. in.)
fluid and install into the brake combo valve and Torx® Head Screws
hydraulic modulator. Attaching Gear Cover 4.0 N·m (35 lb. in.)
3. Hydraulic modulator to brake combo valve. Four Torx® Head Screws
• Hold brake combo value and rock into position Attaching Motor Pack 4.5 N·m (40 lb. in.)
on hydraulic modulator inserting transfer tube Two Banjo Bolts Attaching
assemblies into brake combo valve ports. Brake Combination Valve
4. Two hydraulic modulator to brake combo valve to ABS Hydraulic
banjo bolts. Modulator •••••••••. • 16 N·m (12 lb. ft.)

l~I Tighten Figure22

SPECIAL TOOLS
• Banjo bolts to 16 N·m (12 lb. ft.).
5. With the hydraulic modulator upside down, and
The J 39200 High Impedance Multimeter is the
the gears facing you, rotate each hydraulic
only DVM authorized for use in diagnosing and
modulator gear counterclockwise until movement
servicing the ABS VI system.
stops. This procedure will position the pistons very
close to the top of the modulator bore simplifying
the brake bleeding procedure (refer to Figure 12).
6. Motor pack to hydraulic modulator.
7. Gear cover to hydraulic modulator/motor pack
assembly.
 ANTILOCK BRAKE SYSTEM SE1-185

4
3

J 35589

7000001

BRAKE BLEEDING ADAPTER 3 TECH 1 SCAN TOOL

2 MASS STORAGE CARTRIDGE 4 J 39200 - DIGITAL MULTIMETER

NS 16305
Figure 22 - ABS VI Special Tools
SE1-186 ANTILOCK BRAKE SYSTEM

BLANK
 PARKING BRAKE 5F·1

SECTION SF

PARKING BRAKE
CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake
linings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts
contain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water damp-
ened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, pai1s or system damage could
result.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . SF-1 Rear Cable Assembly (Drum Brakes) . . . . . . 5F-5
Parking Brake System . . . . . . . . . . . . . . . . . . . . SF-1 Rear Cable Assembly (Disc Brakes) . . . . . . . SF-6
Parking Brake Lever Assembly . . . . . . . . . . . . . SF-1 Parking Brake Adjustment ................. SF-7
Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . SF-1 "BRAKE" Indicator Lamp .... Refer to Section 8C
"BRAKE" Indicator Lamp ................ SF-1 Unit Repair
On-Vehicle Service ........................ SF-3 Rotor Refinishing . . . . . . . . . . . Refer to Section 5B2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF-3 Drum Refinishing . . . . . . . . . . Refer to Section 5C2
Parking Brake Lever Assembly . . . . . . . . . . . . . SF-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF- 7
Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . SF-3 Fastener Tightening Specifications . . . . . . . . . . SF- 7
Front Cable Assembly .................. SF-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-8

GENERAL DESCRIPTION
PARKING BRAKE SYSTEM
The parking brake system allows the rear brake
assemblies to be mechanically applied by lifting the park-
ing brake lever assembly. On vehicles with rear drum
brakes, this system mechanically forces the rear brake
shoes outward, forcing the rear primary and secondary
shoes against the brake drum assemblies. On vehicles
with rear disc brakes, this system mechanically forces the
rear brake inner and outer pad assemblies against the
brake rotor assembly.
PARKING BRAKE LEVER ASSEMBLY
This vehicle is equipped with a self-adjusting park-
ing brake lever assembly. This mechanism automatically
takes up any slack in the cable assemblies and provides
the correct amount of tension in the cable assemblies
when the system is engaged. The parking brake cable
assemblies cannot be manually adjusted.
When operating correctly, the rear parking brake
actuator levers on the rear disc brake caliper assemblies or
the rear drum brake assemblies will fully return to their
mechanical stops when the parking brake lever assembly
is fully released.
CABLE ASSEMBLIES
Three separate cables are used in the parking brake
system. The left and right rear cable assemblies are joined
to the front cable assembly at the equalizer, with the rear
cable assemblies running to the rear of the vehicle.
This vehicle is equipped with coated parking brake
cable assemblies. The wire strand is coated with a plastic
material which slides over plastic seals inside the conduit
end fittings. This is for corrosion protection and reduced
parking brake effort.
"BRAKE" INDICATOR LAMP
The red "BRAKE" indicator lamp will illuminate
when the ignition switch is in "START" and the parking
brake lever assembly is applied or not fully released. The
parking brake indicator switch assembly, located in the
parking brake lever assembly, will ground the "BRAKE"
indicator lamp circuit and cause the "BRAKE" indicator
lamp to illuminate.
.5F·2 PARKING BRAKE

jv1ewA I

A ARM, ADJUSTER
B GRIP, PARKING BRAKE LEVER
C BUTTON, PARKING BRAKE LEVER RELEASE
D PAWL, ADJUST
E PIN, ADJUST PAWL
F PULLEY, PARKING BRAKE LEVER
1 LEVER ASSEMBLY, PARKING BRAKE
4 SWITCH, PARKING BRAKE INDICATOR
5 BOLT/SCREW, PARKING BRAKE INDICATOR
SWITCH, 2.8 N•m (25 LB. IN.)
8 EQUALIZER, PARKING BRAKE CABLE
9 GROMMET, PARKING BRAKE CABLE
12 BOLT/SCREW, PARKING BRAKE LEVER,
12 N•m (106 LB. IN.)
15 CABLE ASSEMBLY, PARKING BRAKE FRONT
16 SPRING, PRETENSION

RC0001-5F-F-RP

Figure 1 - Parking Brake Lever Assembly


ON-VEHICLE SERVICE
LUBRICATION
Figure 1
NOTICE: Do not lubricate the parking brake cable
assemblies. Lubrication destroys the plastic coating
on the parking brake cable assemblies.
If the parking brake lever assembly (1) does not
fully return, lubricate the following parts using GM P/N
1052497:
• Adjust pawl pin.
• Handle ratchet.
• Adjusting ratchet.
PARKING BRAKE LEVER ASSEMBLY
Figures 1 and 2
Tool Required:
J 37043 Parking Brake Cable Release Tool
!++I Remove or Disconnect
1. Front floor console assembly. Refer to SECTION
8C.
2. Light switch and wiring from parking brake indica-
tor switch (4).
3. Bolt/screw (5) and parking brake indicator switch
(4) from parking brake lever assembly (1).
4. With parking brake lever assembly (1) in up posi-
tion, remove pretension spring ( 16).
5. With parking brake lever assembly (1) in down posi-
tion, rotate adjuster arm toward front of vehicle until
a 3 mm metal pin can be inserted into hole.
A. Remove and discard remaining piece of plastic
shear pin.
B. Insert 3 mm metal pin into hole, locking out
self adjuster.
6. If there is sufficient parking brake cable slack, skip
to step 10.
7. Raise and suitably support vehicle. Refer to SEC-
TION OA.
8. Rear cable assemblies (17 and 18) from equal-
izer (8).
9. Lower vehicle.
I 0. Bend back cable retainer tab on pulley.
11. Barrel-shaped front cable end fitting from adjuster
track on pulley.
12. Two bolts/screws ( 12) and parking brake lever
assembly (1) from floor pan.
13. Front cable assembly ( 15) and casing from parking
brake lever assembly ( 1) and bracket, using J 37043.
!++I Install or Connect
NOTICE: See "Notice" on page 5F-1 of this
section.
PARKING BRAKE 5F·3
I. Front cable assembly ( 15) and casing to parking
brake lever assembly ( 1) and bracket.
2. Two bolts/screws (12) and parking brake lever
assembly (1) to floor pan.
l~I Tighten
• Bolts/screws (12) to 12 N•m (106 lb. in.).
3. Bolt/screw (5) and parking brake indicator
switch (4).
!~I Tighten
• Bolt/screw (5) to 2.8 N•m (25 lb. in.).
4. Light switch and wiring to parking brake indicator
switch (4).
5. Barrel-shaped front cable end fitting to adjuster
track on pulley.
6. Bend cable retainer tab to original position on
pulley.
7. If rear cable assemblies (17 and 18) were not discon-
nected from equalizer, skip to step 11.
8. Raise and suitably support vehicle. Refer to SEC-
TION OA.
9. Rear cable assemblies (17 and 18) to equalizer (8).
10. Lower vehicle.
11. Rotate adjuster arm toward rear of vehicle and fully
raise parking brake lever assembly (1).
12. Pretension spring ( 16).
13. Remove 3 mm metal pin from hole.
14. Cycle parking brake lever assembly (1) three times.
15. Front floor console assembly. Refer to SEC-
TION 8C.
CABLE ASSEMBLIES
NOTICE: Handling these cables while servicing the
parking brake system requires extra care. Damage to
the plastic coating will reduce corrosion protection
and if the damaged area passes through the seal,
increased parking brake effort could result. Contact-
ing the coating with sharp-edged tools, or with sharp
surfaces of the vehicle underbody, should be
avoided.
Front Cable Assembly
Figures 1 and 2
Tool Required:
J 37043 Parking Brake Cable Release Tool
j++l Remove or Disconnect
1. Front floor console assembly. Refer to SEC-
TION 8C.
2. With parking brake lever assembly (1) in up posi-
tion, remove pretension spring ( 16).
3. With parking brake lever assembly (1) in down posi-
tion, rotate adjuster arm toward front of vehicle until
a 3 mm metal pin can be inserted into hole.
A. Remove remaining piece of plastic shear pin
from hole.
SF-4 PARKING BRAKE

18

10

19

A
17
17

!VIEWA!

19

B
A WITH DISC BRAKE ASSEMBLIES
B WITH DRUM BRAKE ASSEMBLIES
C BRACKET, UNDERBODY
D FITIING, PARKING BRAKE REAR CABLE END
8 EQUALIZER, PARKING BRAKE CABLE
10 CALIPER ASSEMBLY, REAR BRAKE
11 DRUM ASSEMBLY, REAR BRAKE
13 GUIDE, PARKING BRAKE REAR CABLE
17 CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
18 CABLE ASSEMBLY, RIGHT PARKING BRAKE REAR
19 HOUSING ASSEMBLY, REAR AXLE
23 GUIDE, PARKING BRAKE REAR CABLE (DRUM BRAKE
ASSEMBLIES ONLY)
PC0002-5F·F·RP

Figure 2 - Parking Brake Cable Routing

 PARKING BRAKE 5F·5

B. Insert 3 mm metal pin into hole, locking out • Be sure grommet (9) is properly seated in
self adjuster. slot in floor pan.
4. Pull parking brake lever assembly (1) all the way 2. Front parking brake cable casing to parking brake
back. lever assembly (I).
5. Raise and suitably support vehicle. Refer to SEC- 3. Barrel-shaped front cable end fitting into adjuster
TION OA. track on pulley.
6. Left and right rear cable assemblies ( 17 and 18) 4. Bend cable retainer tab to original position on
from equalizer (8). pulley.
7. Fitting of front cable assembly (15) from bracket, 5. Make sure parking brake lever assembly (I) is in
using J 37043. down position.
8. Grommet (9) from slot in underbody assembly. 6. Raise and suitably support vehicle. Refer to SEC-
TION OA.
9. Lower vehicle.
7. Rear cable assemblies ( 17 and 18) to equalizer (8).
10. Bend back cable retainer tab on pulley. 8. Lower vehicle.
11. Barrel-shaped front cable end fitting from adjuster 9. With parking brake lever assembly (I) in up posi-
track on pulley. tion, install pretension spring (16).
12. Front cable assembly ( 15) and casing from parking l 0. Remove 3 mm metal pin from hole.
brake lever assembly (I), using J 37043.
11. Cycle parking brake lever assembly ( 1) three times.
13. Front cable assembly ( 15) from floor pan. 12. Front floor console assembly. Refer to SEC-

!-+~I Install or Connect TION 8C.

Rear Cable Assembly (Drum Brakes)

l. Front cable assembly (15) and grommet (9) into slot
in floor pan.
A. Soapy water can be used as lubricant.
B. Feed forward end of grommet (9) into slot.
C. Use a small, curved, flat-ended pry bar to
gently press rearward end into slot.
Figures 2, 3 and 4
Tool Required:
J 37043 Parking Brake Cable Release Tool
This vehicle is equipped with a blind cable system at
the brake drum assembly. The rear parking brake cable

18

I· 102 mm (4.0") ~

~~.;~ I ..11________...,,I 5 mm (0.2")

5mm (0.2")

A SURFACE OF NOTCHES MUST BE SMOOTH

B SPACER, PARKING BRAKE CABLE EQUALIZER
C BRACKET,UNDERBODY
8 EQUALIZER, PARKING BRAKE CABLE
17 CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
18 CABLE ASSEMBLY, RIGHT PARKING BRAKE REAR

PC0004-5f.f.RP
Figure 3 - Parking Brake Cable Equalizer Spacer (Locally Fabricated)
5F·6 PARKING BRAKE
11
A 7. Drum assembly (11).
11
c • When reassembling drum brake assembly,
A SPRING, GUIDE
B LEFT PARKING BRAKE REAR CABLE ASSEMBLY PRIOR
TO INSTALLATION
C LEFT PARKING BRAKE REAR CABLE ASSEMBLY
INSTALLED
11 DRUM ASSEMBLY, REAR BRAKE
17 CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
PC0005-5f.F·RP
Figure 4 - Installing Rear Parking Brake Cable Assembly to
Rear Brake Drum Assembly
assembly can be installed to the brake drum assembly
without disassembling the brake drum assembly.
!++I Remove or Disconnect
1. Fully disengage parking brake lever assembly. Be
sure handle is down and brake indicator lamp is not
lit. If parking brake lever assembly is partially
engaged, it will not be possible to pull equalizer (8)
rearward in step 3.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Left or right rear cable assembly ( 17 or 18) from
equalizer (8).
A. Pull equalizer (8) rearward to gain necessary
cable slack.
B. Insert locally fabricated spacer to hold equal-
izer (8) in place as shown in Figure 3.
C. Remove left or right rear cable assembly
( 17 or 18) from equalizer (8).
4. Left or right rear cable assembly ( 17 or 18) and cas-
ing from underbody bracket and retainer.
• Use J 37043 to compress retainer fingers on
casing and pull left or right rear cable assembly
( 17 or 18) from underbody bracket.
S. Pull rear cable assemblies (17 and 18) through
guides ( 13 and 23) installed on rear axle housing
assembly (19).
6. Tire and wheel assembly. Refer to SECTION 3E.
• Mark relationship of wheel to axle flange.
8. Left or right rear cable assembly (17 or 18) from
backing plate.
• Use J 37043 to compress retainer fingers and
pull out left or right rear cable assembly
(17 or 18).
9. Cable end fitting from parking brake lever assembly.
Refer to SECTION 5C2.
l,t+I Install or Connect
l. Drum assembly (U).
2. Cable end fitting into parking brake lever assembly.
This can be done by inserting tear-drop shaped end
fitting into guide spring until a click is heard.
[I) Important
make sure guide spring projects through hole
in backing plate so that cable insertion can be
performed. After click is heard, pull on cable to
ensure connection has been made.
3. Left or right rear cable assembly (17 or 18) to back-
ing plate.
• Ensure that retainer fingers are seated.
4. Tire and wheel assembly. Refer to SECTION 3E.
• Align previous marks on axle flange and
wheel.
S. Feed left rear cable assembly ( 17) through guide
(13) or right rear cable assembly (18) through guides
(13 and 23) on rear axle housing assembly (19).
6. Left or right rear cable assembly (17 or 18) into
underbody bracket.
7. Left or right rear cable assembly (17 or 18) to equal-
izer (8).
8. Remove locally fabricated spacer.
9. Lower vehicle.
10. Cycle parking brake lever assembly three times.
Rear Cable Assembly (Disc Brakes)
Figures 2, 3 and 5
Tool Required:
J 37043 Parking Brake Cable Release Tool
!++I Remove or Disconnect
1. Fully disengage parking brake lever assembly. Be
sure handle is down and brake indicator lamp is not

10 CALIPER ASSEMBLY, REAR BRAKE
17 CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
21 LEVER, REAR PARKING BRAKE ACTUATOR
22 BRACKET, PARKING BRAKE CABLE
24 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
Figure 5 - Installing Rear Parking Brake Cable Assembly to
Rear Disc Brake Caliper.Assembly
lit. If parking brake lever assembly is partially
engaged, it will not be possible to pull equalizer (8)
rearward in step 3.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Left or right rear cable assembly (17 or 18) from
equalizer (8).
A. Pull equalizer (8) rearward to gain necessary
parking brake cable slack.
B. Insert locally fabricated spacer to hold equal-
izer (8) in place as shown in Figure 3.
C. Remove left or right rear cable assembly
( 17 or 18) from equalizer (8).
4. Left or right rear cable assembly ( 17 or 18) and cas-
ing from underbody bracket.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Parking Brake Indicator Switch Bolt/Screw .............................. 2.8 N•m (25 lb. in.)
Parking Brake Lever Bolt/Screw ...................................... 12 N•m (106 lb. in.)
PARKING BRAKE 5F·7
• Compress retainer fingers on casing using
J 37043 and pull left or right rear cable assem-
bly (17 or 18) from underbody bracket.
5. Pull left or right rear cable assembly (17 or 18)
through guide (I 3) installed on rear axle housing
assembly (19).
6. Tire and wheel assembly. Refer to SECTION 3E.
• Mark relationship of wheel to axle flange.
7. Left or right rear cable assembly (17 or 18) from
actuator lever (21) and cable bracket (22).
A. Pull all parking brake cable slack to caliper end
of parking brake cable assembly.
B. Remove left or right rear cable assembly
( 17 or 18) from tang on actuator lever (21 ).
C. Using J 37043, compress retainer fingers on
cable casing and pull from cable bracket (22).
!++I Install or Connect
1. Left or right rear cable assembly ( 17 or 18) to actua-
tor lever (21) and cable bracket (22).
• Seat retainer fingers into cable bracket (22).
2. Tire and wheel assembly. Refer to SECTION 3E.
3. Feed left or right rear cable assembly (17 or 18)
through guide (13) on rear axle housing
assembly ( 19).
4. Left or right rear cable assembly (17 or 18) into
underbody bracket.
5. Left or right rear cable assembly (17 or 18) to equal-
izer (8).
6. Remove locally fabricated spacer.
7. Lower vehicle.
8. Cycle parking brake lever assembly three times.
PARKING BRAKE ADJUSTMENT
Adjustments are not normally necessary after
replacing the parking brake cable assemblies or the park-
ing brake lever assembly. Refer to SECTION 582 for
parking brake free-travel adjustment procedures and to
SECTION 5C2 for rear drum brake adjustment.
SF-8 PARKING BRAKE

SPECIAL TOOLS

1. J 37043

1. PARKING BRAKE CABLE RELEASE TOOL

PC0007-Sf.F-RP
 ENGINE GENERAL DESCRIPTION 6·1

ENGINE
CONTENTS
Engine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6
3.4 Liter V6 Engine On-Vehicle Service ..................................... Section 6A2A
3.4 Liter V6 Engine Unit Repair ............................................ Section 6A2B
5. 7 Liter V8 Engine On-Vehicle Service ..................................... Section 6A3A
5.7 Liter V8 Engine Unit Repair .............................•.............. Section 6A3B
Cooling and Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6B
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6C
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6D
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6D 1
Cranking System ...................................... ·. ·. . . . . . . . . . . . . . . . . . Secti.on 6D2
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 603
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6D4
Engine Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 605
Driveability and Emissions - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6E
Driveability and Emissions - Fuel Injection (Port) (3.4L) .................... Section 6E3 (3.4L)
Driveability and Emissions - Fuel Injection (Port) (5.7L) .................... Section 6E3 (5.7L)
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6F

SECTION 6
ENGINE GENERAL DESCRIPTION
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CONTENTS
Description of Section 6 ...................... 6-2
Section 6A-Engine Mechanical .............. 6-2
Section 6B- Cooling and Radiator ............ 6-2
Section 6C - Engine Fuel ................... 6-2
Section 6D - Engine Electrical ............... 6-2
Section 6E - Driveability and Emissions -
General Information ...................... 6-2
Section 6F- Exhaust System ................. 6-2
General Information .......................... 6-2
Cleanliness and Care ....................... 6-2
. General Information on Engine Service ........ 6-2
Engine Performance Diagnosis ............... , . 6-3
Engine Mechanical Diagnosis .................. 6-3
Excessive Oil Loss ......................... 6-3
Oil Leak Diagnosis ........................ 6-3
Finding the Leak ........................ 6-3
Repairing the Leak ....................... 6-3
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVI-
RONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE REGULA-
TIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS CERTIFICATION
IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY STANDARDS. IN MOST
CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN PERMANENTLY SEALED AND/OR MADE
INACCESSIBLE TO PREVENT INDISCRIMINATE OR ROUTINE ADJUSTMENT IN THE FIELD. FOR
THIS REASON, THE FACTORY PROCEDURE FOR TEMPORARILY REMOVING PLUGS, CAPS, ETC.,
FOR PURPOSES OF SERVICING THE PRODUCT MUST BE STRICTLY FOLLOWED AND, WHEREVER
PRACTICABLE, RETURNED TO THE ORIGINAL INTENT OF THE DESIGN.
Low or No Oil Pressure ..................... 6-4
Engine Noise Diagnosis ....................... 6-4
Main Bearing Noise ........................ 6-4
Connecting Rod Bearing Noise ............... 6-4
Timing Gear or Chain and Sprocket Noises ..... 6-4
Piston Noises ............................. 6-4
Valve Mechanism or Valve Train Noises ........ 6-5
Flywheel Noises (Automatic Transmission) ..... 6-5
Engine Knock Diagnosis ...................... 6-5
Knocks Cold and Continues for Two to Three
Minutes and Increases with Torque .......... 6-5
Heavy Knock Hot with Torque Applied ........ 6-5
Light Knock Hot .......................... 6-6
Knocks on Initial Start-Up but Only Lasts
a Few Seconds .......................... 6-6
Knocks at Idle Hot ......................... 6-6
Engine Compression Test ..................... 6-6
6·2 ENGINE GENERAL DESCRIPTION
DESCRIPTION OF SECTION 6
SECTION 6A - ENGINE MECHANICAL
This section contains information on the mechanical
parts of the engine, such as the block, crankshaft, pistons,
valve train, and camshaft. Overhaul procedures, removal
and replacement procedures, and specifications are also
covered. The specific subsections are:
6A2A - 3.4 Liter V6 Engine On-Vehicle Service
6A2B - 3.4 Liter V6 Engine Unit Repair
6A3A - 5. 7 Liter V8 Engine On-Vehicle Service
6A3B - 5.7 Liter V8 Engine Unit Repair
SECTION 68 - COOLING AND RADIATOR
Engine cooling system components such as the
radiator, water pump, hoses, thermostat, and cooling fan,
are covered in this section.
SECTION 6C - ENGINE FUEL
This section contains information on all the parts of
the fuel system except the Throttle Body Injection (TBI)
unit itself. Items covered are: fuel tank, fuel pump, fuel
filter, and fuel lines.
SECTION 60 - ENGINE ELECTRICAL
Items covered in this section are the battery, genera-
tor, starter, distributor, engine wire harness, spark plugs
and wires.
Ignition system diagnosis can be found in the
appropriate 6E Section as a "C-4" chart.
Specific subsections are:
60 - Engine Electrical
601 - Battery
602 - Cranking System
603 - Charging System
604 - Ignition System
605 - Engine Wiring
SECTION 6E - DRIVEABILITY AND
EMISSIONS - GENERAL INFORMATION
This section covers emission control systems, gen-
eral information, and diagnostic procedures which will
lead to repairing performance and driveability related
problems. Emission components are covered, as well as
removal and replacement procedures. Instructions on use
of special tools are also given. Specific subsections are:
6E - Driveability and Emissions - General
Information
6E3 (3.4L)- Driveability and Emissions -Fuel
Injection (Port) (3.4L)
6E3 (5.7L)- Driveability and Emissions -Fuel
Injection (Port) (5.7L)
SECTION 6F - EXHAUST SYSTEM
This section has information on all exhaust system
parts, such as tailpipes, mufflers, and the catalytic
converter.
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten-thousandths of an inch.
When any internal engine parts are serviced, care and
cleanliness are important. A liberal coating of engine oil
should be applied to friction areas during assembly, to
protect and lubricate the surfaces on initial operation.
Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is con-
sidered standard shop practice even if not specifically
stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to discon-
nect cables may result in damage to wiring harness or
other electrical parts.
GENERAL INFORMATION ON ENGINE
SERVICE
rn Important
THE FOLLOWING INFORMATION ON ENGINE
SERVICE SHOULD BE NOTED CAREFULLY, AS IT
IS IMPORTANT IN PREVENTING DAMAGE AND
IN CONTRIBUTING TO RELIABLE ENGINE PER-
FORMANCE.
When raising or supporting the engine for any rea-
son, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump screen,
jacking against the oil pan may cause it to be bent against
the pump screen resulting in a damaged oil pick-up unit.
When working on the engine, remember that the
12-volt electrical system is capable of causing short
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground cable of
the battery should be disconnected at the battery. ·
Any time the air cleaner is removed, the intake
opening should be covered. This will protect against acci-
dental entrance of foreign material, which could follow
that intake passage into the cylinder and cause extensive
damage when ~he engine is started.
IN THE MECHANICAL PROCEDURES
DESCRIBED IN THIS SECTION, REFERENCES
WILL BE MADE TO THE REMOVAL OF EQUIP-
MENT SUCH AS POWER STEERING PUMP, AIR
CONDITIONING COMPRESSOR, ETC.
SHOULD IT BECOME NECESSARY TO
REMOVE ANY SUCH ITEM TO PERFORM OTHER
SERVICES, REFER TO THE APPROPRIATE SEC-
TION OF THIS SERVICE MANUAL FOR SPECIFIC
INFORMATION.

ENGINE PERFORMANCE DIAGNOSIS
Engine performance diagnosis procedures are cov-
ered in Section 6E and should be consulted for diagnosis
of any driveability, emissions, or "Service Engine Soon"
light complaint.
Refer to:
• SECTION 6E - Driveability and Emissions -
General Information
• SECTION 6E3 (3.4L) - Driveability and
Emissions - Fuel Injection (Port) (3.4L)
• SECTION 6E3 (5.7L) - Driveability and
Emissions - Fuel Injection (Port) (5.7L)
ENGINE MECHANICAL DIAGNOSIS
The following diagnostic information covers com-
mon problems and possible causes. When the proper
diagnosis is made, the problem should be corrected by
adjustment, repair or part replacement as required. Refer
to the appropriate section of the manual for these pro-
cedures.
EXCESSIVE OIL LOSS
Excessive oil consumption, not due to leaks, is the
use of 2 quarts (1.9L) or more of engine oil within 2,000
miles or 3 200 kilometers.
• External oil leaks. Tighten bolts and/or replace
gaskets and seals as necessary.
• Improper reading of oil level indicator (dipstick).
Check oil with vehicle on a level surface and allow
adequate drain-down time.
• Improper oil viscosity. Use recommended SAE
viscosity for prevailing temperatures. Refer to SEC-
)'ION OB for engine oil specifications.
• Continuous high speed driving, and/or severe usage
such as trailer hauling, will normally cause
decreased oil mileage.
• Crankcase ventilation system malfunctioning.
• Valve guides and/or valve stem seals worn, or seals
omitted. Ream guides and install oversize service
valves and/or new valve stem seals.
• Piston rings broken, improperly installed, worn, or
not seated. Allow adequate time for rings to seat.
Replace broken or worn rings as necessary.
• Piston improperly installed or misfitted.
OIL LEAK DIAGNOSIS
Most oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedure may
help in locating and repairing most leaks.
Finding the Leak
1. Identify the fluid, determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
ENGINE GENERAL DESCRIPTION 6·3
2. At what point is the fluid leaking from? After run-
ning the vehicle at normal operating temperature,
park the vehicle over a large sheet of paper. After a
few minutes, the approximate location of the leak
should be found by the drippings on the paper.
3. Visually check around the suspected component.
Check around all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that are
hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent. Clean the area well, then dry the
area. Operate the vehicle for several miles at normal
operating temperature and varying speeds. After
operating the vehicle, visually check the suspected
component. If leak still cannot be located, try using
the powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aero~ol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. The leak
path to the source should be found by tracing the
white powder surface.
Black Light and Dye Method
A dye and light kit is available for finding leaks.
Refer to the manufacturer's directions when using the kit.
1. Pour specified amount of dye into leaking compo-
nent.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. The bent flange must be
repaired also. Before attempting to repair a leak, check to
be sure that the following conditions are correct as they
may cause a leak.
Gaskets
IL•l 1nspect
• Fluid level/pressure is too high.
• Crankcase ventilation system malfunctioning.
• Improperly tightened fasteners or dirty/damaged
threads.
• Warped flanges or sealing surface.
• Scratches, burrs or other damage to the sealing
surface.
• Damaged or worn gasket.
6·4 ENGINE GENERAL DESCRIPTION
• Cracking or porosity of the component.
• Improper sealant used (where applicable).
Seals
• Fluid level/pressure is too high.
• Crankcase ventilation system malfunctioning.
• Damaged seal bore (scratched, burred or nicked).
• Damaged or worn seal.
• Improper installation.
• Cracks in components.
• Shaft surface scratched, nicked or damaged.
• Loose or worn bearing causing excess seal wear.
LOW OR NO OIL PRESSURE
• Low oil level. Fill to full mark on oil level indicator.
• Slow idle speed.
• Incorrect or malfunctioning oil pressure switch.
• Incorrect or malfunctioning oil pressure gage.
Replace with proper gage.
• Improper oil viscosity or diluted oil. Install oil of
proper viscosity for expected temperature, or install
new oil if diluted with moisture or unburned fuel
mixtures.
• Oil pump worn or dirty.
• Plugged oil filter.
• Oil pickup screen loose or plugged.
• Hole in oil pickup tube.
• Excessive bearing clearance. Replace if necessary.
• Cracked, porous or plugged oil galleries. Repair or
replace block.
• Gallery plugs missing or misinstalled. Install plugs
or repair as necessary.
• Camshaft worn, or poorly machined. Replace cam-
shaft.
ENGINE NOISE DIAGNOSIS
There are four steps to diagnosing engine noise. You
must determine:
1. Type of noise.
2. Under which operating conditions it exists.
3. At what rate, and at what location in the engine.
4. Compare sounds in other engines to make sure the
condition is not normal.
Identify the type of noise, for example, a light rattle
or a low rumble. Determine the exact operating conditions
under which the noise appears.
Remember, engine noises are generally synchro-
nized to either speed (caused by the crankshaft, connect-
ing rods or pistons) or one-half engine speed (valve train
noises). Try to determine the rate at which the noise is
occurring.
MAIN BEARING NOISE
Damaged or worn main bearing noise is revealed by
dull thuds or knocks which happen on every engine revo-
lution, and this noise is loudest when the engine is under
heavy load.
Excessive crankshaft end play is indicated by an
intermittent rap or knock sharper than a worn main bear-
ing. Causes of main bearing noises include:
• Low oil pump pressure.
• Thin, diluted or dirty oil and/or filter.
• Excessive main bearing clearance.
• Excessive crankshaft end play.
• Out-of-round crankshaft journals.
• Excessive belt tension.
• Loose crankshaft pulley.
• Loose flywheel or torque converter.
• Loose main bearing cap.
CONNECTING ROD BEARING NOISE
A damaged or worn connecting rod bearing will pro-
duce knock under all speeds. During the early stages of
wear, connecting rod noise may be confused with piston
slap or loose wrist pins. Connecting rod knock noise
increases in volume with engine speed and is at its loudest
on deceleration. Causes of connecting rod bearing noise
include:
• Excessive bearing clearance.
• Worn crankshaft connecting rod journal.
• Thin, diluted or dirty oil and/or filter.
• Low oil pressure.
• Crankshaft connecting rod journals out-of-round.
• Misaligned connecting rod.
• Connecting rod bolts not properly torqued.
• Wrong bearing inserts or misaligned bearing half.
TIMING GEAR OR CHAIN AND SPROCKET
NOISES .
Engines designed with timing gears, or those
equipped with timing chain and sprockets, can produce
different noises. The most common noise is a high fre-
quency, light knocking sound. This sound will generally
be the same in intensity whether the engine is idling, oper-
ating at high speeds, or under load. Causes of timing gear
or chain and sprocket noises include:
• Worn timing chain and/or gears.
• Misaligned gears.
• Excessive backlash.
• Damaged tooth.
• Gear or sprocket loose on shaft.
• Too much end play in the camshaft or crankshaft.
PISTON NOISES
Piston pin, piston, and connecting rod noises are
hard to separate. A loose piston pin, for example, causes a
sharp double knock usually heard when the engine is
idling, or during sudden acceleration then deceleration of
the engine. A piston pin that has been improperly fitted
will emit a light ticking noise that is more noticeable with
no load on the engine.

Excessive piston-to-cylinder bore clearance will
cause piston slap noise. The noise is similar to a metallic
knock, as if the piston were "slapping" the cylinder wall
during its stroke. As with most engine noises, under-
standing the cause of the noise will help you imagine what
the noise sounds like. An indication of piston slap is a
decrease in noise as the engine warms up. When the
engine is cold, the piston-to-bore clearance is greater and
piston slap will be louder. Causes of piston noises include:
• Worn or loose piston pin or bushing.
• Improper fit of pin.
• Excessive piston-to-cylinder bore clearance (piston
slap).
• Lack of lubrication.
• Carbon deposits on top of piston striking cylinder
head.
• Worn or broken piston ring land.
• Broken or cracked piston.
• Misaligned connecting rods.
• Worn or damaged rings.
• Worn or out-of-round cylinder walls.
• Excessive ring land clearance.
• Insufficient ring-end gap clearance.
• Piston 180 degrees out of position.
• Incorrect piston cam grind.
VALVE MECHANISM OR VALVE TRAIN
NOISES
A light tapping at one-half engine speed, or any
varying frequency, can indicate a valve train problem.
These tapping noises increase with engine speed.
Before attempting to judge valve train noises, thor-
oughly warm up the engine. This will bring all engine
components to a normal state of expansion. Also, run the
engine at various speeds and listen for engine noise with
the hood closed while sitting in the driver's seat.
If the valve mechanism is abnormally noisy, remove
the rocker arm covers and use an engine stethoscope to
determine which valves or valve train parts are causing
the noise.
CAUTION: This procedure is not rec-
ommended on enP.ines with stainless
steel exhaust manifolds because mani·
fold temperature will exceed the flash
point of the oil causing a fire with
possible personal injury.
Causes of valve mechanism noises include:
• Broken or weak valve spring(s).
• Sticking or warped valves.
• Bent pushrods.
• Dirty, stuck, worn or defective valve lifters.
• Damaged or improperly machined camshaft lobes.
• Insufficient or poor oil supply to valve train (low oil
pressure).
• Excessive valve stem-to-guide clearance.
• Worn valve guides.
ENGINE GENERAL DESCRIPTION 6·5
• Worn rocker arms or pushrods.
• Broken rocker arm studs.
• Loose or worn rocker arm attachments.
• Missing or mispositioned lifter guides (roller lifter
engines).
FLYWHEEL NOISES
(AUTOMATIC TRANSMISSION)
A loose or cracked flywheel will produce an irregu-
lar thud or click. To test for a loose or cracked flywheel,
operate the vehicle at approximately 20 mph (32 km/h)
and shut off the engine. If a thud is heard, the flywheel
may be loose or damaged. This type of thud is loudest on
deceleration.
Loose torque converter-to-flywheel or flywheel-to-
crankshaft bolts will sound similar to bearing knock. This
condition produces several raps during quick acceleration
on a free running engine. Depending on the idle smooth-
ness, when the transmission is in gear, the noise may or
may not appear. Check the torque converter-to-flywheel
and flywheel-to-crankshaft bolts before attempting to
investigate any bearing-related knock.
NOTICE: Be sure the converter-to-flywheel bolts
are not too long. Converter bolts that are too long
may dimple the torque converter clutch surface
causing a shudder condition.
ENGINE KNOCK DIAGNOSIS
Noises in engines are sometimes characteristic of the
design. Compare the sounds in other engines to make sure
the condition is not normal.
KNOCKS COLD AND CONTINUES FOR TWO
TO THREE MINUTES AND INCREASES WITH
TORQUE
• Flywheel contacting splash shield. Reposition
splash shield.
• Loose or broken balancer or drive pulleys. Tighten
or replace as necessary.
• Excessive piston-to-bore clearance. Replace piston.
• Bent connecting rod.
• Cold engine piston knock usually disappears when
the cylinder is grounded out. Cold engine piston
knock which disappears in 1.5 minutes should be
considered acceptable.
HEAVY KNOCK HOT WITH TORQUE
APPLIED
• Broken balancer or pulley hub. Replace parts as
necessary.
• Loose torque converter bolts.
• Exhaust system grounded. Reposition as necessary.
• Flywheel cracked.
• Excessive main bearing clearance. Replace as
necessary.
• Excessive rod bearing clearance. Replace as nec-
essary.
6·6 ENGINE GENERAL DESCRIPTION
LIGHT KNOCK HOT
• Detonation or spark knock. Check operation of EST
or ESC. Refer to SECTION 6E3. Check engine
timing and fuel quality.
• Loose torque converter bolts. Tighten bolts.
• Exhaust leak at manifold. Tighten bolts and/or
replace manifold.
• Excessive rod bearing clearance. Replace bearings
as necessary.
KNOCKS ON INITIAL START-UP BUT ONLY
LASTS A FEW SECONDS
• Improper oil viscosity. Install proper oil viscosity for
expected temperatures. Refer to SECTION OB for
engine oil specifications.
• Hydraulic lifter bleed down. Clean, test and replace
as necessary.
- When the engine is stopped, some valves will
be open. Spring pressure against lifters will
tend to bleed lifter down. Attempts to repair
should be made only if the problem is con-
sistent.
- An engine that is operated for only short
periods between start-ups may have lifter noise
that lasts for a few minutes. This is a normal
condition.
• Excessive crankshaft end clearance. Replace crank-
shaft thrust bearing.
• Excessive front main bearing clearance. Replace
worn parts.
KNOCKS AT IDLE HOT
• NC compressor or generator bearing. Replace as
necessary.
• Valve train. Replace parts as necessary.
• Improper oil viscosity. Install proper viscosity oil for
expected temperature. Refer to SECTION OB for
engine oil specifications.
• Excessive piston pin clearance. Replace piston and
pin.
• Connecting rod alignment. Check and replace rods
as necessary.
• Loose crankshaft balancer. Torque and/or replace
worn parts.
• Piston pin offset to wrong side. Install correct piston.
ENGINE COMPRESSION TEST
A compression pressure test is performed on the
engine cylinders to determine the condition of the rings,
valves and head gasket.
l++I Remove or Disconnect
1. Run engine until it reaches normal operating tem-
perature. Battery must be at or near full charge.
2. Turn engine off.
3. Two-wire terminal connector from distributor.
4. Spark plugs from all cylinders.
5. Air duct or air cleaner from throttle body.
• Block throttle plate in open position.
l@I Measure
• Engine compression.
A. Install compression gage firmly to cylinder
spark plug hole.
B. Have a helper crank the engine through at least
four compression strokes in the cylinder being
tested and check the readings on the gage at
each stroke. Record.the results.
C. Disconnect gage.
D. Repeat compression test for each cylinder.
ll'l'I Inspect
• Record compression readings from all cylinders.
The lowest reading should not be less than 70 per-
cent of the highest and no cylinder reading should be
less than 689 kPa (100 psi).
• Problem areas can be identified as follows:
- Normal - Compression builds up quick and
evenly to specified compression on each cyl-
inder.
- Piston Rings - Compression is low on first
stroke and tends to build up on following
strokes, but does not reach normal. Compres-
sion improves considerably with the addition
of oil. Use approximately three squirts from a
plunger type oiler.
- Valves - Compression is low on first stroke
and it does not tend to build up in following
strokes. Compression does not improve much
with the addition of oil. Use approximately
three squirts.from a plunger type oiler.
- Head Gaskets - Leaking head gaskets give
nearly the same test results as valve problems
but may be recognized by .engine coolant in
the crankcase. Head gasket leakage between
two cylinders will give low readings on both
cylinders.
l++I Install or Connect
1. Remove block from throttle plate.
2. Air duct or air cleaner to throttle body.
3. Spark plugs.
4. Two-wire terminal connector to distributor.
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·1

SECTION 6A2A

3.4 LITER V6 ENGINE

ON-VEHICLE SERVICE
RPO L32 - VIN S
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J-B under "On-Vehicle Service" and the SIR Components and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" or "hot at all times" exposed electrical terminals,
disconnect the battery negative cable to help prevent personal injury and/or damage to the
vehicle or components. Unless instructed otherwise, the ignition switch must be in the
"OFF" or "LOCK" position.

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

CONTENTS
General Description .......... Refer to Section 6A2B
On-Vehicle Service ...................... 6A2A-1
Fuel System Pressure Relief ............. 6A2A- l
Serpentine Drive Belt and Tensioner
Assembly .......................... 6A2A-2
Engine Mount Assemblies and Brackets .... 6A2A-4
Oil Level Indicator and Tube Assemblies ... 6A2A-5
Upper Intake Manifold Assembly ......... 6A2A-5
Valve Rocker Arm Cover Assemblies ...... 6A2A-7
Valve Rocker Arms and Pushrod
Assemblies ......................... 6A2A-8
Lower Intake Manifold Assembly ......... 6A2A-9
Valve Lifter Assemblies ................ 6A2A-10
Exhaust Manifold Assemblies ........... 6A2A-ll
Crankshaft Balancer Assembly .......... 6A2A-14
Engine Front Cover Assembly ........... 6A2A-14
Timing Chain Assembly, and Crankshaft
and Camshaft Sprockets .............. 6A2A-l 5
Camshaft Assembly ................... 6A2A-18
Valve Springs and Stem Seals ........... 6A2A- l 9
Cylinder Head Assembly and Gasket ..... 6A2A-20
Oil Pan Assembly .................... 6A2A-23
Oil Pump Assembly ................... 6A2A-23
Connecting Rod Bearings .............. 6A2A-24
Piston and Connecting Rod Assemblies ... 6A2A-26
Crankshaft Bearings ................... 6A2A-27
Flywheel Assembly ................... 6A2A-29
Crankshaft Rear Oil Seal Assembly ...... 6A2A-29
Engine Assembly ..................... 6A2A-29
Thread Repair ....................... 6A2A-32
Specifications .......................... 6A2A-33
Fastener Tightening Specifications ....... 6A2A-33
Engine Assembly Specifications
(3.4L L32) ........................ 6A2A-33
Special Tools .......................... 6A2A-36

ON-VEHICLE SERVICE • After relieving system pressure, a

small amount of fuel may be
released when servicing fuel lines
FUEL SYSTEM PRESSURE RELIEF or connections. In order to reduce
the chance of personal injury,
CAUTION: cover fuel pipe fittings with a shop
• To reduce the risk of fire and per- towel before disconnecting, to
sonal injury, it is necessary to catch any fuel that may leak out.
relieve the fuel system pressure Place the towel in an approved
before servicing fuel system com- container when disconnect is
ponents. completed.
6A2A·2 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

Tool Required: The indicator on the movable portion of the ten-

J 34730-1 Fuel Pressure Gage
I. Disconnect battery negative cable assembly termi-
nal to avoid possible fuel discharge if an additional
attempt is made to start the engine.
2. Loosen fuel filler cap to relieve tank vapor pressure.
3. Connect J 34730-1 to fuel pressure connection.
Wrap a shop towel around fitting while connecting
J 34730-1 to avoid spilling.
4. Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel connec-
tions are now safe for servicing.
5. Drain any fuel remaining in J 34730-1 into an
approved container.
SERPENTINE DRIVJ: BELT AND TENSIONER
ASSEMBLY
Figures 1 and 2
NOTICE: Routine inspection of the belt may reveal
cracks in the belt ribs: These cracks will not impair
belt performance and therefore should not be con-
sidered a problem requiring belt replacement. How-
ever, the belt should be replaced if belt slip occurs or
if sections of the belt ribs are missing.
A single serpentine drive belt is used to drive all
engine accessories. All belt driven accessories are rigidly
mounted with belt tension maintained by a spring loaded
tensioner assembly.
sioner assembly must be within the limits of the marks of
the stationary portion of the tensioner assembly. Any
reading outside of these limits indicates either a defective
belt or tensioner assembly.
D.rive Belt
!L'l'I Inspect
• Belt length scale on drive belt tensioner assembly
for proper installed length. If belt length scale does
not indicate proper installed length, install a new
drive belt.
!++I Remove or Disconnect
CAUTION: See "Caution" on page
6A2A-1 of this section.
1. Battery negative cable assembly.
2. Lift drive belt tensioner assembly (145) downward
(clockwise) off drive belt using a socket and handle
on tensioner pulley bolt/screw.
3. Drive belt (148).
!~I Clean
• Accessory drive belt surfaces.
!++I Install or Connect
1. Drive belt (148) over tensioner pulley by pushing
down on drive belt tensioner assembly (145).

!VIEW Al

145

A INDICATOR MARK
B READING FOR REPLACING BELT IN SERVICE
C DEFECTIVE PARTS CHECK RANGE
D MAXIMUM TOLERANCE BELT READING
E MINIMUM TOLERANCE BELT READING
28 PULLEY, CRANKSHAFT
50 PULLEY, WATER PUMP
145 TENSIONER ASSEMBLY, DRIVE BELT
147 GENERATOR ASSEMBLY
148 BELT, SERPENTINE DRIVE
149 COMPRESSOR ASSEMBLY, AIR CONDITIONING
28 150 PULLEY ASSEMBLY, DRIVE BELT IDLER
229 PULLEY, POWER STEERING PUMP
PC0001-6A2A·F·RP

Figure 1 - Serpentine Drive Belt

 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·3
• Be sure drive belt (148) is aligned into proper
grooves of accessory drive pulleys.
2. Battery negative cable assembly.
Drive Belt Tensioner Assembly
!+-+I Remove or Disconnect
1. Drive belt (148) by lifting drive belt tensioner
assembly (145) downward (clockwise) off drive belt
using a socket and handle on tensioner pulley bolt/
screw.
2. Drive belt tensioner bolts/screws (152).
3. Drive belt tensioner assembly (145).
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Drive belt tensioner assembly (145).
2. Drive belt tensioner bolts/screws ( 152).
l~I Tighten
• Drive belt tensioner bolts/screws (152) to
33 N•m (24 lb. ft.).
3. Drive belt (148) over tensioner pulley by pushing
down on drive belt tensioner assembly (145).
• Be sure drive belt (148) is aligned into proper
grooves of accessory drive pulleys.
151
145 TENSIONER ASSEMBLY, DRIVE BELT
150 PULLEY ASSEMBLY, DRIVE BELT IDLER
151 BOLT/SCREW, DRIVE BELT IDLER PULLEY
152 BOLT/SCREW, DRIVE BELT TENSIONER
Figure 2 - Drive Belt Tensioner Assembly and Idler Pulley
Drive Belt Idler Pulley
The drive belt idler pulley assembly is used in place
of the A/C compressor when the vehicle is not equipped
with air conditioning.
!+-+I Remove or Disconnect
1. Drive belt (148) by lifting drive belt tensioner
assembly (145) downward (clockwise) off drive belt
using a socket and handle on tensioner pulley bolt/
screw.
2. Idler pulley bolts/screws ( 151 ).
3. Drive belt idler pulley assembly (150).
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
section.
1. Drive belt idler pulley assembly (150).
2. Idler pulley bolts/screws (151 ).
!~I Tighten
• Idler pulley bolts/screws (151) to 50 N•m
(37 lb. ft.).
3. Drive belt (148) over tensioner pulley by pushing
down on drive belt tensioner assembly (145).
• Be sure belt is aligned into proper grooves of
accessory drive pulleys.
152
PC0002·6A2A·F·RP
6A2A·4 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

ENGINE MOUNT ASSEMBLIES AND

BRACKETS
Figure 3
NOTICE: When raising or supporting the engine for
any reason, do not use a jack under the oil pan,
crankshaft pulley, or any sheet metal. Due to small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen, resulting in a damaged
oil pickup unit.
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Exhaust crossover pipe. Refer to SECTION 6F.
3. Engine mount through-bolts/screws (120) and nuts
(117).
4. Raise engine with a jacking fixture.
5. Engine mount bolts/screws ( 118) and mount assem-
blies (119).

!L•l 1nspect 6. Engine bracket bolts/screws and brackets ( 116).

• Engine mounts for damage to rubber portions of

mount.
!++! Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
- Rubber surface covered with heat check section.
cracks.
I. Engine brackets ( 116) and bolts/screws.
- Rubber cushion separated from plate of mount.
2. Engine mount assemblies ( 1I 9) and bolts/screws
- Rubber cushion split through center. (118).

A LEFT-HAND SIDE
B RIGHT-HAND SIDE
116 BRACKET, ENGINE
117 NUT, ENGINE MOUNT THROUGH-BOLT/SCREW
118 BOLT/SCREW, ENGINE MOUNT
119 MOUNT ASSEMBLY, ENGINE
120 THROUGH-BOLT/SCREW, ENGINE MOUNT

!VIEWA!
PC0003~-F-RP

Figure 3 - Engine Mount Assemblies and Brackets

 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·5

6. Accelerator cable bracket bolts/screws, bracket and

I~! Tighten cables from throttle body assembly.
7. Relieve fuel system pressure. Refer to "Fuel System
• Engine mount bolts/screws (118) and bracket
bolts/screws to 58 N•m (43 lb. ft.). Pressure Relief" in this section.
8. Fuel pipe connectors.
3. Lower engine. 9. Fuel pipe bracket bolts/screws.
4. Engine mount through-bolts/screws (120) and nuts 10. Fuel pipe hold down plate bolt/screw (167).
(117). 11. Fuel pipe assembly and reposition.
12. Coolant hoses from throttle body assembly.
l~! Tighten 13. Fuel rail stud (169).
• Engine mount through-bolt/screw nuts ( 117) to 14. Fuel pressure regulator vacuum hose.
80 N•m (59 lb. ft.).
15. Wiring harness electrical connectors from the fol-
-or- lowing:
• Engine mount through-bolts/screws ( 120) to • Idle air control
95 N•m (70 lb. ft.).
• Throttle position sensor
5. Exhaust crossover pipe. Refer to SECTION 6F.
• Manifold absolute pressure sensor
6. Lower vehicle.
• Evaporative emissions canister purge solenoid
valve
OIL LEVEL INDICATOR AND TUBE
16. Blow dirt out of injector bores with compressed air.
ASSEMBLIES
17. Fuel rail assembly (166).
l++! Remove or Disconnect 18. Vacuum harness assembly.
1. Nut securing tube bracket to left cylinder head stud 19. Exhaust gas recirculation (EGR) flexible pipe bolts/
bolt/screw. screws and reposition EGR flexible pipe assembly
and gasket at upper intake manifold assembly (155).
2. Level indicator and tube assemblies from engine
block. 20. Upper intake manifold bolts/screws (156).
21. Upper intake manifold assembly (155) and gasket
!++! Install or Connect (154).
NOTICE: See "Notice" on page 6A2A-l of this
section. !r,! Clean
I. Clean tube assembly and apply sealant, GM PIN • Upper intake manifold bolts/screws ( 156).
12345493 or equivalent, around tube 12. 7 mm • Upper intake manifold sealing surfaces.
(0.50 inch) below bead.
2. Tube assembly into engine block and rotate into
position.
!++I Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
3. Nut securing tube bracket. section.

l~! Tighten
1. Upper intake manifold gasket (154) and manifold
assembly (155).
• Oil level indicator tube nut to 21 N •m 2. Upper intake manifold bolts/screws (156).
(15 lb. ft.).
4. Level indicator. !~! Tighten
• Upper intake manifold bolts/screws (156) to
UPPER INTAKE MANIFOLD ASSEMBLY 25 N•m (18 lb. ft.).
Figures 4 and 5 3. EGR flexible pipe gasket, pipe assembly and bolts/
screws at upper intake manifold assembly (155).
l++! Remove or Disconnect A. Apply teflon sealant GM PIN 1052080 to
threads of bolts/screws.
CAUTION: See "Caution" on page B. Gasket must be installed with text "tube side"
6A2A-1 of this section.
facing the tube.
I. Battery negative cable assembly.
2. Drain coolant. Refer to SECTION 6B. l~I Tighten
3. Throttle body air duct. • EGR flexible pipe bolts/screws to 26 N•m
4. Fuel rail injector wiring harness connectors. (19 lb. ft.).
5. Wiring harness retaining nut and lay harness aside. 4. Vacuum harness assembly.
6A2A·6 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

~ 167

155 MANIFOLD ASSEMBLY, UPPER INTAKE

166 RAIL ASSEMBLY, FUEL INJECTOR FUEL
167 BOLT/SCREW, FUEL PIPE HOLD DOWN PLATE
169 STUD, FUEL INJECTOR FUEL RAIL

PC0006-6A2A-F-RP

Figure 4 - Fuel Rail Assembly

v----156

155

142 MANIFOLD ASSEMBLY, LOWER INTAKE

154 GASKET, UPPER INTAKE MANIFOLD
155 MANIFOLD ASSEMBLY, UPPER INTAKE
156 BOLT/SCREW, UPPER INTAKE MANIFOLD

142

PC0007-6A2A-F-RP

Figure 5 - Upper Intake Manifold Assembly

 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A-7

m Important
• Do not press on the regulator cover or pied-
VALVE ROCKER ARM COVER ASSEMBLIES
Figure 6
mont valve when installing fuel rail assembly. Right Side
5. Fuel rail assembly (166).
A. Lightly lubricate fuel injector 0-rings using
!+-+I Remove or Disconnect
clean engine oil. 1. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this Section.
B. Install injectors of fuel rail assembly ( 166) into
bores of manifold. 2. EGR valve adapter bolt/screw, stud, and adapter
with EGR valve assembly from exhaust manifold
C. Carefully press on fuel rail assembly (166) assembly.
with palms of both hands until injectors are
fully seated. 3. Crankcase vent pipe.
4. Spark plug wiring harness assembly from clips.
6. Fuel rail stud (169).
5. Nuts (192) and reinforcements (193).
!~I Tighten 6. Valve rocker arm cover assembly (194) and gasket
(195).
• Fuel rail stud (169) to 25 N•m (18 lb. ft.).
7. Wiring harness electrical connectors to the follow-
ing:
l~I Clean
• Rocker cover assembly and cylinder head gasket
• Idle air control surfaces.
• Throttle position sensor
• Manifold absolute pressure sensor l++I Install or Connect .

• Evaporative emissions canister purge solenoid
valve
8. Fuel pressure regulator vacuum hose.
9. Fuel rail wiring harness retaining nut.
10. Fuel pipe assembly to fuel rail assembly (166).
• Slide fuel line hold down plate over fuel pipe
assembly.
11. Fuel pipe hold down plate bolt/screw ( 167).
• Apply teflon sealant GM P/N 1052080 to
threads of bolt/screw ( 167).
l~I Tighten
• Fuel pipe hold down plate bolt/screw (167) to
25 N•m (18 lb. ft.)
12. Fuel pipe bracket bolts/screws.
13. Accelerator cable bracket, bolts/screws and cables.
l~I Tighten
• Accelerator cable bracket bolts/screws to 10
N•m (90 lb. in.).
• Fuel pipe bracket-to-front brace bolt/screw to
8 N•m (71 lb. in.)
• Fuel pipe bracket-to-intake manifold assembly
bolt/screw to 10 N•m (89 lb. ft.).
14. Fuel pipe connectors.
15. Fuel rail injector wiring harness connectors.
16. Coolant hoses to throttle body assembly.
I 7. Throttle body air duct.
18. Battery negative cable assembly.
19. Refill with coolant. Refer to SECTION 6B.
NOTICE: See "Notice" on page 6A2A-1 of this
section. ·
1. Valve rocker arm cover gasket (195) and cover
assembly (194).
2. Reinforcements (193) and nuts (192).
l~I Tighten
• Nuts (192) to 10 N•m (89 lb. in.).
3. Spark plug wiring harness assembly to clips.
4. Crankcase vent pipe.
5. EGR valve adapter, bolt/screw and stud with EGR
valve assembly to exhaust manifold assembly.
l~I Tighten
• EGR valve adapter bolt/screw and stud to
31 N•m (23 lb. ft.).
6. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
Left Side
l+-+I Remove or Disconnect
1. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
2. PCV valve and hose assembly.
3. Spark plug wire harness assembly from clips.
4. Nuts (192) and reinforcements (193).
5. Valve rocker arm cover assembly (194) and gasket
( 195).
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
section.
6A2A·8 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

192

194

A APPLY SEALANT AT CYLINDER HEAD TO

INTAKE MANIFOLD MATING SURFACE 193
113 HEAD ASSEMBLY, CYLINDER
192 NUT, VALVE ROCKER ARM COVER
193 REINFORCEMENT, VALVE ROCKER ARM COVER
194 COVER ASSEMBLY, VALVE ROCKER ARM
195 GASKET, VALVE ROCKER ARM COVER
196 STUD, VALVE ROCKER ARM COVER

---195

PC0008-6A2A-F-RP

Figure 6 - Valve Rocker Arm Cover Assemblies

1. Valve rocker arm cover gasket ( 195) and cover 2. Valve rocker arm nuts (124) and balls (123).
assembly (194). 3. Valve rocker arms (122) and pushrod assemblies
2. Reinforcements (193) and nuts (192). (93).
• Place valve rocker arms (122), balls (123) and
l~I Tighten pushrod assemblies (93) in a rack so they can
be reinstalled in same locations from which
• Nuts (192) to 10 N•m (89 lb. in.).
they were removed.
3. Spark plug wire harness assembly to clips.
4. PCV valve and hose assembly.
5. Upper intake manifold assembly. Refer to "Upper
rn Important
• Refer to SECTION 6A2B for inspection of the
Intake Manifold Assembly" in this section. rocker arms, studs and pushrod assemblies.
VALVE ROCKER ARMS AND PUSHROD
ASSEMBLIES
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
Figure 7 section.

!+-+I Remove or Disconnect

1. Valve rocker arm cover assemblies. Refer to "Valve
rn Important
• When installing valve rocker arms (122), balls
Rocker Arm Cover Assemblies" in this section. (123) and pushrod assemblies (93), coat their
 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·9

124

113

93 PUSHRODASSEMBLY, VALVE
113 HEAD ASSEMBLY, CYLINDER
121 STUD, VALVE ROCKER ARM
122 ARM, VALVE ROCKER
123 BALL, VALVE ROCKER ARM
124 NUT, VALVE ROCKER ARM

PC0009-&A2A-F-RP

Figure 7 - Valve Rocker Arms and Pushrod Assemblies

bearing surfaces with prelube, GM P/N
l 052365 or equivalent. Install these compo-
nents in the locations from which they were
removed.
1. Pushrod assemblies (93). Make sure pushrod assem-
blies (93) seat in lifter sockets.
2. Valve rocker arms (122).
3. Valve rocker arm balls (123) and nuts (124).
12) Adjust
A. Turn crankshaft assembly until arrow on
crankshaft hub and balancer assembly are in 12
o'clock position and number 1 cylinder is in
firing position (top dead center).
• Watch number 1 cylinder valves as arrow
approaches 12 o'clock position. If a valve
moves as the arrow moves to position, the
engine is in number 6 cylinder firing
position. Crankshaft assembly must then
be turned one more time to reach number
l cylinder firing position.
B.. With engine in number 1 cylinder firing posi-
tion, the following valves can be adjusted:
• Exhaust 1, 2, 3
• Intake I, 5, 6
C. Back off rocker arm nut ( 124) until lash is felt
in pushrod assembly (93). Then tighten rocker
arm nut (124) until all lash is removed. Zero
lash can be felt by moving pushrod assembly
(93) up and down using thumb and forefinger
until there is no more movement.
D. When all free play has been removed, tighten
rocker arm nut ( 124) one additional turn.
E. Turn crankshaft assembly one revolution until
hub arrow is again at 12 o'clock position. This
is number 6 cylinder firing position. The fol-
lowing valves can now be adjusted:
• Exhaust 4, 5, 6
• Intake 2, 3, 4
4. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
LOWER INTAKE MANIFOLD ASSEMBLY
Figure 8
!++! Remove or Disconnect
1. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
2. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
3. Upper radiator hose from lower intake manifold
assembly (142).
4. Heater hose from lower intake manifold assembly
(142).
5. Wiring harness ground leads.
6. Manifold bolts/screws (144) and nuts (143).
6A2A·10 3.4 LITER VS ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

8 4 5 9

7 3 2 6 10

A APPLY SEALANT
B TIGHTENING SEQUENCE
113 HEAD ASSEMBLY, CYLINDER
140 STUD, CYLINDER HEAD
141 GASKET, LOWER INTAKE MANIFOLD
142 MANIFOLD ASSEMBLY, LOWER INTAKE
143 NUT, LOWER INTAKE MANIFOLD
144 BOLT/SCREW, LOWER INTAKE MANIFOLD

PC0010-6A2A-F-RP

Figure 8 - Lower Intake Manifold Assembly

7. Lower intake manifold assembly (142) and gaskets 8. Valve rocker arm cover assemblies. Refer to "Valve
(141 ). Rocker Arm Cover Assemblies" in this section.
9. Upper intake manifold assembly. Refer to "Upper
!++I Install or Connect Intake Manifold Assembly" in this section.
l. Gaskets (141 ). VALVE LIFTER ASSEMBLIES
2. Apply sealant GM P/N 12345739 at engine block to
manifold mating surface. Bead should be 2.0-3.0 Figures 9 and 1O
mm (0.08-0.12 inch) wide and 3.0-5.0 mm No service parts are available for valve lifter assem-
(0.12-0.20 inch) thick. blies. They are replaced as a unit when worn and when a
3. Lower intake manifold assembly (142). new camshaft assembly is installed.
Valve lifters should be kept in order so they may be
4. Manifold bolts/screws (144) and nuts (143). installed in their original position. Some engines will
l~I Tighten
have both standard and 0.25 mm (.010 inch) oversize
(0.S.) valve lifters.
• Manifold bolts/screws (144) and nuts (143) to Where oversize lifters are used, the cylinder case
30 N•m (22 lb. ft.). will be marked with a daub of white paint and/or "0.25
mm O.S." stamped on the lifter boss.
5. Wiring harness ground leads.
If the lifters are removed, they must be installed in
6. Heater hose. their original location. If replacement is necessary, use
7. Upper radiator hose. lifters with a narrow flat ground along the lower 3/4 of
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A-11

~UJ

Figure 9 - Oversize Lifter Marking

lifter. These flats provide additional oil to the cam lobe

and lifter surfaces.

l++I Remove or Disconnect A

B
PLUNGER
LIFTER BODY
I. Upper intake manifold assembly. Refer to "Upper C CHECK BALL SPRING
Intake Manifold Assembly" in this section. D PLUNGER RETURN SPRING
E CHECK BALL (CLOSED)
2. Valve rocker arm cover assemblies. Refer to "Valve F CHECK BALL (OPEN)
Rocker Arm Cover Assemblies" in this section. 93 PUSHROD ASSEMBLY, VALVE
94 LIFTER ASSEMBLY, VALVE
3. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
4. Valve rocker arms and pushrod assemblies. Refer to
PC0038-6A2A-F-RP
"Valve Rocker Arms and Pushrod Assemblies" in
this section. Figure 10 - Valve Lifter Assembly Operation
5. Valve lifter assembly (94).
2. Raise and suitably support vehicle. Refer to SEC-
TION OA. ,
[ ] ] Important
3. Exhaust crossover pipe. Refer to SECTION 6F.
• Refer to SECTION 6A2B for cleaning and inspec- 4. Lower vehicle.
tion of the valve lifter assemblies.
5. Oxygen sensor electrical connector.
!++I Install or Connect 6. Secondary air injection check valve pipe bracket nut
and reposition pipe (manual transmission only).
l. Coat lifters with prelube, GM P/N 1052365 or 7. Exhaust manifold bolts/screws (102).
equivalent.
8. Exhaust manifold assembly (105) and heat shields
2. Valve lifter assembly (94). (103 and 104).
3. Valve rocker arms and pushrod assemblies. Refer to 9. Exhaust manifold gasket (106).
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
4. Lower intake manifold assembly. Refer to "Lower
lr:;tl Clean
Intake Manifold Assembly" in this section. • Exhaust manifold and cylinder head sealing sur-
5. Valve rocker arm cover assemblies. Refer to "Valve faces.

6.
Rocker Arm Cover Assemblies" in this section.
Upper intake manifold assembly. Refer to "Upper
!++I Install or Connect
Intake Manifold Assembly" in this section. 1. Exhaust manifold gasket (106).
2. Exhaust manifold assembly (105) and heat shields
EXHAUST MANIFOLD ASSEMBLIES (103 and 104).
Figures 11 and 12 3. Exhaust manifold bolts/screws (102).

Left Side !~I Tighten

l++I Remove or Disconnect • Exhaust manifold bolts/screws (102) to 25
N•m (18 lb. ft.).
CAUTION: See "Caution" on page 4. Oxygen sensor electrical connector.
6A2A-1 of this section. 5. Secondary air injection check valve pipe bracket nut
1. Battery negative cable assembly. (manual transmission only).
6A2A·12 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE BPO L32-VIN S

111

102

'
103

102 BOLT/SCREW, EXHAUST MANIFOLD

103 SHIELD, EXHAUST MANIFOLD HEAT
104 SHIELD, EXHAUST MANIFOLD HEAT
105 MANIFOLD ASSEMBLY; EXHAUST
106 GASKET, EXHAUST MANIFOLD
111 SENSOR ASSEMBLY, OXYGEN
113 HEAD ASSEMBLY, CYLINDEFF
102

102
PC0012-6A2A·F·RP

Figure t1 - Left. l::xhaust Manifold Assembly

5. A/C compressor rear bracket bolts/screws. Refer to

!~! Tighten SECTION lB.
6. Rear two exhaust manifold bolts/screws (202).
• Secondary air mJection check valve pipe
bracket nut to 25 N•m (18 lb. ft.). 7. Lower vehicle.
6. Raise and suitably support vehicle. Refer to SEC- 8. Serpentine drive belt. Refer to "Serpentine Drive
TION OA. Belt and Tensioner Assembly" in this section.
7. Exhaust crossover pipe. Refer to SECTION 6F. 9. Oxygen sensor electrical connector.
8. Lower vehicle. 10. Generator. Refer to SECTION 6D3.
9. Battery negative cable assembly. 11. A/C compressor from bracket and reposition. Refer
to SECTION lB.
Right Side 12. Generator rear "Y" brace. Refer to SECTION 6D3.
!+.+! Remove or Disconnect 13. EGR valve, adapter, and flexible pipe. Refer to SEC-
TION 6E3.
CAUTION: See "Caution" on page 14. Secondary air injection pipe assembly from exhaust
6A2A-1 of this section. manifold assembly (215) (manual transmission
1. Battery negative cable assembly. only). Refer to SECTION 6E3.
2. Raise and suitably support vehicle. Refer to SEC- 15. Exhaust manifold front and middle bolts/screws
TION OA. (202).
3. Exhaust crossover pipe. Refer to SECTION 6F. 16. Exhaust manifold assembly (215), heat shields (203
4. Transmission filler tube. Refer to SECTION 7A. and 205) and gasket (216).
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A·13

202

113 HEAD ASSEMBLY, CYLINDER

202 BOLT/SCREW, EXHAUST MANIFOLD
203 SHIELD, EXHAUST MANIFOLD HEAT
202 205 SHIELD, EXHAUST MANIFOLD HEAT
215 MANIFOLD ASSEMBLY, EXHAUST
216 GASKET, EXHAUST MANIFOLD

PC0011-6A2A·F·RP
Figure 12 - Right Exhaust Manifold Assembly

4. EGR valve adapter and flexible pipe. Refer to SEC-

!~I Clean TION 6E3.
• Exhaust manifold and cylinder head sealing 5. Generator rear "Y" brace. Refer to SECTION 603.
surfaces.
6. Generator. Refer to SECTION 603.
!++f Install or Connect 7. A/C compressor. Refer to SECTION lB.
NOTICE: See "Notice" on page 6A2A-1 of this
section. 8. Oxygen sensor electrical connector.
1. Exhaust manifold gasket (216).
9. Serpentine drive belt. Refer to "Serpentine Drive
2. Exhaust manifold assembly (215) and heat shields Belt and Tensioner Assembly" in this section.
(203 and 205).
3. Exhaust manifold front and middle bolts/screws 10. Raise and suitably support vehicle. Refer to SEC-
(202). TION QA.

!~I Ti.ghten
11. Transmission filler tube. Refer to SECTION 7A.

• Exhaust manifold bolts/screws (202) to 25 12. A/C compressor rear bracket bolts/screws. Refer to
N•m (18 lb. ft.). SECTION lB.
6A2A-14 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

13. Exhaust crossover pipe. Refer to SECTION 6F.

14. Exhaust manifold rear bolts/screws (202).

l~I Tighten
• Exhaust manifold rear bolts/screws (202) to
25 N•m (18 lb. ft.).
15. Lower vehicle.
16. Battery negative cable assembly.
17. Refill transmission. Refer to SECTION 7 A.

CRANKSHAFT BALANCER ASSEMBLY

Figures 13 and 14
Tools Required:
J 24420-B Torsional Damper Remover
J 29113 Torsional Damper Installer

!+-+I Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
27 BALANCER ASSEMBLY, CRANKSHAFT
PC0015-6A2A-F-RP
Figure 13 - Removing Crankshaft Balancer Assembly

3. Crankshaft balancer bolt/screw and washer.

4. Crankshaft pulley bolts/screws and pulley.
5. Crankshaft balancer assembly (27) using J 24420-B.

!-++I Install or Connect

NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Crankshaft balancer assembly (27) using J 29113.
2. Remove J 29113.
3. Crankshaft pulley and bolts/screws.
4. Crankshaft balancer washer and bolt/screw.

(I] Important
• If balancer assembly is replaced, new balance 27 BALANCER ASSEMBLY, CRANKSHAFT PC0050-&A2A-F-RP
weights of the same size must be installed on
the new balancer assembly in the same hole Figure 14 - Installing Crankshaft Balancer Assembly
locations as the old balancer assembly.

l~I Tighten ENGINE FRONT COVER ASSEMBLY

• Crankshaft balancer bolt/screw to 78 N•m
(58 lb. ft.).
• Crankshaft pulley bolts/screws. to 50 N•m
(37 lb. ft.).
5. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
6. Lower vehicle.
Figure 15
l++I Remove or Disconnect
1. Throttle body air duct.
2. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
3. Water pump assembly. Refer to SECTION 6B.
 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A·15

54

52 BOLT/SCREW, WATER PUMP

53 BOLT/SCREW, WATER PUMP
59 54 PUMP ASSEMBLY, WATER
55 GASKET, WATER PUMP
58 SEAL ASSEMBLY, ENGINE FRONT COVER
58 59 BOLT/SCREW, ENGINE FRONT COVER
52 53 60 COVER ASSEMBLY, ENGINE FRONT
61 GASKET, ENGINE FRONT COVER
71 ENGINE BLOCK
PC0048-6A2A-F-RP

Figure 15 - Engine Front Cover Assembly

4. Crankshaft balancer assembly. Refer to "Crankshaft

Balancer Assembly" in this section. !~! Tighten
5. Power steering pump and bracket. Refer to SEC- • Engine front cover bolts/screws (59) to 21
TION 3Bl. N•m (15 lb. ft.).
6. Oil pan assembly. Refer to "Oil Pan Assembly" in 3. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section. this section.
7. Lower radiator hose from the front cover assembly. 4. Crankshaft sensor.
8. Crankshaft sensor. 5. Lower radiator hose.
9. Engine front cover bolts/screws (59). 6. Crankshaft balancer assembly. Refer to "Crankshaft
IO. Engine front cover assembly (60) and gasket (61). Balancer Assembly" in this section.
7. Lower vehicle.
!r:.w! Clean 8. Water pump assembly. Refer to SECTION 6B.
• Engine front cover and engine block gasket surfaces. 9. Power steering pump and bracket. Refer to SEC-
TION 3Bl.
!l'l'l tnspect 10. Serpentine drive belt. Refer to "Serpentine Drive
• Engine front cover assembly (60) for.damage to the Belt and Tensioner Assembly" in this section.
seals or gasket surface. Refer to SECTION 6A2B to 11. Throttle body air duct.
replace front cover seals if necessary.
TIMING CHAIN ASSEMBLY, AND
!-++I Install or Connect CRANKSHAFT AND CAMSHAFT
NOTICE: See "Notice" on page 6A2A-1 of this SPROCKETS
section.
I. Gasket (61) and engine front cover assembly (60). Figures 16 through 19
Tools Required:
• Coat both sides of lower tabs of gasket (61)
with sealer, GM PIN 1052080. J 23444-A Crankshaft Sprocket Remover
2. Engine front cover bolts/screws (59). J 38612 Crankshaft Sprocket Installer
6A2A·16 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

A ALIGNMENT MARKS
25 CHAIN ASSEMBLY, TIMING
I I I I I I
26 SPROCKET, CRANKSHAFT
71 ENGINE BLOCK
97 BOLT/SCREW, CAMSHAFT SPROCKET
98 SPROCKET, CAMSHAFT
100 CAMSHAFT ASSEMBLY

98

A
25 26 71

PC0046-6A2A-F-RP

Figure 16 - Camshaft Assembly, Sprockets and Timing Chain Assembly

24 KEY, CRANKSHAFT SPROCKET

26 SPROCKET, CRANKSHAFT
71 ENGINE BLOCK
J 23444-A

PC0016-6A2A·F-RP

Figure 17 - Removing Crankshaft Sprocket

(71) or timing chain dampener. See Figure 16. This

!++I Remove or Disconnect 3.
is the number 4 piston at top dead center.
Camshaft sprocket bolts/screws (97).
1. Engine front cover assembly. Refer to "Engine
4. Camshaft sprocket (98) and timing chain assembly
Front Cover Assembly" in this section.
(25).
2. Rotate crankshaft assembly (22) until timing marks 5. Crankshaft sprocket (26) using J 23444-A.
punched on crankshaft sprocket (26) and camshaft
6. Timing chain dampener bolts/screws (62) and
sprocket (98) are aligned to marks on engine block
dampener (63).
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A·17

71
l++l tnstall or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
A section.
1. Key (24 ), if previously removed.
2. Crankshaft sprocket (26) using J 38612.
3. Camshaft sprocket (98) and timing chain assembly ·
(25).
• Make sure timing marks on camshaft and
crankshaft sprockets are aligned with marks
cast into engine block.
• Coat crankshaft and camshaft sprockets with
62
engine oil.
A TIMING ALIGNMENT MARKS
62 BOLT/SCREW, TIMING CHAIN DAMPENER 4. Camshaft sprocket bolts/screws (97).
63
71
DAMPENER, TIMING CHAIN
ENGINE BLOCK l~I Tighten
PC0047-6A2A-F-RP • Camshaft sprocket bolts/screws (97) to 24
N•m (18 lb. ft.).
Figure 18 - Timing Chain Dampener
5. Timing chain dampener (63) and bolts/screws (62).

7. Key (24), if necessary. l~I Tighten

• Bolts/screws (62) to 21 N•m (15 lb. ft.).
ll•l tnspect 6. Engine front cover assembly. Refer to "Engine
• Refer to SECTION 6A2B for component inspection. Front Cover Assembly" in this section.

A TIMING ALIGNMENT MARKS

22 CRANKSHAFT ASSEMBLY
24 KEY, CRANKSHAFT SPROCKET
26 SPROCKET.CRANKSHAFT
71 ENGINE BLOCK

26
PC0045-6A2A-F-RP

Figure 19 - Installing Crankshaft Sprocket

6A2A·18 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

CAMSHAFT ASSEMBLY
Figures 20, 21 and 22 91

Measuring Camshaft Lobe Lift

Tool Required:
J 8520 Cam Lobe Lift Indicator
Measuring lobe lift procedure is similar to that used
for checking valve timing. If improper valve operation is
indicated, measure lift of each pushrod in consecutive
order and record readings.
1. Remove valve rocker arm. Refer to "Valve Rocker
Arms and Pushrod Assemblies" in this section.
2. Position J 8520 with ball socket adapter on pushrod.
Make sure pushrod is in lifter socket.
3. Rotate crankshaft slowly in direction of rotation
until lifter is on heel of camshaft lobe. At this point,
pushrod is in its lowest position.
4. Set dial indicator on zero, then rotate crankshaft
slowly until pushrod is in fully raised position (Fig-
ure 20).
90 DRIVE ASSEMBLY, OIL PUMP
5. Compare total lift recorded from dial indicator with 91 BOLT/SCREW, OIL PUMP DRIVE CLAMP
specifications. 92 CLAMP, OIL PUMP DRIVE
6. If camshaft readings for all lobes are within specifi-
cations, remove dial indicator assembly.
PCOOCM-6A2A-F-RP
7. Install and adjust rocker arms. Refer to "Valve
Rocker Arms and Pushrod Assemblies" in this sec- Figure 21 - Oil Pump Drive Assembly
tion.
5. Engine front cover assembly. Refer to "Engine
l++I Remove or Disconnect Front Cover Assembly" in this section.
l. Upper intake manifold assembly. Refer to "Upper 6. Camshaft sprocket. Refer to "Timing Chain Assem-
Intake Manifold Assembly" in this section. bly, and Crankshaft and Camshaft Sprockets" in this
section.
2. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in 7. Valve lifter assemblies. Refer to "Valve Lifter
this section. Assemblies" in this section.
3. Lower intake manifold assembly. Refer to "Lower 8. Discharge air conditioning system. Refer to SEC-
Intake Manifold Assembly" in this section. TION lB.
4. Bolt/screw (91 ), clamp (92) and oil pump drive 9. Air conditioning compressor and condenser hose
assembly (90). from condenser.
10. Air conditioning receiver and dehydrator hose from
condenser.
11. Radiator assembly with air conditioning condenser.
Refer to SECTION 6B.
12. Air conditioning condenser support assembly.
NOTICE: All camshaft journals are the same diam-
eter so care must be used in removing the camshaft
to avoid damage to the bearings.
13. Camshaft assembly ( 100).
A. Install three 5/16-18 x 4-inch bolts/screws in
camshaft bolt/screw holes.
B. Carefully rotate and pull camshaft assembly
( 100) out of bearings.

rn Important
• Refer to "Cleaning, Inspection and Repair" in SEC-
TION 6A2B for inspection and measurement proce-
Figure 20 - Measuring Camshaft Lobe Lift dures for camshaft assembly.
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A·19

11. Camshaft sprocket. Refer to "Timing Chain Assem-

A bly, Crankshaft and Camshaft Sprockets" in this
section.
12. Engine front cover assembly. Refer to "Engine
Front Cover Assembly" in this section.
13. Oil pump drive assembly (90), clamp (92) and bolt/
screw (91).
• Lubricate oil pump drive gear with prelube,
GM P/N 1052365 or equivalent.
• Lubricate assembly with engine oil for ease of
installation.

1~1 Tighten
• Oil pump drive clamp bolt/screw (91) to 34
N•m (25 lb. ft.).
14. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
15. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section. ·
16. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
A BOLTS
100 CAMSHAFT ASSEMBLY
VALVE SPRINGS AND STEM SEALS

PC0044-6A2A-F-RP
Figures 23 and 24
Figure 22 - Removing and Installing Camshaft Assembly Tools Required:
J 23590 Spark Plug Port Adapter
J 5892-C Valve Spring Compressor (Head-On)
!l"SI Inspect J 23738-A Valve Stem Seal Tester

• Camshaft bearings for scratches, pits, or loose fit in

their bores. Replace camshaft bearings, if necessary.
!++I Remove or Disconnect
Refer to SECTION 6A2B. 1. Valve rocker arms and pushrod assemblies at cylin-
der to be serviced. Refer to "Valve Rocker Arms and
!-++I Install or Connect Pushrod Assemblies" in this section.
2. Spark plug at cylinder to be serviced.
NOTICE: See "Notice" on page 6A2A of this sec-
tion. 3. Install J 23590 to spark plug hole and apply com-
pressed air to hold valve (125 or 132) in place.
1. When installing a new camshaft assembly (100),
coat camshaft lobes with "Molykote" or its equiva- NOTICE: When using the valve spring compressor,
lent. be careful not to scratch or gouge the valve stem.
2. When installing a new camshaft assembly (100), 4. Compress valve spring ( 128 or 135) using J 5892-C
replace all valve lifter assemblies to ensure durabil- (Figure 23).
ity of camshaft lobes and lifter rollers. 5. Valve stem key (131 or 139).
3. Lubricate all camshaft journals with engine oil. 6. Valve spring cap (130 or 138), and oil shield (137)
4. Camshaft assembly (100). on exhaust valves.
7. Valve spring (128 or 135) and dampener (127 or
5. Air conditioning condenser support assembly.
134).
6. Radiator assembly with air conditioning condenser.
8. Intake valve stem oil seal (126).
Refer to SECTION 6B.
9. Valve stem 0-ring seal (129 or 136).
7. Air conditioning receiver and dehydrator hose to

8.
condenser.
Air conditioning compressor and condenser hose to
!++I Install or Connect
condenser. NOTICE: See "Notice" on page 6A2A-1 of this
9. Charge air conditioning system. Refer to SECTION section.
I B. 1. Intake valve stem oil seal (126) and seat seal against
10. Valve lifter assemblies. Refer to "Valve Lifter cylinder head, or valve spring shim, if equipped.
Assemblies" in this section. 2. Valve stem 0-ring seal (129 or 136).
6A2A-20 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

3. Valve spring dampener (127 or 134) and spring (128

or 135).
4. Valve spring oil shield (137) on exhaust valve and
valve cap ( 130 or 138).
5. Compress valve spring (128 or 135) using J 5892-C.
6. Valve stem key (131 or 139).
A. Use grease to hold key in place while discon-
necting J 5892-C.
B. Remove J 23590.
C. Make sure key seats properly in upper groove
of valve stem.
D. Tap end of stem with a plastic-faced hammer to
seat key, if necessary.
7. Spark plug.

!~! Tighten
• Spark plug to 15 N•m (11 lb. ft.).
8. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.

!L"l'I Inspect
• Valve stem 0-ring seal (129 or 136) for leaks.
- Place J 23738-A in position over end of valve
PC0018-6A2A-F-RP stem and against valve spring cap (130 or 138).
Operate J 23738-A and make sure no air leaks
Figure 23 - Compressing Valve Spring
past valve stem 0-ring seals (129 or 136).

!@! Measure
• Valve spring installed height.
131 ~~ 139 - Use a narrow, thin scale and measure from bot-
~~ ~138
tom of valve spring (128 or 135) on dampener
130---® lip to bottom inside of oil shield (137) for
exhaust valve (132) and to top of valve spring
®-137 cap (130) for intake valve (125). If measure-
129 ® ment exceeds specified height, install valve
®- 136 spring seat shims as necessary. Do not shim so

~
128 height is less than specified.

CYLINDER HEAD ASSEMBLY AND GASKET

Figure 25
125 132

~
Tool Required:
J 36660 Torque Angle Meter
~126
134 Left Cylinder Head Assembly
125 VALVE, INTAKE
126
127
128
SEAL, VALVE STEM OIL
DAMPENER, VALVE SPRING
SPRING, VALVE
I++! Remove or Disconnect
129 SEAL, VALVE STEM 0-RING 1. Raise and suitably support vehicle. Refer to SEC-
130 CAP, VALVE SPRING TION OA.
131 KEY, VALVE STEM
132 VALVE.EXHAUST 2. Drain coolant. Refer to SECTION 6B.
134 DAMPENER, VALVE SPRING 3. Lower vehicle.
135 SPRING, VALVE
136 SEAL, VALVE STEM 0-RING 4. Upper intake manifold assembly. Refer to "Upper
137 SHIELD, VALVE STEM OIL Intake Manifold Assembly" in this section.
138 CAP, VALVE SPRING 5. Valve rocker arm cover assemblies. Refer to "Valve
139 KEY, VALVE STEM
PC0035-6A2A·F-RP Rocker Arm Cover Assemblies" in this section.
Figure 24 - Valve Assemblies 6. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A·21

115

~FRT

0 02 03 0
6 7
/ /

5 4 8

A
112 115

A TIGHTENING SEQUENCE
71 ENGINE BLOCK
112 GASKET, CYLINDER HEAD
71 113 HEAD ASSEMBLY, CYLINDER
115 BOLT/SCREW, CYLINDER HEAD

PC0043-6A2A-F-RP

Figure 25 - Cylinder Head Assembly

7. Left exhaust manifold assembly. Refer to "Exhaust 18. Cylinder head bolts/screws ( 115).
Manifold Assemblies" in this section. 19. Cylinder head assembly (113) and gasket (112).
8. Oil level indicator and tube assemblies. Refer to
"Oil Level Indicator and Tube Assemblies" in this
section.
m Important
• Refer to SECTION 6A2B for cylinder head assem-
9. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section. bly cleaning, inspection and repair.
10. Coolant temperature sensor connector.
11. Spark plug wires from spark plugs.
!-++! Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
12. Spark plugs. section.
13. Engine lift bracket.
l. New cylinder head gasket (112).
14. Wiring harness clip from rear of cylinder head
assembly (113). 2. Cylinder head assembly (113) over locator pins and
gasket (112).
15. Secondary air injection pipe bracket bolt/screw.
16. Power steering pump assembly and brackets and lay 3. C?at thr~ads of cylinder head bolts/screws (115)
aside. Refer to SECTION 3B l. with sealmg compound, GM P/N 1052080 or equiv-
alent.
17. Loosen rocker arms until pushrod assemblies can be
removed. 4. Cylinder head bolts/screws ( 115) finger tight.
6A2A-22 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
l~I Tighten
• Cylinder head bolts/screws (115) in sequence
to 55 N•m (41 lb. ft.) (Figure 25).
• Turn cylinder head bolts/screws (115) in
sequence an additional 90 degrees using
J 36660
5. Pushrod assemblies and rocker arms. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
6. Power steering pump assembly and brackets. Refer
to SECTION 3Bl.
7. Secondary air injection pipe bracket bolt/screw.
8. Spark plugs.
l~I Tighten
• Spark plugs to 15 N•m (11 lb. ft.).
9. Spark plug wire harness assembly to spark plugs.
l 0. Wiring harness clip to rear of cylinder head assem-
bly (113).
11. Engine lift bracket.
12. Coolant temperature sensor connector.
13. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
14. Oil level indicator and tube assemblies. Refer to
"Oil Level Indicator and Tube Assemblies" in this
section.
15. Left exhaust manifold assembly. Refer to "Exhaust
Manifold Assemblies" in this section.
16. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
17. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
18. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
19. Refill with coolant. Refer to SECTION 6B.
Right Cylinder Head Assembly
l+-+I Remove or Disconnect
I. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Drain coolant. Refer to SECTION 6B.
3. Lower vehicle.
4. Serpentine drive belt tensioner assembly. Refer to
"Serpentine Drive Belt and Tensioner Assembly" in
this section.
5. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
6. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
7. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
8. Right exhaust manifold assembly. Refer to "Exhaust
Manifold Assemblies" in this section.
9. Generator and brackets. Refer to SECTION 603.
10. Spark plug wires from spark plugs.
11. Spark plugs.
12. Loosen rocker arms until pushrod assemblies can be
removed.
13. Cylinder head bolts/screws (115).
14. Cylinder head assembly (113) and gasket (112).
m Important
• Refer to SECTION 6A2B for cylinder head assem-
bly cleaning, inspection and repair.
1-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
section.
1. New cylinder head gasket (112).
2. Cylinder head assembly ( 113) over locator pins and
gasket (112).
3. Coat threads of cylinder head bolts/screws (115)
with sealing compound, GM P/N 1052080 or equiv-
alent.
4. Cylinder head bolts/screws ( 115) finger tight.
l~I Tighten
• Cylinder head bolts/screws ( 115) in sequence
to 55 N •m (41 lb. ft.) (Figure 25).
• Turn cylinder head bolts/screws (115) in
sequence an additional 90 degrees using
J 36660
5. Pushrod assemblies and rocker arms. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
6. Spark plugs.
l~I Tighten
• Spark plugs to 15 N•m (11 lb. ft.).
7. Spark plug wires to spark plugs.
8. Generator and brackets. Refer to SECTION 603.
9. Right exhaust manifold assembly. Refer to "Exhaust
Manifold Assemblies" in this section.
10. Lower intake manifold assembly. Refer to "Lower
Intake Manifold Assembly" in this section.
11. Valve rocker arm covers. Refer to "Valve Rocker
Arm Cover Assemblies" in this section.
12. Upper intake manifold assembly. Refer to "Upper
Intake Manifold Assembly" in this section.
13. Serpentine drive belt tensioner assembly. Refer to
"Serpentine Drive Belt and Tensioner Assembly" in
this section.
 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A·23

14. Refill with coolant. Refer to SECTION 6B. 1. Oil pan gasket (2) and oil pan assembly (1).
2. Oil pan nuts (11 ), reinforcements (10), bolts/screws
OIL PAN ASSEMBLY (12) and studs (13).

Figure26 l~I Tighten

!++I Remove or Disconnect • Front corner oil pan nuts (11) to 33 N•m
(24 lb. ft.).
CAUTION: See "Caution" on page • Rear corner oil pan bolts/screws to 25 N •m
6A2A·1 of this section. (18 lb. ft.)
l. Battery negative cable assembly. • Oil pan side rail bolts/screws (12) to 10 N•m
2. Air intake duct. (89 lb. in.).
3. Raise and suitably support vehicle. Refer to SEC- • Oil pan studs (13) to 6 N•m (53 lb. in.).
TION QA. 3. Lower engine.
4. Drain engine oil. 4. Engine mount through-bolts/screws.
5. Wiring harness clips from left side of oil pan assem- 5. Oil level sensor assembly.
bly (1).
6. Oil level sensor connector. l~I Tighten
7. Oil level sensor assembly. • Engine mount through-bolts/screws to 95 N•m
8. Exhaust crossover pipes from exhaust manifold (70 lb. ft.)
assemblies. Refer to SECTION 6F. • Engine oil level sensor assembly to 22 N•m
9. Exhaust pipe hanger bolt/screw and reposition pipe. (16 lb. ft.).
Refer to SECTION 6F. 6. Converter cover and bolts/screws (automatic trans-
10. Transmission fluid cooler lines from clip at oil pan mission). Refer to SECTION 7A.
assembly (automatic transmission). 7. Starter motor assembly. Refer to SECTION 602.
11. Starter motor assembly. Refer to SECTION 602. 8. Transmission fluid cooler lines to clip at oil pan
12. Converter cover bolts/screws and cover (automatic assembly (automatic transmission).
transmission). Refer to SECTION 7A. 9. Exhaust pipe hanger bolt/screw.
13. Engine mount through-bolts/screws. 10. Exhaust crossover pipes to exhaust manifold assem-
blies. Refer to SECTION 6F.
14. Raise engine with jacking fixture.
11. Oil level sensor connector.
15. Oil pan bolts/screws (12), studs (13), nuts (11) and
reinforcements ( 10). 12. Wiring harness clips to oil pan assembly (1).
16. Oil pan assembly (1) and gasket (2). 13. Lower vehicle.
• Rotate crankshaft assembly to reposition coun- 14. Air intake duct.
terweights if necessary. 15. Refill engine with oil.

rn Important
• If adequate clearance is not available, to re-
16. Battery negative cable assembly.

OIL PUMP ASSEMBLY

move the oil pan assembly from the engine,
follow these steps:
A. With engine raised from its mounts, place
jackstands at either end of engine frame
assembly for additional support.
B. Loosen engine frame assembly mounting
bolts/screws NO MORE THAN SIX
COMPLETE REVOLUTIONS.
!~I Clean
1. Oil pan and engine block gasket surfaces.
2. Apply a small amount of sealer, GM P/N 12345739
or equivalent, where oil pan gasket tabs seat on rear
crankshaft bearing cap groove.
I++! Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
section.
Figure 27
!++I Remove or Disconnect
1. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
2. Bolt/screw ( 16) attaching oil pump assembly ( 17) to
rear crankshaft bearing cap.
3. Oil pump assembly (17) and driveshaft (18).
[TI Important
• Refer to SECTION 6A2B for oil pump assembly
cleaning, inspection and repair. ·
!++I Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Oil pump assembly (17) and driveshaft (18).
6A2A-24 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

13
12

1 PAN ASSEMBLY, OIL

2 GASKET, OIL PAN
3 STUD, OIL PAN
10 REINFORCEMENT, OIL PAN
11 NUT, OIL PAN
12 BOLT/SCREW, OIL PAN
13 STUD, OIL PAN
71 ENGINE BLOCK

PC0013-8A2A·F·RP

Figure 26 - Oil Pan Assembly

• Align slot on end of intermediate shaft ( 18)

with drive tang on oil pump drive assembly. !++I Remove or Disconnect
2. Bolt/screw (16) attaching oil pump assembly (17) to 1. Oil pan assembly. Refer to "Oil Pan Assembly" in
rear crankshaft bearing cap. this section.

l~I Tighten
• Bolt/screw (16) to 41 N•m (30 lb. ft.).
3. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
CONNECTING ROD BEARINGS
Figures 28, 29 and 30
Connecting rod bearings are the precision insert type
and do not use shims for adjustment. Do not file connect-
ing rods or rod caps. If clearances are found to be exces-
sive, a new bearing will be required. Service bearings are
available in standard size and 0.013 and 0.026 mm under-
size for use with new and used standard size crankshafts.
2. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
rn Important
• Place matchmarks or numbers on connecting
rod assemblies (83) and connecting rod caps
(81). Connecting rod caps (81) must be
assembled to their original connecting rod
assemblies (83).
3. Connecting rod nuts (80).
4. Connecting rod cap (81) and bearings (82).
• Keep bearings (82) with their original connect-
ing rod assembly (83) and cap (81) for reas-
sembly.
• Wipe oil from bearings (82) and crankpins.
 3.4 LITER V6 ENGINE ON.VEHICLE SERVICE RPO L32 - VIN S 6A2A·25

87

85

80 NUT, CONNECTING ROD

81 CAP, CONNECTING ROD
82 BEARING, CONNECTING ROD
83 ROD ASSEMBLY, CONNECTING
84 BOLT, CONNECTING ROD
85 PIN, PISTON
86 PISTON ASSEMBLY
87 RING, PISTON

PC0027-6A2A-F-RP

Figure 28 - Piston and Connecting Rod Assembly

16 BOLT/SCREW, OIL PUMP thickest in center and bearing clearance

17 PUMP ASSEMBLY, OIL
18 DRIVESHAFT, OIL PUMP must be measured at this location.
20 CAP, CRANKSHAFT BEARING B. Install connecting rod cap (81) with bearing
71 ENGINE BLOCK
(82) onto connecting rod assembly (83).
PC0017·6A2A-F-RP
C. Install connecting rod nuts (80).
Figure 27 - Oil Pump Assembly
l~I Tighten
• Connecting rod nuts (80), evenly, to
50 N•m (37 lb. ft.).
ll'l'I Inspect NOTICE: Do not turn the crankshaft assembly with
the gaging plastic installed or the accuracy of the
• Bearings (82) for excessive wear or damage. measurement will be affected.
l@I Measure D. Remove connecting rod nuts (80) and cap (81).
Gaging plastic will be found adhering to either
1. Crankpin for out-of-round and taper with a microm- connecting rod cap (81) or crankshaft journal
eter. Refer measurements to "Specifications" in this and is measured without removing it.
section.
E. Measure gaging plastic at its widest, using
• If not within specifications, replace or recondi- scale provided with gaging plastic. Refer mea-
tion crankshaft assembly. surements to "Specifications" in this section.
• If installing new bearings (82), determine new • If clearance is greater than specified,
bearing size from the maximum crankpin select an undersize bearing (82) and re-
diameter. measure clearance.
2. Bearing clearances, using gaging plastic. • If clearance cannot be brought to specifi-
A. Place piece of gaging plastic the full width of cations, regrind crankpin. If crankpin is
bearing (82), (parallel to crankshaft assembly) already at maximum undersize, replace
onto the crankpin. crankshaft assembly (22).
• Gaging plastic should be positioned in F. Remove all gaging plastic material after mea-
middle of bearing (82). Bearing (82) is suring.
6A2A·26 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
Figure 29 - Measuring Bearing Clearance
Figure 30 - Measuring Connecting Rod Side Clearance
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Coat inside surface of bearings (82) with engine oil.
2. Connecting rod cap (81) and bearings (82).
3. Connecting rod nuts (80).
l~I Tighten
• Connecting rod nuts (80), evenly, to 50 N•m
(37 lb. ft.).
l@I Measure
• Connecting rod side clearance.
A. When all connecting rod bearings (82)
have been installed, tap each connecting
rod assembly (83) lightly parallel to
crankpin to make sure they have clear-
ance.
B. Measure side clearance between connect-
ing rod caps (81) using a feeler gage, or
dial indicator.
C. Rod side clearance should be 0.18 to
0.44 mm (0.007 to 0.017 inch).
4. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
5. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
PISTON AND CONNECTING ROD
ASSEMBLIES
Figures 28 and 31
Tools Required:
J 5239 Connecting Rod Bolt Guide Set
J 8037 Piston Ring Compressor
!+-+I Remove or Disconnect
1. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
2. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
3. Cylinder head assembly. Refer to "Cylinder Head
Assembly and Gasket" in this section.
4. Ring ridge.
A. Turn crankshaft assembly (22) until piston
assembly (86) is at bottom of its stroke.
B. Place a cloth on top of piston assembly (86).
C. Use a ridge reamer to remove ring ridge.
D. Turn crankshaft assembly (22) so piston
assembly (86) is at top of its stroke.
E. Remove cloth and cutting debris.
rn Important
• Place matchmarks or numbers on connecting
rod assemblies (83) and connecting rod caps
(81). Connecting rod caps (81) must be
assembled to their original connecting rod
assemblies (83).
5. Connecting rod nuts (80) and cap (81).
6. Connecting rod assembly (83) and piston assembly
(86) out of top of engine block using J 5239.
rn Important
• Refer to SECTION 6A2B for cleaning, inspection
and repair of piston and connecting rod assembly.
!.,I Clean
1. Cylinder bores with hot water and detergent or with
a light honing.
2. Swab bores with engine oil and a clean, dry cloth.
!-++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
section.
1. Coat piston assembly (86), piston rings, cylinder
bore, and bearing surfaces with engine oil.
2. Piston assembly (86) into its original bore using
J 5239 and J 8037 and lightly tapping top of piston
assembly (86) with a wooden hammer handle.
 3.4 LITER VS ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A-27

A. When installing piston assembly (86) and con-

necting rod assembly (83), stamped arrow on
piston assembly (86) must point to front of
engine while flange on connecting rod assem-
bly (83) must face toward front of piston on
left hand assembly and face toward rear of pis-
ton on right hand assembly.
B. Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
3. Connecting rod caps (81) onto their original con-
necting rod assemblies (83).
• Align matchmarks or numbers which were
placed on connecting rod assembly (83) and
connecting rod cap (81) during removal.
4. Connecting rod nuts (80).

l~I Tighten
• Connecting rod nuts (80), evenly, to 50 N•m
(37 lb. ft.).

)L'l'l lnspect
• Connecting rod assembly (83) for binding by
prying back and forth with a suitable tool. If
necessary, loosen and retighten connecting rod
cap (81).

l@I Measure
• Connecting rod side clearance. Refer to
"Specifications" in this section.
5. Cylinder head assembly. Refer to "Cylinder Head
Assembly and Gasket" in this section.
6. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
7. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.

CRANKSHAFT BEARINGS
Figures 31 and 32
Tools Required:
J 8080 Main Bearing Shell Remover and
Installer
J 36660 Torque Angle Meter
Crankshaft bearings are of the precision insert type.
If clearances are found to be excessive, a new bearing,
A ASSEMBLE WITH ARROWS ON CAP
both upper and lower halves, will be required. Service TOWARD FRONT OF ENGINE .
bearings are available in both standard size and undersize. 19 BOLT/SCREW, CRANKSHAFT BEARING CAP
Replace both bearing shells as a set. 20 CAP, CRANKSHAFT BEARING
22 CRANKSHAFT ASSEMBLY
l++I Remove or Disconnect 23 BEARING, CRANKSHAFT
71 ENGINE BLOCK
1. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
2. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
3. Spark plugs.
PC0019-6A2A·F·RP
4. Cap (20) and lower crankshaft bearing (23) requir-
ing replacement. Figure 31 - Crankshaft Assembly
6A2A-28 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft assembly (22) allowing J 8080 to
push against insert's straight (unnotched) side. This
will roll upper crankshaft bearing (23) out of block.
7. Remove J 8080 from crankshaft assembly (22).
ll'l'I Inspect
• In general, lower half of crankshaft bearing insert
(except number 1 bearing) shows a greater wear and
most distress from fatigue. If upon inspection lower
half is suitable for use, it can be assumed that upper
half is also satisfactory. If lower half shows evidence
of wear or damage, both upper and lower halves
should be replaced. Never replace one half without
replacing other half.
m Important
• To obtain most accurate results when checking
crankshaft bearing clearances, use gaging plastic.
• When engine is in vehicle, crankshaft assembly
must be supported upward to remove any clearance
from upper bearing. Total clearance can then be
measured between lower bearing and journal.
• To assure proper seating of crankshaft assembly, all
bearing cap bolts/screws should be at their specified
torque. In addition, prior to checking fit of bearings,
surface of crankshaft journal and bearing should be
wiped clean of oil.
l@I Measure
1. With oil pan and oil pump assemblies removed, and
starting with rear crankshaft bearing, remove bear-
ing cap and wipe oil from journal and bearing cap.
2. Place a piece of gaging plastic full width of bearing
(parallel to crankshaft assembly) on journal.
m Important
• Do not rotate crankshaft assembly while gag-
ing plastic is between bearing and journal.
3. Install bearing cap and evenly tighten retaining
bolts/screws to specifications. Bearing cap must be
tightened to specification in order to assure proper
reading. Variations in torque affect compression of
gaging plastic.
l~I Tighten
• Crankshaft bearing cap bolts/screws (19) to
50 N•m (37 lb. ft.).
• Turn crankshaft bearing cap bolts/screws ( 19)
an additional 77 degrees using J 36660.
4. Remove bearing caps. Flattened gaging plastic will
be found adhering to either bearing shell or journal.
5. Without removing gaging plastic, measure its com-
pressed width (at widest point) with graduations on
gaging plastic envelope. Normally crankshaft bear-
ing journals wear evenly and are not out-of-round.
However, if a bearing is being fitted to an out-of-
KC004 7-8A3-F-RP
Figure 32 - Removing Crankshaft Bearing
round journal 0.005 mm (0.0002 inch maximum), be
sure to fit to maximum diameter of journal. If bear-
ing is fitted to minimum diameter, and journal is out-
of-round 0.005 mm (0.0002 inch) or more,
interference between bearing and journal will result
in rapid bearing failure. If flattened gaging plastic
tapers toward middle or ends, there is a difference in
clearance indicating taper, low spot or other irregu-
larity of bearing or journal. Be sure to measure jour-
nal with a micrometer if flattened gaging plastic
indicates this difference.
6. If bearing clearance is within specifications, bearing
insert is satisfactory. If clearance is not within speci-
fications, replace insert. Always replace both upper
and lower inserts as a unit. When bearing cap is
installed and clearance is less than 0.032 mm
(0.0012 inch), inspect for burrs or nicks.
7. An undersize bearing may produce proper clear-
ance. If not, it will be necessary to regrind crank-
shaft journal for use with next undersize bearing.
After selecting new bearing, recheck clearance.
8. Proceed to next bearing. When checking number 1
crankshaft bearing, remove serpentine drive belt so
as to prevent tapered reading with gaging plastic.
After all bearings have been checked, rotate crank-
shaft assembly to see that there is no excessive drag.
l,.+I Install or Connect
NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Crankshaft bearings (23) into engine block (71) and
crankshaft bearing caps (20).
A. Coat crankshaft bearings (23) with oil.
B. Insert plain (unnotched) end between crank-
shaft assembly and indented or notched side of
block. Rotate bearing into place using J 8080
as previously described, and remove J 8080
from oil hole in crankshaft journal.
2. Crankshaft bearing caps (20) with assembled crank-
shaft bearings (23) with arrows pointing toward·
front of engine.
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·29
3. Crankshaft bearing cap bolts/screws (19) .
• With crankshaft assembly (22), crankshaft
bearings (23) and crankshaft bearing caps (20)
installed and bolts/screws (19) started, thrust
crankshaft assembly (22) rearward to set and
align bearing caps (20). Then force crankshaft
assembly forward to align crankshaft thrust
bearing.
l~I Tighten
• Crankshaft bearing cap bolts/screws (19) to
50 N•m (37 lb. ft.). . • If flywheel assembly (33) is replaced, new balance
• Turn crankshaft bearing cap bolts/screws ( 19)
evenly an additional 77 degrees using J 36660.
1@1 Measure
• Crankshaft end play, using a dial indicator or feeler
gage. Refer to "Specifications" in this section.
- If using a feeler gage, measure between front
of number three crankshaft bearing cap (20)
and crankshaft thrust surface.
4. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
5. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
6. Spark plugs.
FLYWHEEL ASSEMBLY
Figure33
Flywheel Assembly Replacement
!++I Remove or Disconnect
1. Transmission assembly. Refer to SECTION 7 A for
an automatic transmission or SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
2. Flywheel bolts/screws (36), retainer (34) and fly-
wheel assembly (33).
!++I Install or Connect
NOTICE: See "Notice" on page 6A2A-l of this
section.
1. Flywheel assembly (33), retainer (34) and flywheel
bolts/screws (36).
l~I Tighten
• Flywheel bolts/screws (36) to 83 N•m (61 lb.
ft.).
2. Transmission assembly. Refer to SECTION 7 A for
an automatic transmission or SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
Flywheel Assembly Balancing
Figure 33
!L•f 1nspect
• Flywheel assembly (33) for missing or loose con-
verter-to~flywheel bolts/screws. Tighten or replace
as necessary.
• Converter for damage or missing balance weights. If
converter is damaged or balance weights are mis-
sing, replace converter.
weights of same size must be installed on new fly-
wheel assembly in same hole locations as old fly-
wheel assembly.
CRANKSHAFT REAR OIL SEAL ASSEMBLY
Tool Required:
J 34686 Rear Main Bearing Oil Seal Installer
Figures 34 and 35
l++I Remove or Disconnect
1. Flywheel assembly. Refer to "Flywheel Assembly
Replacement" under "Flywheel Assembly" in this
section.
• Care should be taken not to nick crankshaft
sealing surface when removing seal.
2. Crankshaft rear oil seal assembly.
• Insert a screwdriver or similar tool through
dust lip at an angle as shown in Figure 34. Pry
seal out by moving handle of tool towards end
of crankshaft. Repeat as necessary around seal.
!++I Install or Connect
1. Coat new seal assembly entirely with engine oil.
2. Seal assembly onto J 34686.
3. J 34686 onto rear of crankshaft assembly. Tighten
screws snugly to ensure seal assembly will be
installed squarely over crankshaft assembly.
4. Crankshaft rear oil seal assembly to crankshaft
assembly.
5. Tighten wing nut on J 34686 until it bottoms.
6. Remove J 34686 from crankshaft assembly.
7. Flywheel assembly. Refer to "Flywheel Assembly
Replacement" in this section.
ENGINE ASSEMBLY
!++I Remove or Disconnect
CAUTION: See "Caution"
6A2A-1 of this section.
on page
1. Battery negative cable assembly.
2. Battery positive cable assembly.
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. Front wheels and tires. Refer to SECTION 3E.
6A2A·30 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

22 CRANKSHAFT ASSEMBLY
33 FLYWHEEL ASSEMBLY
34 RETAINER, FLYWHEEL
36 BOLT/SCREW, FLYWHEEL
PC0005-6A2A-F-RP

Figure 33 - Flywheel Assembly

5. Drain coolant. Refer to SECTION 6B.

DUST LIP 6. Drain engine oil.
7. Exhaust crossover pipe assembly from intennediate
pipe. Refer to SECTION 6F.
8. Converter bolts/screws (automatic transmission).
Refer to SECTION 7 A.
9. Front fascia lower deflectors. Refer to SECTION
10-5.
10. Stabilizer bar bolts/screws. Refer to SECTION 3C.
11. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
12. Transmission fluid cooler lines from radiator assem-
bly (automatic transmission). Refer to SECTION
6B.
13. Lower radiator hose from radiator assembly. Refer
J10210-6A3-J-RA to SECTION 6B.
Figure 34 - Removing Crankshaft Rear Oil Seal Assembly 14. Heater hoses from pipes at engine assembly. Refer to
SECTION 1B 1.
15. Electrical ground straps from right side of engine
ALIGNMENT HOLE block.
DUST
LIP 16. Shift linkage from transmission assembly. Refer to
SECTION 7A or SECTION 7B.
17. Propeller shaft assembly after matchmarking. Refer
to SECTION 4A.
18. Torque arm from transmission assembly. Refer to
SECTION 3D.
19. Intermediate steering shaft from rack and pinion as-
sembly. Refer to SECTION 3F4.
20. Electrical ground straps from left side of frame rail.
21. Lower vehicle.
22. Air intake duct.
23. Fuel pipe assembly. Refer to "Upper Intake Man-
ifold Assembly" in this section.
MC0019-6A4-A-RA 24. Cruise and accelerator control cables from throttle
Figure 35 - Installing Crankshaft Rear Oil Seal Assembly
body assembly. Refer to SECTION 6E3.
25. Upper radiator hose from intake manifold assembly.
Refer to SECTION 6B.
 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·31

26. Lower radiator hose from front cover assembly. Re-

fer to SECTION 6B.
27. Brake booster vacuum hose.
l~I Tighten
• Engine mount through-bolts/screws to 95 N•m
28. "Y" brace from right exhaust manifold assembly. (70 lb. ft.).
Refer to SECTION 6D3. 3. Power steering lines to power steering pump. Refer
29. Generator and air conditioning compressor bracket to SECTION 3B.
and reposition. Refer to SECTION 6D3. 4. Clutch housing and clutch assembly. Refer to SEC-
30. Brace lines from antilock brake system (ABS) brake TION 7C.
combination valve. Refer to SECTION 5. 5. Transmission assembly. Refer to SECTION 7 A or
31. Brake lines and clips from ABS hydraulic modulator SECTION 7B.
assembly. Refer to SECTION 5. 6. Position engine lift table and install engine, trans-
32. Right-hand body hinge pillar trim panel assembly. .mission and engine frame assemblies by lowering
Refer to SECTION 10-5. vehicle to crossmember assembly.
7. Engine frame and transmission support bolts/
33. Three engine wiring harness connectors (blue, black screws. Refer to SECTION 10-3.
and white connectors) and evaporator temperature
sensor connector. 8. Engine lift table.
34. Forward lamp wiring harness connectors. 9. Lower vehicle.
10. Upper control arm ball stud assembly to steering
35. Powertrain control module (PCM) and harness.
knuckle assembly. Refer to SECTION 3C.
• Place PCM and harness on top of engine. 11. Lower shock attachment bolts/screws and nuts to
36. Engine wire harness through front of dash. lower control arm.
• Place harness on top of engine. 12. Negative· lead at mounting stud (located next to
junction block).
37. Positive lead at generator.
13. Positive lead at generator.
38. Positive lead at junction block.
14. Engine wire harness though front of dash.
39. Negative lead at mounting stud (located next to the
junction block).
40. Lower shock attachment bolts/screws and nuts from
[TI Important
lower control arm. • When reinstalling engine wiring harness back
through front of dash, the rubber grommet
41. Upper control arm ball stud assembly from steering MUST BE INSTALLED PROPERLY to en-
knuckle assembly. Refer to SECTION 3C. sure correct sealing. If grommet is tom or dam-
42. Raise and suitably support vehicle. Refer to SEC- aged for any reason, it must be replaced.
TION OA. 15. ECM and harness.
43. Position lift table under engine and engine frame as- 16. Forward lamp wiring harness connectors.
sembly. Use Kent-Moore tool number 204-BX-75G 17. Wiring harness connectors.
or equivalent.
18. Right-hand body hinge pillar trim panel assembly.
44. Engine frame and transmission support bolts/ Refer to SECTION 10-5.
screws. Refer to SECTION 10-3. 19. Brake lines and clips to ABS hydraulic modulator
45. Raise vehicle from engine, transmission and engine assembly. Refer to SECTION 5.
frame assemblies. 20. Brake lines to ABS brake combination valve. Refer
46. Secure strut assemblies to engine frame. to SECTION 5.
47. Transmission assembly. Refer to SECTION 7A or 21. Generator and air conditioning compressor bracket
SECTION 7B. and reposition. Refer to SECTION 6D3.
48. Clutch housing and clutch assembly (manual trans- 22. "Y" brace to right exhaust manifold assembly. Re-
mission). Refer to SECTION 7C. fer to SECTION 6D3.
49. Power steering lines from power steering pump as- 23. Brake booster vacuum hose.
sembly. Refer to SECTION 3B. 24. Lower radiator hose to front cover assembly. Refer
50. Engine mount through-bolts/screws. to SECTION 6B.
25. Upper radiator hose to intake manifold assembly.
. 51. Engine assembly from engine frame.
Refer to SECTION 6B.
!++I Install or Connect 26. Cruise and accelerator control cables to throttle
body assembly. Refer to SECTION 6E3.
NOTICE: See "Notice" on page 6A2A-1 of this 27. Fuel pipe assembly. Refer to "Upper Intake Man-
section. ifold Assembly" in this section.
1. Engine assembly to engine frame. 28. Raise and suitably support vehicle. Refer to SEC-
2. Engine mount through-bolts/screws. TION OA.
6A2A-32 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
29. Electrical ground straps to left side of frame rail.
30. Intermediate steering shaft to rack and pinion as-
sembly. Refer to SECTION 3F4.
31. Torque arm to transmission assembly. Refer to SEC-
TION 30.
32. Propeller shaft assembly. Refer to SECTION 4A.
33. Shift linkage to transmission assembly. Refer to
SECTION 7A or SECTION 7B.
34. Electrical ground straps to right side of engine
block.
35. Heater hoses to pipes at engine assembly. Refer to
SECTION 1B 1. . 1. Determine size, pitch and depth of damaged thread.
36. Lower radiator hose to radiator assembly. Refer to
SECTION 6B.
37. Transmission fluid cooler lines to radiator assembly
(automatic transmission). Refer to SECTION 6B.
38. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in the section.
39. Stabilizer bar bolts/screws. Refer to SECTION 3C.
40. Front fascia lower deflectors. Refer to SECTION
10-5.
41. Converter bolts/screws (automatic transmission).
Refer to SECTION 7A.
42. Exhaust crossover pipe assembly from intermediate
pipe. Refer to SECTION 6F.
43. Lower vehicle.
44. Refill with engine oil. Refer to SECTION OA.
45. Refill with engine coolant. Refer to SECTION 6B.
46. Front wheels and tires. Refer to SECTION 3E.
47. Battery positive cable assembly.
48. Battery negative cable assembly.
49. Bleed brake system. Refer to SECTION 5El.
50. Bleed power steering system. Refer to SECTION
3B.
STEP 2 STEP 3
Figure 36 - Repairing Threaded Holes
51. Air intake duct.
52. Align wheels. Refer to SECTION 3A.
THREAD REPAIR
Figure 36
Damaged threads may be reconditioned by drilling
out, re-threading and installing a suitable thread insert.
General purpose thread repair kits are available commer-
cially.
CAUTION: Wear safety glasses to avoid
eye damage.
If necessary, adjust stop collars on cutting tool and
tap to required depth.
m Important
• Refer to kit manufacturer's instructions re-
garding size of drill and tap to be used.
2. Drill out damaged thread. Clean out chips.
3. Tap hole.
A. Lubricate tap with light engine oil.
B. Clean thread.
m Important
• Avoid build-up of chips. Back out tap every
few turns and remove chips.
4. Thread the thread insert onto mandrel of installer.
Engage tang of insert onto end on mandrel.
5. Lubricate insert with light engine oil (except when
installing in aluminum) and install.
m Important
• When correctly installed, insert should be flush
to one turn below surface.
6. If tang of insert does not break off when backing out
installer, break tang off with a drift pin.
STEP 4 STEP 5
KC0049-6A4-B-RP
 3.4 LITER Vp E~GINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·33

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ............................ 10 N•m (90 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 24 N•m (18 lb. ft.)
Connecting Rod Nut ................................................. 50 N•m (37 lb. ft.)
Crankshaft Balancer Bolt/Screw ......................................... 78 N•m (58 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw (plus 77 degrees) ...................... 50 N•m (37 lb. ft.)
Crankshaft Pulley Bolt/Screw .......................................... 50 N•m (37 lb. ft.)
Cylinder Head Bolt/Screw (plus 90 degrees) .............................. 55 N•m (41 lb. ft.)
Drive Belt Idler Pulley Bolt/Screw ...................................... 50 N•m (37 lb. ft.)
Drive Belt Tensioner Bolt/Screw ....................................... 33 N•rn (24 lb. ft.)
EGR Flexible Pipe Bolt/Screw ......................................... 26 N•rn (19 lb. ft.)
EGR Valve Adapter Tube Bolt/Screw ................................... 31 N•m (23 lb. ft.)
Engine Bracket Bolt/Screw .....................•...................... 58 N•rn (43 lb. ft.)
Engine Front Cover Bolt/Screw ........................................ 21 N•m (15 lb. ft.)
Engine Mount Through-Bolt/Screw ..................................... 95 N•rn (70 lb. ft.)
Engine Mount Through-Bolt/Screw Nut ..............•................... 80 N•rn (59 lb. ft.)
Engine Mount-to-Frame Bolt/Screw ..................................... 58 N•rn (43 lb. ft.)
Engine Oil Level Sensor Assembly ..................................... 22 N•m (16 lb. ft.)
Exhaust Manifold Bolt/Screw .......................................... 25 N•rn (18 lb. ft.)
Flywheel Bolt/Screw ................................................. 83 N•rn (61 lb. ft.)
Fuel Injector Fuel Rail Stud ........................................... 25 N•m (18 lb. ft.)
Fuel Pipe Bracket-to-Front Brace Bolt/Screw .............................. 8 N•m (71 lb. in.)
Fuel Pipe Bracket-to-Intake Manifold Bolt/Screw .......................... 10 N•rn (89 lb. in.)
Fuel Pipe Hold Down Plate Bolt/Screw .................................. 25 N•m (18 lb. ft.)
Lower Intake Manifold Bolt/Screw ..................................... 30 N•rn (22 lb. ft.)
Oil Level Indicator Tube Nut .......................................... 21 N•m (15 lb. ft.)
Oil Pan
Front Corner Bolt/Screw and Nut ..................................... 33 N•m (24 lb. ft.)
Rear Corner Bolt/Screw ............................................ 25 N•m (18 lb. ft.)
Side Rail Bolt/Screw ............................................... 10 N•m (89 lb. in.)
Stud .......................................... : ..... : ............ 6 N•m (53 lb. in.)
Oil Pan Drain Plug ................................... , .............. 25 N•m (18 lb. ft.)
Oil Pump Drive Clamp Bolt/Screw ..................................... 34 N•m (25 lb. ft.)
Oil Pump-to-Crankshaft Bearing Cap Bolt/Screw .......................... 41 N•m (30 lb. ft.)
Secondary Air Injection Check Valve Pipe Bracket Bolt/Screw ............... 25 N•m (18 lb. ft.)
Secondary Air Injection Pipe Fitting .................................... 25 N•rn (18 lb. ft.)
Timing Chain Dampener Bolt/Screw .................................... 21 N•m (15 lb. ft.)
Upper Intake Manifold Bolt/Screw ...................................... 25 N•rn (18 lb. ft.)
Valve Rocker Arm Cover Nut ........................................... 10 N•m (89 lb. in.)

ENGINE ASSEMBLY SPECIFICATIONS (3.4L L32).

General
Type ....................................... ,....,:··'. ................ ·............. V6
Displacement ................................... '...... . . . . . . . . . . . . . . . . 3.4L (204 CID)
Bore ........................................· .... .' ................... 92 mm (3.622 ")
Stroke .......................................... .'s. . . . . . . . . . . . . . . . . . . 84 mm (3.312 ")
Compression Ratio .......................... .·i; .·.: ... ·.......................... 9.0:1
Firing Order ................................... : . ........................ 1-2-3-4-5-6
Oil Pressure (Minimum at operating temperature) .•.•.•.... 103 kPa (15 psig) at 1,100 engine rpm
Oil Filter Torque ........................... , ......................... 16 N•m (12 lb. ft.)

Cylinder Bore
Diameter ........................................... 92.020-92.038 mm (3.6228-3.6235")
Out-of-Round ............................................... 0.007 mm (0.0003 ") MAX.
6A2A·34 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

Piston Assembly
Diameter ........................................... 91.977-91.992 mm (3.6211-3.6217")
Piston Bore Clearance ................................... 0.028-0.061 mm (0.0011-0.0024")
Piston Rings
Piston Compression Ring
Groove Clearance
Top ................................................ 0.05-0.09 mm (0.002-0.0035")
2nd ................................................. 0.05-0.09 mm (0.002-0.00351/)
Gap
Top ................................................. 0.18-0.41 mm (0.007-0.016 11 )
2nd .................................................. 0.48-0.74 mm (0.019-0.029 11 )
Piston Oil Ring
Groove Clearance-MAX ............................................ 0.20 mm (0.008")
Gap ................................................... 0.25-0.76 mm (0.010-0.030")
Piston Pin
Diameter ......................................... 22.9915-22.9964 mm (0.9052-0.9054")
Clearance in Piston Assembly .......................... 0.0116-0.0218 mm (0.0005-0.0009")
Fit In Connecting Rod Assembly ............. 0.0165-0.0464 mm (0.00065-0.0018") Interference
Crankshaft Assembly
Main Journal
Diameter-All ...................................... 67.239-67.257 mm (2.6473-2.6483")
Taper-Max ................................................ 0.005 mm (0.0002") MAX.
Out-of-Round ............................................. 0.005 mm (0.0002") MAX.
Crankshaft Bearing Clearance ............................ 0.032-0.077 mm (0.0012-0.0030")
Crankshaft Thrust Bearing Clearance ....................... 0.032-0.077 mm (0.0012-0.0030")
Crankshaft Assembly End Play ............................. 0.06-0.21 mm (0.0024-0.0083")
Connecting Rod Assembly
Connecting Rod Journal
Diameter ......................................... 50.768-50.784 mm (1.9987-1.9994")
Taper~Max ..................................................... 0.005 mm (0.0002")
Out-of-Round-Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 mm (0.0002")
Rod Bearing Clearance .................................. 0.028-0.082 mm (0.0011-0.0032")
Rod Side Clearance ......................................... 0.18-0.44 mm (0.007-0.017")
Camshaft Assembly
Journal Diameter ......................................... 47.44-47.52 mm (1.868-1.871 ")
Bearing Inside Diameter ................................. 47.523-47.549 mm (1.871-1.872")
Journal Clearance ........................................ 0.026-0.101 mm (0.001-0.004")
Lobe Lift
Intake .......................................................... 6.67 mm (0.2626")
Exhaust ........................................................ 6.94 mm (0.2732")
Valve System
Lifter Assembly ........................................................... Hydraulic
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Valve Lash ............................................. 1 ± 1/2 turn down from zero lash
Face Angle .................................................................... 45 °
Seat Angle ..................................................................... 46°
Seat Runout .................................................. 0.025 mm (0.001 ") MAX.
Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55-1.85 mm (0.061-0.073 ")
Exhaust ................................................. 1.70-2.00 mm (0.067-0.079")
Stem Clearance ·
Intake ........................................ 0.0356 mm-0.0686 mm (0.0014-0.0027")
Exhaust ....................................... 0.0381 mm-0.0737 mm (0.0015-0.0029")
Valve Spring
Free Length ....................................................... 48.5 mm (1.91 ")
Pressure
Closed ........................................... 356 Nat 40.9 mm (80 lb. at 1.61 ")
Open ........................................... 841 Nat 30.5 mm (190 lb. at 1.20")
Installed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.9 mm (1.61 ")
Approximate # of Coils ........................................................... 4
 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A·35

Oil Pump
Gear Lash ............................................ 0.094-0.195 mm (0.0037-0.0077")
Gear Pocket
Depth ................................................ 30.53-30.61 mm (1.202-1.205")
Diameter ........................................... .' 38.202-38.252 mm (1.504-1.506")
Gear
Length ............................................... 30.45-30.48 mm (1.199-1.200")
Diameter .............................................. 38.05-38.10 mm (1.498-1.500")
Side Clearance ........................................... 0.08-0.10 mm (0.003-0.004")
End Clearance .......................................... 0.05-0.152 mm (0.002-0.006")
Valve-to-Bore Clearance ................................. 0.038-0.089 mm (0.0015-0.0035")
6A2A-36 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S

SPECIAL TOOLS

1. · ~ J23444-A 8. J 8520

2. J 29113 9. sq~.,., , J 23590

3.
~ J 8037 10.

~ J 23738-A

4.
<Ji J 24420-B 11.

5. J 34686

12.
6.

J 34730-1
J 38612

7. J 5892-C 13.

1. CRANKSHAFT SPROCKET REMOVER

~~,.:::~::::>> J 8080
2. TORSIONAL DAMPER INSTALLER
3. PISTON RING COMPRESSOR
4. TORSIONAL DAMPER REMOVER
5. REAR MAIN BEARING OIL SEAL INSTALLER
6. CRANKSHAFT SPROCKET INSTALLER 14.
7. VALVE SPRING COMPRESSOR
8.
9.
CAM LOBE LIFT INDICATOR
SPARK PLUG PORT ADAPTER ;; J5239

10. VALVE STEM SEAL TESTER

11. TORQUE ANGLE METER
12. FUEL PRESSURE GAGE
13. MAIN BEARING SHELL REMOVER & INSTALLER
14. CONNECTING ROD BOLT GUIDE SET

PC0014-6A2A-F-RP
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A2B-1

SECTION 6A2B

3.4 LITER V-6 VIN CODE S UNIT REPAIR

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for
the vehicle at the opposite end from which components are being removed. This will reduce the
possibility of the vehicle falling off of the hoist.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correct torque value must
be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage
could result.

CONTENTS
General Description ............................... 6A2B- 6
Engine Construction ............................ 6A2B- 6
Engine Lubrication .............................. 6A2B- 6
Disassembly ......................................... 6A2B- 6
Flywheel ........................................... 6A2B- 6
Draining the Engine ............................ 6A2B- 6
Upper Intake Manifold ......................... 6A2B-11
Valve Rocker Cover ............................ 6A2B-11
Valve Rocker Arm and Pushrod ............. 6A2B-11
Lower Intake Manifold ......................... 6A2B-13
Valve Lifters ..................................... 6A2B-13
Exhaust Manifold ................................ 6A2B-14
Oil Pan ............................................ 6A2B-15
Electronic Ignition Module .................... 6A2B-16
Coolant Pump .................................... 6A2B-17
Torsional Damper ............................... 6A2B-17
Engine Front Cover ............................. 6A2B-18
Timing Chain and Sprockets .................. 6A2B-18
Camshaft .......................................... 6A2B-18
Cylinder Head .................................... 6A2B-20
Oil Pump .......................................... 6A2B-20
Piston and Connecting Rod ................... 6A2B-21
Crankshaft ........................................ 6A2B-21
Rear Main Seal .................................. 6A2B-22
Camshaft Bearings .............................. 6A2B-22
Cleaning, Inspection and Repair ................ 6A2B-22
Cylinder Block ................................... 6A2B-22
Thread Repair .................................... 6A2B-25
Crankshaft ........................................ 6A2B-25
Pistons and Connecting Rods ................. 6A2B-25
Main Bearing and Rod Bearing Selection .. 6A2B-29
Oil Pump Unit Repair .......................... 6A2B-31
Cylinder Head Reconditioning ................ 6A2B-33
Camshaft Inspection ............................ 6A2B-38
Timing Chain and Sprockets .................. 6A2B-38
Engine Front Cover ............................. 6A2B-38
Oil Pan ............................................ 6A2B-39
Coolant Pump .................................... 6A2B-39
Valve Lifters ..................................... 6A2B-39
Valve Rocker Arms and Pushrods ........... 6A2B-39
Valve Rocker Covers ........................... 6A2B-40
Upper Intake Manifold ......................... 6A2B-40
Lower Intake Manifold ......................... 6A2B-41
Assembly ............................................ 6A2B-41
Cylinder Block ................................... 6A2B-41
Camshaft Bearings .............................. 6A2B-41
Crankshaft ........................................ 6A2B-42
Rear Main Oil Seal ............................. 6A2B-43
Pistons and Connecting Rods ................. 6A2B-44
Oil Pump ..................... : .................... 6A2B-44
Cylinder Head .................................... 6A2B-45
Camshaft .......................................... 6A2B-46
Timing Chain and Sprockets .................. 6A2B-46
Engine Front Cover ............................. 6A2B-48
Coolant Pump .................................... 6A2B-48
Torsional Damper ............................... 6A2B-49
Electronic Ignition Module .................... 6A2B-49
Oil Pan ............................................ 6A2B-50
Exhaust Manifold ................................ 6A2B-50
Valve Lifters ..................................... 6A2B-50
Valve Rocker Arm and Pushrod ............. 6A2B-50
Lower Intake Manifold ......................... 6A2B-51
Valve Rocker Cover ............................ 6A2B-51
Upper Intake Manifold ......................... 6A2B-51
Flywheel ........................................... 6A2B-52
Specifications ....................................... 6A2B-52
Fastener Tightening Specifications ........... 6A2B-52
Engine Specifications ........................... 6A2B-53
Special Tools ....................................... 6A2B-56
6A2B·2 3.4 LITER V-6 VIN CODE S UNIT REPAIR

.:~ f-'°

54

27

··-i
17~

16- J
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A28-3

1 PAN, OIL 54 PUMP, COOLANT

2 GASKET, OIL PAN 55 GASKET, COOLANT PUMP
3 STUD, OIL PAN 56 BOLT, CRANKSHAFT POSITION SENSOR
4 CLIP, WIRING HARNESS 57 SENSOR, CRANKSHAFT POSITION
5 NUT, OIL PAN 58 SEAL, FRONT COVER OIL
6 CLIP, OIL COOLER PIPE 59 BOLT, ENGINE FRONT COVER
7 NUT, OIL PAN 60 COVER, ENGINE FRONT
8 WASHER, OIL DRAIN PLUG 61 GASKET, ENGINE FRONT COVER
9 PLUG, OIL DRAIN 62 BOLT, TIMING CHAIN DAMPER
10 REINFORCEMENT, OIL PAN 63 DAMPER, TIMING CHAIN
11 NUT, OIL PAN 64 PLUG, OIL GALLERY - 1/8"
12 BOLT, OIL PAN - SMALL 65 PLUG, OIL GALLERY - 1/4"
13 STUD, OIL PAN 66 BOLT, IGNITION TIMING SENSOR
14 BOLT, OIL PAN - LARGE 67 SENSOR, IGNITION TIMING
15 SENSOR, OIL LEVEL 68 SENSOR, KNOCK
16 BOLT, OIL PUMP 69 PLUG,COOLANTJACKET
17 PUMP ASSEMBLY, OIL 70 PLUG, COOLANT JACKET
18 ROD, OIL PUMP DRIVE 71 BLOCK, ENGINE
19 BOLT, MAIN BEARING CAP 72 DOWEL
20 CAP, MAIN BEARING 74 PLUG,COOLANTJACKET
21 0-RING 75 GASKET, REAR CAMSHAFT COVER
22 CRANKSHAFT 76 COVER, REAR CAMSHAFT
23 BEARING, MAIN 77 BOLT, REAR CAMSHAFT COVER
24 KEY, CRANKSHAFT 78 PLUG, OIL GALLERY - 1/4"
25 CHAIN, TIMING 79 PLUG, OIL GALLERY - 3/8"
26 SPROCKET, CRANKSHAFT 80 NUT, CONNECTING ROD
27 DAMPER, TORSIONAL 81 CAP, CONNECTING ROD
28 PULLEY, CRANKSHAFT 82 BEARING, CONNECTING ROD
29 WASHER, TORSIONAL DAMPER 83 ROD, CONNECTING
30 BOLT, TORSIONAL DAMPER 84 BOLT, CONNECTING ROD
31 BOLT, COOLANT PUMP PULLEY 85 PIN, PISTON
32 SEAL, REAR MAIN 86 PISTON
33A FLYWHEEL, AUTOMATIC TRANSMISSION 87 RINGS, OIL CONTROL
338 FLYWHEEL, MANUAL TRANSMISSION 88 RING, LOWER COMPRESSION
34 REINFORCEMENT, FLYWHEEL 89 RING, UPPER COMPRESSION
36 BOLT, FLYWHEEL 90 DRIVE ASSEMBLY, OIL PUMP
37 STUD, BRACE 91 BOLT, DRIVE ASSEMBLY CLAMP
38 BRACE, POWER STEERING PUMP 92 CLAMP, OIL PUMP DRIVE ASSEMBLY
39 NUT, BRACE 93 PUSH ROD
40 GASKET, OIL FILTER ADAPTER 94 LIFTER
41 ADAPTER, OIL FILTER 95 BOLT, CAMSHAFT POSITION SENSOR
42 0-RING 96 SENSOR, CAMSHAFT POSITION
43 BOLT, OIL FILTER ADAPTER 97 BOLT, CAMSHAFT SPROCKET
44 SENSOR, OIL PRESSURE 98 SPROCKET, CAMSHAFT
45 FILTER.OIL 99 PIN, DOWEL
46 TUBE, OIL LEVEL INDICATOR 100 CAMSHAFT
47 NUT, OIL LEVEL INDICATOR TUBE 101 BEARING, CAMSHAFT
48 INDICATOR, OIL LEVEL
49 BOLT, COOLANT PUMP PULLEY
50 PULLEY, COOLANT PUMP
51 BOLT, COOLANT PUMP - SMALL
52 BOLT, COOLANT PUMP - LARGE
53 BOLT, COOLANT PUMP - MEDIUM

RC0012-6A2B-F-RA

Figure 2 Legend View 1

6A2B-4 3.4 LITER V-6 VIN CODE S UNIT REPAIR

199 157

~
19~/ 182
/ 173
183

162 I
161

159

158
200 l

164 201 ~ - I

~163

194

227

102
Figure 3 Engine Disassembled View 2 of 2
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A2B·5

102 BOLT, EXHAUST MANIFOLD 150 PIPE, HEATER INLET 194 COVER, VALVE ROCKER
103 SHIELD, EXHAUST MANIFOLD 151 SCREW, HEATER INLET PIPE 195 GASKET, VALVE ROCKER COVER
HEAT 152 CLAMP, HOSE 196 STUD, VALVE ROCKER COVER
104 SHIELD, EXHAUST MANIFOLD 153 HOSE,HEATERINLET 197 TUBE, CRANKCASE VENT
HEAT
154 GASKET,UPPERINTAKE 199 FITTING, TUBE
105 MANIFOLD, EXHAUST - LEFT MANIFOLD 200 BRACKET, REAR ENGINE LIFT
106 GASKET, EXHAUST MANIFOLD 155 MANIFOLD, UPPER INTAKE 201 STUD, REAR ENGINE LIFT
111 SENSOR, OXYGEN 156 BOLT, UPPER INTAKE MANIFOLD BRACKET
112 GASKET, CYLINDER HEAD 157 TUBE, VACUUM 202 BOLT, EXHAUST MANIFOLD
113 HEAD, CYLINDER 158 SENSOR, MAP 203 SHIELD; EXHAUST MANIFOLD
114 SENSOR, COOLANT TEMPERA- 159 CLIP, ENGINE WIRING HARNESS HEAT
TURE GAGE 205 SHIELD, EXHAUST MANIFOLD
160 SCREW, MAP SENSOR
115 BOLT, CYLINDER HEAD HEAT
161 BRACKET, ACCELERATOR CABLE
116 BRACE, FUEL LINE 206 VALVE, EGR
162 BOLT,ACCELERATOR
117 BOLT, FUEL LINE BRACE CABLE BRACKET 207 BOLT, EGR VALVE
118 BRACKET, FRONT ENGINE LIFT 163 GASKET, THROTTLE BODY 208 GASKET, EGR VALVE
119 BOLT, FRONT ENGINE LIFT 164 BODY, THROTTLE 209 PIPE, EGR ADAPTER
BRACKET 210 BOLT, EGR ADAPTER PIPE
165 BOLT,THROTTLE BODY
120 STUD, FRONT ENGINE LIFT 211 GASKET, EGR ADAPTER PIPE
166 RAIL ASSEMBLY, FUEL INJEC-
BRACKET
TOR 212 PIPE, FLEXIBLE ADAPTER
121 STUD, ROCKER ARM
167 BOLT, FUEL LINE HOLD DOWN 213 GASKET, FLEXIBLE ADAPTER
122 ARM,ROCKER PLATE PIPE
123 BALL, ROCKER ARM 168 PLATE, FUEL LINE HOLD DOWN 214 BOLT, FLEXIBLE ADAPTER PIPE
124 NUT, ROCKER ARM 169 STUD, FUEL RAIL ASSEMBLY 215 MANIFOLD, EXHAUST - RIGHT
125 VALVE, INTAKE 170 HARNESS, FUEL INJECTOR RAIL 216 GASKET, EXHAUST MANIFOLD
126 SEAL, INTAKE VALVE STEM 171 STUD, FUEL RAIL HARNESS 217 SENSOR,OXYGEN
127 DAMPER, SPRING 172 HARNESS, VACUUM 219 WIRES, SPARK PLUG - RIGHT
128 SPRING, VALVE 173 HOSE, FUEL PRESSURE 220 WIRES, SPARK PLUG - LEFT
129 0-RING REGULATOR VACUUM 221 PLUG, SPARK
130 CAP, SPRING 175 LINE, FUEL 222 SYSTEM, ELECTRONIC IGNITION
131 KEY 176 SCREW, FUEL LINE RETAINING 223 COIL, ELECTRONIC IGNITION
132 VALVE, EXHAUST 177 SCREW, EVAP CANISTER PURGE 224 BRACKET, REAR POWER
133 SHIM - SELECTIVE 178 CANISTER PURGE, EVAP STEERING PUMP
134 DAMPER, SPRING 179 HOSE, SECONDARY AIR 225 PUMP, POWER STEERING
135 SPRING, VALVE INJECTION 226 NUT, ELECTRONIC IGNITION
136 0-RING 180 VAL VE, AIR CHECK SYSTEM
137 SHEDDER, OIL 181 PIPE, SECONDARY AIR 227 BRACKET, POWER STEERING
138 CAP, SPRING INJECTION PUMP
139 KEY 182 PIPE, SECONDARY AIR 228 BOLT, POWER STEERING PUMP
INJECTION BRACKET
140 STUD,LOWERINTAKE
MANIFOLD 183 BOLT, AIR PIPE 229 PULLEY, POWER STEERING
184 NUT, AIR PIPE PUMP
141 GASKET, LOWER INTAKE
MANIFOLD 185 CLAMP, AIR HOSE 230 BOLT, POWER STEERING PUMP
142 MANIFOLD, LOWER INTAKE 186 HOSE, SECONDARY AIR 231 SHIELD, SPARK PLUG WIRING
143 NUT, LOWER INTAKE MANIFOLD INJECTION 232 NUT, SPARK PLUG WIRING SHIELD
144 BOLT, LOWER INTAKE MANI- 187 CAP, OIL FILL
FOLD 188 TUBE, OIL FILL
145 SENSOR, COOLANT 189 SCREW, OIL FILL TUBE
TEMPERATURE 190 VALVE, PCV
146 BOLT, THERMOSTAT HOUSING 191 GROMMET
147 HOUSING, THERMOSTAT 192 NUT, VALVE ROCKER COVER
148 THERMOSTAT 193 REINFORCEMENT, VALVE
149 NIPPLE, HEATER INLET ROCKER COVER

RC0014·6A2B·F·RA

Figure 4 Legend View 2

6A2B-6 3.4 LITER V-6 VIN CODES UNIT REPAIR
GENERAL DESCRIPTION
ENGINE CONSTRUCTION
Figures 1 through 4
Cylinder Block
The cylinder block is made of cast alloy iron and
has six cylmders arranged in a "V" shape with three
cylinders in each bank. The cylinder banks are set at a
60° angle from each other.
The right bank cylinders are (1,3,5) and the left
bank cylinders are (2,4,6).
Four main bearings support the crankshaft
which is retained by bearing caps that are machined
with the block for proper alignment and clearances.
Cylinder Head
The cast iron cylinder heads have individual in-
take and exhaust ports for each cylinder. Valve guides
are integral, and rocker arms are retained on individ-
ual threaded studs with locking nuts.
Crankshaft and Bearings
The crankshaft is cast nodular iron with deep
rolled fillets on all six crankpins and all four main
journals. Four steel-backed aluminum bearings are
used, with the #3 bearing being the end-thrust bear-
ing.
Camshaft and Drive
The camshaft is cast alloy iron with tapered
13.2 mm wide lobes, offset from the lifters and ta-
pered to provide positive valve lifter rotation. The
camshaft 1s supported by four journals and includes an
oil pump drive gear.
Pistons and Connecting Rods
The pistons are cast aluminum with steel struts
using two compression rings and one oil control ring.
The piston pin is offset 0.8 mm towards the major
thrust side. This allows a gradual change in thrust
pressure against the cylinder wall as the piston travels
its path. Pms are chromium steel and have a floating
fit m the pistons. They are retained in the connecting
rods by a press fit.
Connecting rods are made of forged steel. Full
pressure lubrication is directed to the connecting rods
by drilled oil passages from the adjacent main bearing
journal.
Valve Train
A very simple ball-pivot and rocker type valve
train is used. Motion is transmitted from the camshaft
through the hydraulic lifter and J?Ushrod to the rocker
arm. The rocker arm pivots on its ball and transmits
the camshaft motion to the valve. The rocker arm ball
locates on a stud, threaded into the head, and is re-
tained by a nut. The pushrod is located by a guide
plate held under the rocker arm stud, assuring that the
rocker arm operates in the plane of the valve.
Intake Manifold
The intake manifold is a two-piece cast alumi-
!}~m unit. It centrally supports a fuel rail with six fuel
m1ectors.
Exhaust Manifolds
The exhaust manifolds are cast nodular iron.
ENGINE LUBRICATION
Figures 5 through 8
Full pressure lubrication, through a full flow oil
filter is furnished by a gear type oil pump. Oil is
drawn up through the pickup screen and tube, and
passed through the pump to the oil filter.
_Th~ oil filter is .a full flow paper element unit.
An 011 filter bypass 1s used to ensure adequate oil
supply, should the filter become plugged or develop
excessive pressure drop. The bypass is designed to
open at 69-83 kPa (10-12 psi).
A new priority oil delivery system supplies oil
first t_o the crankshaft journals. The passages supply-
mg 011 to the crankshaft main bearings also supply oil
to ,the camshaft bearings through intersecting vertical
dnlled holes. Oil from the crankshaft main bearings is
supplied to the connecting rod bearings by means of
intersecting passages drilled in the crankshaft. The
front cam bearing has a 0.25 mm deep slot on its
outside diameter to supply oil to the cam sprocket
thrust face, and oil passages from the camshaft jour-
nals supply oil to the hydraulic lifters.
The hydraulic lifters pump oil up through the
pushrods to the rocker arms. Oil drainmg back from
the rocker arms is directed by cast dams m the crank-
case casting to supply the camshaft lobes. Oil also
drains past SJ?ecific hydraulic lifter flats to oil cam-
shaft lobes directly.
DISASSEMBLV
FLYWHEEL
Figure 9
E3 Remove or Disconnect
1. Retainer bolts (36) and retainer.
2. Flywheel (33).
DRAINING THE ENGINE
!+ •! Remove or Disconnect
1. Oil drain plug (9) and drain engine oil.
2. Oil filter (45).
3. Coolant drain plugs (69 and 70) and drain
coolant.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-7

7 :
----~

P0101·6A2B·F·RA

Figure 5 Engine Lubrication View 1 of 4

6A2B·8 3.4 LITER V-6 VIN CODE S UNIT REPAIR

P0102·WB-F·RA

Figure 6 Engine Lubrication View 2 of 4

 LUBRICATION ENDy:··
154° B.T.D.C. -~'-"'-~
,r I L~I\
BEGINNING OF
LUBRICATION
::!'!
cc
c:
....
CD
~

m END OF
::,
cc VIEW IN DIRECTION OF LUBRICATION
::, ARROW C
CD
FOR CYL'S 2, 4 & 6
F
O'"
::::!.
0
Ql
~-
0
::, BEGINNING OF
LUBRICATION w
:5 :si.
CD
:E r-
w =i
m
s. ::D
~
~
<
LUBRICATION ENDS
190° DURATION
OF LUBRICATION
z
134° B.T.D.C. n
0

END OF
\ IC
m
Cl)

i=i
LUBRICATION
~ ~
2 FOR CYL'S 1, 3 & 5 m
E VIEWS SHOWING INTERMITTENT OILING OF ;:
'!" CONNECTING ROD BEARING THROUGH GROOVE :ij
i ON UPPER HALF OF MAIN BEARINGS.
~
m
co
6A2B-10 3.4 LITER V-6 VIN CODES UNIT REPAIR

P0104·6A2B·F·RA

Figure 8 Engine Lubrication View 4 of 4

 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-11

33A

22 CRANKSHAFT
33A FLYWHEEL (AUTOMATIC) TRANSMISSION
338 FLYWHEEL, MANUAL TRANSMISSION
22
34 RETAINER (AUTOMATIC) TRANSMISSION
35 PIN, FLYWHEEL MANUAL TRANSMISSION
338
36 BOLT, FLYWHEEL 35 RC0001-6A2B·F-RA

Figure 9 Flywheel

UPPER INTAKE MANIFOLD 11. PCV valve (190).

12. EGR flexible tube bolts at upper intake manifold
Figure 10 and 11 (155).
E3 Remove or Disconnect
13.
14.
MAP sensor electrical connector.
Upper intake manifold bolts (156).
1. Throttle body heater hose clamps (152) and 15. Upper intake manifold (155) and gasket (154).
hoses (153).
2. Fuel line clamp bolts ( 176 and 177). VALVE ROCKER COVER
[I] Important Figure 12
• The fuel line hold down plate and pivot bolt are
part of the fuel rail assembly. Do not remove the
E3 Remove or Disconnect
pivot bolt. 1. Nuts (192) and reinforcements (193).
3. Fuel line hold down plate bolt (167). 2. Valve rocker cover (194) and gasket (195).

• Rotate fuel line hold down plate (168) VALVE ROCKER ARM AND PUSHROD
counter-clockwise.
Figure 13
4. Fuel lines (175).
5. Fuel injector rail wiring harness retaining nut. E3 Remove or Disconnect
6. Fuel rail stud (169). 1. Rocker arm nuts (124).
7. Fuel pressure regulator vacuum hose (173).
• Place valve train parts in a rack so that
8. Coolant sensor electrical connector. they can be installed in the same location
9. Blow dirt out of injector bores with compressed which they were removed.
air.
2. Rocker arms (122) and balls (123).
10. Fuel injector rail assembly (166).
3. Pushrods (93).
• Pry carefully on injector rail (166).
Remove injectors one side at a time.
6A2B-12 3.4 LITER V-6 VIN CODES UNIT REPAIR

155 MANIFOLD, UPPER INTAKE

166 RAIL ASSEMBLY, FUEL INJECTOR
167 BOLT, FUEL INJECTOR
169 STUD, FUEL INJECTOR

00006-6A2B-F-RA

Figure 10 Fuel Injector Rail

__J----156

155

142 MANIFOLD, LOWER INTAKE

154 GASKET, UPPER INTAKE MANIFOLD
155 MANIFOLD, UPPER INTAKE
156 BOLT, UPPER INTAKE MANIFOLD

142

00007·6A2B-F-RA

Figure 11 Upper Intake Manifold

 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A2B·13

192

A APPLY SEALANT AT CYLINDER HEAD TO INTAKE 194

MANIFOLD MATING SURFACE
113 HEAD, CYLINDER
193
192 NUT, VALVE ROCKER COVER
193 REINFORCEMENT, VALVE ROCKER COVER
194 COVER, VALVE ROCKER
195 GASKET, VALVE ROCKER COVER
196 STUD, VALVE ROCKER COVER

---195

POOOB-6A2B-F-RA

Figure 12 Valve Rocker Cover

LOWER INTAKE MANIFOLD VALVE LIFTERS

Figure 14 Figure 13

E3 Remove or Disconnect E3 Remove or Disconnect

1. Retaining bolts (144) and nuts (143). 1. Valve lifters (94).
2. Lower intake manifold (142) and gaskets (141).
6A28-14 3.4 LITER V-6 VIN CODES UNIT .REPAIR

93 PUSH ROD
113 HEAD, CYLINDER
121 STUD, ROCKER ARM
122 ARM, ROCKER
113
123 BALL, ROCKER ARM
124 NUT, ROCKER ARM

P0009-6A2B·f·RA

Figure 13 Valve Rocker Arms and Pushrods

EXHAUST MANIFOLD 6. AIR pipe fitting from right exhaust manifold, if

equipped.
Figures 15 and 16 7. AIR pipe retaining nut (184) and bolt (183), if
E3 Remove or Disconnect 8.
equipped.
Secondary air injection pipe assembly, if
1. Serpentine drive belt. equipped.
2. Rear A/C compressor bracket mounting bolts 9. Exhaust manifold retaining bolts (102 and 202).
and bracket. 10. Exhaust manifolds (105 and 215) and heat
3. Generator pencil brace bolts and braces. shields (103, 104, 203 and 205).
4. A/C compressor and generator mounting 11. Exhaust manifold gaskets (106 and 216).
bracket bolts.
5. A/C compressor and generator mounting
bracket.
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A2B-15

8 4 5 9

7 3 2 6 10
B

A APPLY SEALANT
B TIGHTENING SEQUENCE
113 HEAD, CYLINDER
140 STUD, LOWER INTAKE MANIFOLD
141 GASKET, LOWER INTAKE MANIFOLD
142 MANIFOLD, LOWER INTAKE
143 NUT, LOWER INTAKE MANIFOLD
144 BOLT/STUD, LOWER INTAKE MANIFOLD

P0010·6A2B-F-RA

Figure 14 Lower Intake Manifold

OIL PAN
Figure 17

E3 Remove or Disconnect
1. Oil pan nuts (11) and reinforcements (10).
2. Oil pan bolts (12) and studs (13).
3. Oil pan (1) and gasket (2).
6A2B-16 3.4 LITER V-6 VIN CODE S UNIT REPAIR

202

113 HEAD, CYLINDER

202 BOLT, EXHAUST MANIFOLD
203 SHIELD, HEAT
205 SHIELD, HEAT
215 MANIFOLD, EXHAUST
216 GASKET, EXHAUST MANIFOLD
RC0002·6A2B-F-RA

Figure 15 Exhaust Manifold - Right

ELECTRONIC IGNITION MODULE I+ +j Remove or Disconnect

Figure 18 1. Power steering pump pulley (229) using
J 25034-B and J 25034-5.
Tools Required: 2. Power steering pump bracket retaining bolts.
J 25034-B Power Steering Pump Pulley 3. Power steering pump bolts (228) and pump
Remover (225).
J 25034-5 Adapter 4. Electronic ignition module nuts (226) and
electronic ignition module (223).
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-17

111

102

103

102

102 BOLT/STUD, EXHAUST MANIFOLD

103 SHIELD, HEAT
104 SHIELD, HEAT
105 MANIFOLD, EXHAUST
106 GASKET, EXHAUST MANIFOLD
111 SENSOR, OXYGEN 102
113 HEAD, CYLINDER

102
P0012-6A2B·F·RA

Figure 16 Exhaust Manifold - Left

COOLANT PUMP TORSIONAL DAMPER

Figure 76 Figure 19

E3 Remove or Disconnect
Tool Required:
J 24420-B Torsional Damper Remover
1. Power steering pump mounting bracket bolts

2.
(230) and bracket (227).
Coolant pump pulley bolts (49) and pulley (50).
E3 Remove or Disconnect

3. Coolant pump bolts (51, 52 and 53). 1. Torsional damper bolt (30) and washer (29).
4. Coolant pump (54) and gasket (55). 2. Crankshaft pulley bolts (31) and pulley (28).
3. Torsional damper (27) using J 24420-B.
6A2B-18 3.4 LITER V-6 VIN CODE S UNIT REPAIR

11

1 PAN, OIL
2 GASKET, OIL PAN
3 STUD, OIL PAN
10 REINFORCEMENT, OIL PAN
11 NUT, OIL PAN 12
12 BOLT, OIL PAN
13 STUD, OIL PAN
14 BOLT, OIL PAN
71 BLOCK, ENGINE

RC0003-6A2B-F-RA

Figure 17 Oil Pan

ENGINE FRONT COVER CAMSHAFT

Figure 73 Figure 69

E3 Remove or Disconnect E3 Remove or Disconnect

1. Engine front cover bolts (59). 1. Oil pump driven gear hold down clamp bolt (91)
2. Engine front cover (60) and gasket (61). and clamp (92).
2. Oil pump driven gear assembly (90).
TIMING CHAIN AND SPROCKETS
NOTICE: Camshaft journals are all the same
Figure 20 diameter so care must be used when removing the
camshaft to avoid bearing damage.
Tool Required:
3. Camshaft (100).
J 5825-A Crankshaft Sprocket Remover
• Install three 4-inch bolts in the camshaft
E3 Remove or Disconnect bolt holes.
• Carefully rotate and pull the camshaft
1. Cam sprocket bolts (97). (100) out of the camsliaft bearings.
2. Cam sprocket (98) and timing chain (25).
3. Crankshaft sprocket (26) using J 5825-A.
4. Timing chain damper bolts (62) and damper
(63).
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-19

222

71 BLOCK, ENGINE
222 MODULE, ELECTRONIC IGNITION
226 NUT, ELECTRONIC IGNITION MODULE

226 P0014·6A2B-F-RA

Figure 18 Electronic Ignition Module

J 5825-A

J24420-B~
24 KEY
26 SPROCKET, CRANKSHAFT
71 BLOCK, ENGINE
27 DAMPER, TORSIONAL RC0004-6A2B·F·RA RC0005·6A2B·F·RA

Figure 19 Torsional Damper Removal Figure 20 Crankshaft Sprocket Removal

6A2B·20 3.4 LITER V-6 VIN CODE S UNIT REPAIR

CYLINDER HEAD
Right
Figure 68

E3 Remove or Disconnect
1. Pencil brace bracket bolts.
2. Cylinder head bolts (115).
3. Cylinder head (113) and gasket (112).
Left
Figure 68

E3 Remove or Disconnect
1. Power steering pump stud and bracket (224).
2. Power steering pump brace nut (39), stud (37)
and brace (38). ·
3. Oil level indicator tube nut (47).
4. Engine lift bracket bolts (119 and 120) and
bracket (118).
5. Engine coolant temperature sensor (114).
6. Cylinder head bolts (115).
7. Cylinder head (113) and gasket (112).
OIL PUMP
Figure 21

E3 Remove or Disconnect 16
17
BOLT, OIL PUMP
PUMP, OIL
1. Oil pump bolt (16). 18 ROD, DRIVE
2. Oil pump (17) and drive rod (18). 20 CAP, MAIN BEARING
71 BLOCK, ENGINE
RC0006-6A2B-F-RA

Figure 21 Oil Pump

 3.4 LlJER V·6 VIN CODE S UNIT REPAIR .6A2B-21

PISTON ANO CONNECTING ROD

Figure 22

E3 Remove or Disconnect
1. Mark the piston (86) with the number of the
cylinder from which it is being removed.
2. Mark the connecting rod (83) and the rod cap
(81) so that they can be assembled correctly.
3. Turn the crankshaft (22) to bottom dead center.
~ Clean
• Carbon from the top end of the cylinder.
4. Connecting rod nut (80) and cap (81).
NOTICE: If there is a pronounced ridge at the
top of the piston travel, this ridge must be re-
moved with a ridge reamer before removing pis-
ton and connectmg rod assembly. Do not use
force. Avoid breakmg piston rings and damaging
the piston.
NOTICE: Install thread protector to avoid dam-
age to the crankshaft journal.
5. Connecting rod (83) and piston assembly (86).
Push out with a smtable tool.

A USE A SHORT PIECE OF

3/8" HOSE AS A GUIDE P0018-6A2B·F-RA

A ASSEMBLE WITH ARROWS ON

Figure 22 Connecting Rod Protector
CAP TOWARD FRONT OF ENGINE

CRANKSHAFT 19 BOLT, MAIN BEARING CAP

20 CAP, MAIN BEARING
Figure 23 22 CRANKSHAFT
23 BEARING, MAIN
E3 Remove or Disconnect 71 BLOCK, ENGINE

1. Main bearing cap bolts (19).

2. Main bearing caps (20) a.nd lower bearing
halves (23).
3. Crankshaft (22).
RC0007·8A2B·F·RA
'4. Upper bearing halves (23).
Figure 23 Crankshaft
6A2B·22 3.4 LITER V-6 VIN· CODE S UNIT REPAIR

REAR MAIN SEAL CLEANING, INSPECTION AND REPAIR

E3 Remove or Disconnect CYLINDER BLOCK
Figures 25 through 30
1. Rear main seal from crankshaft (32).
Tool Required:
CAMSHAFT BEARINGS J 8087 Cylinder Bore Checking Gage
Figure 24
Tool Required:
1±) Disassemble
1. Oil filter adapter bolt (43).
J 33049 Camshaft Bearing 2. Oil filter adapter (41) and gasket (40).
Remover/Installer
3. Knock sensor.
E3 Remove or Disconnect 4. Ignition timing sensor retaining bolt (66) and
sensor (67).
1. Camshaft cover bolts (77), cover (76) and 5. Camshaft sensor retaining bolt (95).
gasket (75).
6. Camshaft sensor (96).
2. Camshaft bearings (101).
7. Coolant jacket plugs (74).
A. Select the proper expander assembly and 8. Coolant jacket threaded plugs (69 and 70).
driving washer.
9. Oil gallery plugs (64, 65, 78 and 79).
B. Assemble J 33049. Tighten the expander
assembly snug with the camshaft bearing.
C. Drive out bearings.
rn Important
IT] Important • Caustic cleaning solution destroys the bearing
material. All bearings must be replaced after
• Camshaft bearings (101) must not be re-used cleaning with a caustic ~olution. Do. not cle~n
after they have been removed. bearing material or alummum parts with caustic
solutions.
c
~ Clean
• Sealing material from mating surfaces.
• Boil in caustic solution.
- Flush with clean water or steam.
• Oil passages.
• All blind holes.
• Spray or wipe cylinder bores and machined
surfaces with engme oil.

A EXPANDER ASSEMBLY D DRIVE BAR

!L•! Inspect
• Check surface for flatness. Use a straight edge
B BEARING, CAMSHAFT E GUIDE CONE
and a feeler gage (Figure 26). If the cylinder
C DRIVING WASHER F DRIVE BAR HANDLE head deck flatness exceeds O. lmm (0.004 inch),
P0019-6A5B-ALNW-RA the surface should be machined flat. If more than
0.25 mm (0.010 inch) must be removed, replace
Figure 24 Removing/Installing Camshaft Bearings the block.
• Oil pan rail and timing cover attaching area for
nicks. Minor irregularities may be deaned up
with a flat mill file.
• Head bolt tapped holes.
• Transaxle case mating surface.
NOTICE: If this surface is not flat, a broken
flywheel may result.
• Temporarily install the crankshaft. Measure
crankshaft flange run-o~t. Refer to "Crankshaf(
in Cleaning, Inspection and Repau of this
section.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B·23

64
65

\
1
6 9 - - -...
71

I VIEWA I

71

64 PLUG, OIL GALLERY - 1/8" 71

65 PLUG, OIL GALLERY - 1/4"
69 PLUG, COOLANT DRAIN
70 PLUG, COOLANT DRAIN
71 BLOCK, ENGINE I VIEW BI
78 PLUG, OIL GALLERY - 1/4"
79 PLUG, OIL GALLERY - 3/8"
RC0017·6A28-F-RA

Figure 25 Engine Block

!4U Measure
A STRAIGHT EDGE • Cylinder block flange surface runout at six
B FEELER GAGE mounting hole bosses (Figure 27).
'1. Hold gage plate flat against the crankshaft
flange (Figure 27).
2. Place dial indicator stem on the transaxle
mounting bolt hole boss (Figure 28) and
set indicator to 0.
3. Take and record the readings obtained on
the remaining transaxle mounting bolt hole
A bosses (Items A-F, Figure 27).
P0085-&A6B-ALNW·RA Measurements should not vary more than
0.25 mm (0.010 inch).
Figure 26 Measuring Cylinder Block for Flatness
4. If the readings vary more than 0.25 mm
(0.010 inch), recheck crankshaft flange
run-out. If the run-out is excessive, replace
the crankshaft.
6A2B·24 3.4 LITER V-6 VIN CODES UNIT REPAIR

2. Camshaft and Crankshaft bearing bores,· using

J 8087, measure concentricity and alignment.
3. Cylinder bore, with J 8087 measure for wear,
taper, run-out and ridging (Figures 29 and 30).
• If the bore is worn out of specifications, it
may be rebored, honed and fitted with
oversize pistons. The smallest available
oversize should be selected. Refer to
"Pistons and Connecting Rods" in
Cleaning, Inspection and Repair of this
section. -
rn Important
• Leave sufficient material to allow finish
honing in conjunction with fitting the
piston.
P0023·6A2B-F-RA
• If the bore is glazed but otherwise
serviceable, break. the glaze lightly with a
Figure 27 Transaxle Mounting Surface Checking
Points
hone and replace the piston rmgs.
• Make sure the honing stones are clean,
sharp and straight. Move the hone slowly
up and down to produce a cross-hatch
pattern. Clean bore thoroughly with soap
and water. Dry and rub in clean engine
oil; then measure.

U:

Figure 28 Measuring Transaxle Mounting Surface

Figure 29 Measuring Cylinder Bore
ll•I ·Inspect
1. Threaded holes. If necessary, clean with a tap or
drill out and install thread inserts. Refer to
"Thread Repair" in Cleaning, Inspection and
Repair of this section.
rn Important
• The following inspections as well as
reconditioning, if necessary, must be
carried out with the main bearing caps
installed and tightened to specification.
• Make sure main bearing caps are installed
correctly, with the arrows pointing toward J10286-6A-W

the front of the engine.

Figure 30 Cylinder Wear Pattern
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A28·25

THREAD REPAIR
Figure 31
Damaged threads may be reconditioned by drill-
ing out, rethreading and mstalling a suitable thread
insert.
CAUTION: Wear safety glasses to
avoid eye damage.
1. Determine size, pitch and depth of damaged
thread. If necessary, adjust stop collars on
lGl
• Crankshaft journals. With a micrometer measure
cutting tool and tap to the required depth.
[I] Important
• Refer to the kit manufacturer's
instructions regarding the size of the drill
rn •
Important
.If cracks, severe gouges or burned spots
are found, the crankshaft must be
replaced. Slight roughness may be
removed with a fine P.olishing cloth
soaked in clean engine ml. Burrs may be
removed with a fine oil stone ..
Measure
taper and run-out. If the readings are· within
specifications. Refer to "Engine Specifications''
in this section, note results for later selection of
bearing inserts. If not within limits, the
crankshaft must be replaced.

2.
and tap to be used. .
Drill out damaged thread. Clean out chips.
Refer to Figure 31-A.
rn•
Important
Note the location of main bearing high
3. Tap hole. Lubricate tap with light engine oil. spots. If they are not in line, the
Clean the thread. Refer to Figure 31-B. crankshaft is bent and must be replaced.
PISTONS AND CONNECTING RODS
[I] Important
Figures 32 through 39
• Avoid build-up of chips. Back out the tap
every few hJrns and remove chips. Tool Required:
4. Thread the thread insert onto the mandrel of the J 24086-C Piston Pin Remover/Installer
installer (Figure 31-C). Engage the tang of the
insert onto the end of the mandrel. F:3 Disassemble
5. Lubricate the insert with light engine oil (except CAUTION: Use care when handling
when installing in aluminum) and install. Refer the piston. Worn piston rings are sharp
to Figure 31-D. and may cause bodily injury.
[I] Important
1. Piston rings (87, 88 and 89). Use a suitable tool
to expand the rings. Piston rings must not be
• When correctly installed, the insert should re-used.
be flush to one turn below the surface.
2. Place the piston (86) and connecting rod (83)
6. If the tang o.f the insert does not break off when assembly into J 24086-C and press out the
backing out the installer, break the tang off with piston pm. Refer to Figure 32. Be sure the flat
a drift pin. side or inside of piston is up when installing
CRANKSHAFT piston and rod assembly into fork.
Figure 23 rn Important
~ Clean
• Make sure no load is put on piston (86)
during disassembly.
• Oil, sludge and carbon. CAUTION: Avoid inhaling fumes or
• Probe oil passages for obstructions. exposure of the skin to carburetor
cleaning fluid, as bodily injury may
IL•l Inspect result.
• Keyway.
• Threads. ~ Clean
• Piston (86), piston pin (85) and connecting rod
.• Bearing. journals and thrust surfaces for: (83) of:
Cracks.
Sludge.
Chips.
Carbon.
Gouges.
• It is essential that the piston ring
Roughness. grooves. are cleaned of carbon to the
Grooves. bare metal.
Overheating (discoloration). Varnish from the piston pin (85) by
• Corresponding bearing inserts for embedded soaking in carburetor cleaning solution.
foreign matenal and determine its source. • Do not scrape the piston skirt.
6A2B·26 3.4 LITER V-6 VIN CODE S UNIT REPAIR
A B
DRILL HOLE TO TAP HOLE TO
PROPER SIZE PROPER SIZE
Figure 31 Repairing Threaded Holes
J 24086-BA
Figure 32 Removing Piston Pin
IL•! Inspect
1. Connecting rod (83) for:
• Bending or twisting.
A. Install the connecting rod cap (81).
B. Place the connecting rod assembly
(83) on a checking fixture and check
for bending or twisting.
Do not attempt to straighten the
connecting roo.
c D
INSTALL INSERT INSTALL INSERT INTO
ON MANDREL NEWLY THREADED HOLE
J10289-6A-W
The connecting rods should not
be bent more than 0.007 inch for
every three inches of rod length.
The connecting rods should not
be twisted more then 0.0015 inch
for every inch of rod length. If
bent or twisted, replace.
- Check new connecting rods
before using them.
• Outside of the connecting rod bearing and
the ID of the connecting rod lower end for
wear indicating high spots in the
connecting rod lower end.
• Upper end for scoring.
2. Piston pin (85) for:
• Scoring.
• Galling caused by improper installation.
• Fit in connecting rod and piston.
3. Piston (86) for:
• Scoring of the skirt.
• Cracks.
• Broken ring groove lands.
• Wear.
Piston to Bore Clearance
II] Important
• When fitting pistons, both piston and cylinder
bore condit10n must be considered together.
Production and service pistons have the same
nominal weight and can be intermixed without
affecting engine balance. If n~cessary, used
pistons may f>e fitted selectively to any cylinder
• Carbon can be removed with a wire brush.
of the engine, providing they are in good
condition and the same weight.
• Do not cut oversize pistons down or engine
balance will be affected.
 3.4 LITER V~6 VIN CODE S UNIT REPAIR 6A2B-27

A GAGING POINT
B SIZING POINT

A
r
58mm
B

BORE GAGING POINTS PISTON GAGING POINTS RC0016-6A2B-F-RA

Figure 33 Cylinder Bore and Piston Gaging Points

l@I Measure
1. Piston diameter. When measuring piston for
size or taper, measurement must be made as
shown with the piston pin removed (Figure 34).
If worn or damaged, replace with a standard or
oversize piston.
[TI Important
• Finish hone when selecting piston.
2. Cylinder bore (Figure 33), with a telescoping
gage. If "".om beyond specifications, rebore and
hone to size.
3. Subtract piston diameter from cylinder bore
diameter to determine piston-to-bore clearance.
4. Compare piston-to-bore clearance with
specifications in "Engine Specifications" of this P01CI0-6A2B-F-RA
section to determine if clearance is in acceptable
range. Figure 34 Measuring Piston
5. If used piston is not acceptable, check service
piston sizes and determine if a new piston can be Piston Pin Bore-to-Piston Pin Clearance
selected. (Service pistons are available in
standard, and several oversizes.) l@I Measure
6. If cylinder bore must be reconditioned, measure 1. Measure the piston pin bore diameter with an
new piston diameter then hone cylinder bore to inside micrometer.
correct clearance.
2. Measure the piston pin diameter with a
7. Select new piston and mark piston to identify micrometer.
the cylinder for which it was fitted.

3. Subtract piston pin bore diameter from piston

pin diameter to determine clearance.
4. Compare clearance with Specifications in
"Engine Specifications" of this section to
determine if clearance is in acceptable range.
5. If it is not acceptable, replace piston assembly.
6A2B·28 3.4 LITER V-6 VIN CODES UNIT REPAIR

Piston Compression Ring End Gap

(I] Important
.• Do not reuse piston rings. Fit rings to match the
cylinder they will be used in.

ICiil Measure
1. Place piston into the cylinder at the bottom of
the ring travel. 89 TOP COMPRESSION RING
2. Place a piston ring on top of the piston. A INSERT FEELER GAUGE AT TOP OF
RING GROOVE TO MEASURE RING SIDE
3. Back off the piston. CLEARANCE P0026-6A2B-F-RA
4. Measure the ring gap (Figure 35). If the gap is
below specification, increase the gap by Figure 36 Measuring Piston Ring Side Clearance
carefully filing off excess material.

A FEELER GAUGE
r!i Assemble
Important
89 PISTON RING • Make sure that the arrow on top of the piston
MEASURE RING GAP CLEARANCE WITH RING faces towards the front of the engine.
POSITIONED AT BOTTOM RING TRAVEL AS SHOWN
1. Place piston (86) and connecting rod (83) into
J 24086-B (Figure 37).
2. Coat the piston pin (85) with clean engine oil.
3. Press the piston pin (85) into place.
IL•I Inspect
• Piston (86) for freedom of movement.

Figure 35 Measuring Piston Ring Gap

Piston Ring Side Clearance

(I] Important
• Do not attempt to cut the ring groove, although
high spots in the ring groove may be cleaned up
by careful use of a point file.

ICiif Measure
1. Piston compression ring side clearance. RC0009·6A5B-ALNW-RA
2. Roll the piston ring around the groove in which
it is to be installed and measure the side Figure 37 Installing Piston Pin
clearance (Figure 36). If the ring is too thick, try,
another ring. Refer to "Engine Specifications '
in this section for specifications.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-29

89
Q ENGINE LEFT
c
ENGINE FRONT ENGINE RIGHT ~

B - - -...

c-- --AD

85 86
A OIL RING SPACER GAP
(TANG IN HOLE OR SLOT WITH ARC)
B OIL RING RAIL GAPS
C 2ND COMPRESSION RING GAP
D TOP COMPRESSION RING GAP P002B·&A2B·F·RA

Figure 39 Piston Ring Gap Locations

83 ROD - CONNECTING
84 BOLT MAIN BEARING AND ROD BEARING
85 PIN - PISTON SELECTION
86 PISTON ASM.
87 RING-OIL CONTROL Figures 40 through 42
88 RING - PISTON COMP. LWR.
80 Evaluate bearings as specified in this section. If
89 RING - PISTON COMP. UPR.
the engine is out of the vehicle and upside down, the
P0027·6A2B·F-RA crankshaft will rest on the upper bearings and the total
clearance can be measured between the lower bearing
Figure 38 Piston and Rod Assembly and journal. If the engine is to remain in the vehicle,
the crankshaft must tie supported upward to remove
4. Oil control ring assembly (87). any clearance from the upper bearing. The total clear-
ance can then be measured between the lower bearing
• Expander. and journal.
• Lower oil control ring. Engine bearings are of the precision insert type.
• Upper oil control ring. They are available for service use in standard and
NOTICE: Use a piston ring expander to install various undersizes (Figure 40).
the rings. Avoid expanding the rings more than NOTICE: Bearing inserts must not be
necessary, which may cause ring damage. shimmed, scraped or filed. Do not touch the bear-
5. Upper and lower compression ring (88 and 89). ing surface of the insert with bare fingers. Skin
Manufacturer's mark facing up. oil and acids will etch the bearing surface.

(I] Important
• In order to provide an effective
compression seal, the ring gaps must be
staggered (Figure 39). A A AMOUNT UNDERSIZE
STAMPED AT EITHER
END (.016, .032)

P0029-6A2B·F·RA

Figure 40 Main Bearing Insert Markings

6A28·30 3.4 LITER V-6 VIN CODE S UNIT REPAIR
l~I Inspect
1. Bearing surfaces for:
• Wear.
• Gouges.
• Embedded foreign material. If foreign
material is found, determine its nature and
source. Inspect oil pan sludge and
residue.
• Uneven side-to-side wear. If uneven wear
is found, check for a bent crankshaft or
tapered bearing journals.
2. Outer surfaces for:
Wear. Surface wear indicates either
• run-out.
movement of the insert or high spots in
the surrounding material (spot wear).
• Overheating (discoloration).
• Looseness or rotation (flattened tangs and
wear grooves). . 1. Measure the journal diameter with a micrometer
3. Thrust surfaces (main thrust bearing) for:
• Wear.
• Grooving. Grooves are caused by
irregulanties of the crankshaft thrust
surface. Refer to "Crankshaft" in
Cleaning, Inspection and Repair of this
section.
m Important
• Bearing failure, other than normal wear,
must be investigated carefully. Inspect the
crankshaft or connecting rod and the
bearing bores.
4. Connecting rods or main bearing bores as
follows:
A. Tighten the bearing cap to specifications.
B. Measure the bore for taper and out of
round (Figure 41).
C. No taper or out of round should exist.
J 8087
71 BLOCK, ENGINE RC0020·6A2B·f·RA
Figure 41 Measuring Bearing Bore
l@l Measure
• Bearing clearance. To determine the correct
replacement insert size, the bearing clearance
must be measured accurately. Either of the
following two methods may be used, however,
method "A" gives more reliable results and is
preferred.
[]] Important
• Method "A" yields measurement from
which the bearing clearance can be
computed. Method "B" yields the
bearing clearance directly. Method "B"
does not give any indication of bearing
• Do not mix inserts of different nominal
size in the same bearing bore.
Method "A"
in several places, approximately 90° apart, and
average the measurements.
2. Measure taper and run-out. Refer to "Engine
Specifications" for allowable limits.
3. Install bearing inserts and tighten bearing cap
bolts or nuts to specification. Measure ID with
an inside micrometer.
LI] . Important
• The bearing cap must be tightened t_o
specification wlien the measurement 1s
taken.
• Measure the connecting rod ID in the
same direction as the length of the rod.
4. Select a set of bearing inserts that will produce
the desired clearance, refer to "Engine
Specifications" in this section. If the specified
ckarances cannot be met, the crankshaft journal
must be re-conditioned and undersized bearing
inserts installed. Replace both bearing shells
as a set.
11
Method 8"
Tool Required:
J 36660 Torque Angle Meter
1. Clean and install the used bearing inserts.
2. Place a piece of gaging plastic across the entire
bearing width.
NOTICE: In order to prevent the possibility of
cylinder block and/or main bearing cap damage,
tlie main bearing caps are to be tapped into their
cylinder block cavity using a brass or leather mal-
let before attaching bolts are installed. Do not use
attaching bolts to pull main bearing caps into
their seats. Failure to observe this mformation
may damage a cylinder block or bearing cap.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-31

3. Seat the bearing cap carefully by tapping it 3. Pump cover bolts and cover.
lightly with a suitabfe tool. 4. Pump gears.
4. Bearing cap bolts or nuts.
CAUTION: The pressure regulator
l~I Tighten
valve spring in some models is under
pressure. Exercise caution when remov-
• Main bearing cap bolts (19) evenly to ing the retaining pin, as bodily injury
50 N·m (37 lb. ft.). may result.
• Turn main bearing cap bolts (19) evenly 5. Pressure regulator valve.
an additional 77° using J 36660.
• Rod cap nuts (80) evenly to 50 N·m • Cotter pin.
(37 lb. ft.). • Spring.
• Valve. If the valve is stuck, soak the
[I] Important pump housing in carburetor cleaning
• Do not rotate the crankshaft. solvent.
5. Remove the bearing cap, leaving the gaging CAUTION: Avoid breathing of fumes
plastic in place. It does not matter whether the or exposure of the skin to the cleaning
gagi!}g plastic adheres to the journal or to the solvent, as bodily injury may result.
beanng cap.
6. Measure the gaging plastic at its widest point ~ Clean
with the scale printed on the gaging plastic • All parts of sludge, oil and varnish.
package (Figure 42). • Varnish may be removed by soaking rn
7. Remove all traces of the gaging plastic after carburetor or cleaning solvent.
measuring.
8. Select a set of bearing inserts that will produce
the desired clearance refer to "Engine
IL•! Inspect
Specifications" in this section. Replace both • For foreign material and determine source.
bearing shells as a set. • Pump housing and cover for:
Cracks.
Scoring.
Casting imperfections.
Damaged threads.
Do not attempt to repair the pump housing.
If in doubt, replace the spring.
• Idler gear shaft. If loose in the housing, replace
the pump.
• Pressure regulator valve for:
Scoring.
- Sticking. Burrs may be removed with a
fine oil stone.
Figure 42 Measuring Bearing Clearance
• Pressure regulator valve spring for:
OIL PUMP UNIT REPAIR - Loss of tension.
Figure 43 through 48 - Bending.
Tool Required: • Suction pipe and screen assembly for:
J 21882 Oil Suction Tube Installer Looseness, if permanently pressed into the
pump body. If the suction pipe is loose,
1±) Disassemble bent or has been removed, tfie pump body
cover and suction pipe must be replaced.
1. Drain oil from pump. - Broken wire mesh or screen.
2. Drive shaft (18).
• Gears for:
II] Important Chipping.
• Do not remove pickup tube from cover Galling.
unless loose or broken. Wear.
6A2B-32 3.4 LITER V-6 VIN CODE S UNIT REPAIR

• Drive sbaft and drive shaft extension for: IL•I Inspect

Looseness. 1. Oil pressure as follows:
- Wear. A. Prime engine oil galleries by removing
engine oil pump drive unit and rotate 011
l@I Measure pump drive shaft using drill motor and
appropriate socket and extension.
Figures 44 through 48
B. Remove the oil pressure sending unit and
• Refer to "Engine Specifications" in this section install a pressure gage.
for Specifications.
NOTICE: If the oil pressure does not build up
• Gear lash. Install gears, and measure in several almost immediately, remove the oil pan and
places (Figure 44). check oil pump suction pipe attachment to the
• Pump housing gear pocket (Figure 45). pump. Running the engine without measurable
• Gears (Figure 46). oil pressure will cause extensive damage.
• Gear side clearance (Figure 47).
A PUMP BODY
• Gear end clearance (Figure 48). B IDLER GEAR AND DRIVE GEAR

[I] Important
C
D
PUMP COVER
PRESSURE REGULATOR VALVE
• When deciding pump serviceability based E PRESSURE REGULATOR SPRING
on end clearance, consider depth of wear
pattern in the pump cover.

l+:+I Assemble
1. Lubricate all internal parts with engine oil
during assembly.
A
2. Pump gears. E
NOTICE: To avoid engine damage, use only
WI
f~i-~
original equipment gaskets. The gasket thickness
is critical to proper functioning of the pump. D

3. Cover and gasket. G

l~I Tighten
Figure 43 Oil Pump

• Pump cover bolts to 10 N·m (89 lb. in.).

4. Pressure regulator valve and spring.
[I] Important
• Make sure the cotter pm is properly
secured.
5. Cotter pin.
6. Apply seal~r GM p/n 1950026 (or ~quivalent),
to a new pipe, and tap mto place with a plastic
hammer, using J 21882.
[I] Important
• Whenever the oil pump is overhauled,
clean the oil pan of oil and sludge; replace
the oil filter; and fill crankcase with clean
oil.
Figure 44 Measuring Oil Pump Gear Lash
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A28-33

A DEPTH OF POCKET
B DIAMETER OF POCKET
A

P0032·6A2B-F-RA

Figure 45 Measuring Oil Pump Gear Pocket Figure 48 Measuring Oil Pump End Clearance

CYLINDER HEAD RECONDITIONING

P0033-6A2B·F-RA
Figure 46 Measuring Oil Pump Gears
Figures 49 through 56
Tools Required:
J 8001 Dial Indicator Set
J 8062 Valve Spring Compressor.
J 8101 Valve Guide Cleaner
J 9666 Valve Spring Tester
J 37377 Valve Guide Reamer 0.089 mm
(0.003 inch) OS.
J 37378 Valve Guide Reamer 0.394 mm
(0.015 inch) OS.
J 37379 Valve Guide Reamer 0. 775 mm
(0.030 inch) OS.
[I] Important
• Before removing the cylinder head(s) from the
engine and before disassembling the valve
mechanism, perform a compression test and note
the results.
• During disassembly of the cylinder head, be sure
that the valve train components are kept together
and identified so that they can be installed in
their original locations.

!•:3 Disassemble
1. Spark plugs (221 ).
2. Right cylinder head engine lift hook bolts (201).
3. Engine lift hook (200).
4. Intake manifold mounting stud (140).
5. Rocker cover studs (196).
6. Compress the valve springs (128 and 135) using
J 8062.
KC0004-6A-W-RA
7. Valve locks (131 and 139).
Figure 47 Measuring Gear Side Clearance
6A2B·34 3.4 LITER V-6 VIN CODE S UNIT REPAIR

8. Valve caps (130 and 138).

9. Exhaust valve oil shedders (137).
10. Valve springs (128 and 135) and dampers ~~139
(127 and 134). 131
11. Spring shims (133), if equipped.
12. Intake valve stem oil seals (126). ~~ @----138

13. Valve stem 0-rings (129 and 136). 130~ ©--137

NOTICE: Avoid damaging the valve guide. If 129-,-----® 136

the valve stem has mushroomed due to wear from
the rocker arm, remove burrs by chamfering the
valve stem with an oil stone. Do not remove the 128----ic-,i ~
valve from the guide with a hammer and punch.
14. Valve.s (125 and 132). ~127
132
15. Rocker arm studs (121) and pushrod guide 125
plates.
16. Water jacket plugs.
~ 126
INTAKE EXHAUST

125 INTAKE VALVE 132 EXHAUST VALVE

126 OIL SEAL 134 DAMPER
127 DAMPER 135 VALVE SPRING
128 VAL VE SPRING 136 0-RING
129 0-RING 137 OIL SHEDDER
130 CAP 138 CAP
131 KEY 139 KEY P0035-liA2B-F-RA

Figure 50 Valves and Components

!L•! Inspect
• Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause:
113 CYLINDER HEAD A. Improper installation.
P0034-6A2B-F-RA
B. Loose or warped cylinder head.
Figure 49 Compressing Valve Spring C. Missing, off location or not fully seated
dowel pins.
D. Low torque on cylinder head bolts.
E. Warped case (block) surface.
F. Scratched surfaces.
G. Excessive inlet manifold torque.
H. Cracked engine block tapped holes.

~ Clean
CAUTION: Safety glasses must be
worn when using a power wire brush to
avoid damage to the eyes.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-35

1. Cylinder head bolts (115). 4. Cylinder head deck, intake and exhaust
2. Cylinder head (113). Carefully remove all manifold mating surfaces for flatness as shown
varnish, soot and carbon to the bare metal. DO in Figure 52. These surfaces may be
NOT use a motorized wire brush on any gasket re-conditioned by milling. If the surfaces are
sealing surface. "out of flat" by more than O.lmm (0.004 inch),
3. Valve guides as shown in Figure 51. the surface should be milled. If more than
0.25 mm (0.010 inch) of metal must be removed
4. Valves (125 and 132) of carbon, oil and varnish. from the head, it should be replaced.
• Remove varnish by soaking in carburetor 5. All threaded holes for damage. Threads may be
cleaning fluid. reconditioned with thread inserts. Refer to
• Do not scratch the valve stem with the "Thread Repair" in this section.
wire brush. 6. Cooling jacket plugs seating surfaces.
5. Threaded holes. 7. Valve seats for excessive wear and burned
6. Remains of sealer from plug holes. spots.
• Since the valve guide serves to support
and center the valve grinder, it is essential
that the valve guide is cleaned properly. If
ll l ll
' •••• 1, ·~l:
/Oo• ~
the valve guide requires reaming, measure
valve guide clearance to determine if an
oversized valve will be required. This
procedure must be performed before
valve seats can be reconditioned.
• If a burnt valve condition exists, it may be
necessary to recondition the valve seat. At
VALVE GUIDE CLEANER no time should there be less than 4 mm of
BT·6415 OR J·8101 valve seat material remaining after
reconditioning.
• Valve seats may be reconditioned by
grinding. Follow the grinder
manufacturer's instructions. Refer to
"Engine Specifications" in this section for
seat angles. If, after grinding, the new
seat is too wide, it may be narrowed by
using a 70° stone. The 70° stone will raise
the seat.
8. Valve stem tip for wear.
9. Valve lock (131 and 139) and oil seal grooves
for chipped or worn lands. Replace the valve if
chipped or worn.
10. Valve face for burning or cracking. If pieces are
RC0024·6A2B·f·RA broken off, inspect the corresponding piston and
cylinder head area for damage.
Figure 51 Cleaning Valve Guide 11. Valve stem for burrs and scratches. Burrs and
minor scratches may be removed with an oil
IL•I Inspect stone.
1. Cylinder head bolts (115) for damaged threads 12. Valve stem for straightness and valve head for
or stretching, and damaged heads caused by bending or distortion. Use "V" blocks. Bent or
improper use of tools. distorted valves must be replaced.
13. Valve face for grooving. If the groove is so deep
[I] Important that refacing would result in a knife edge, the
• Suspect bolts must be replaced. valve must be replaced.
2. Cylinder head (113) for cracks, especially 14. The valve face may be ground to specifications
between valve seats and in the exhaust ports. if it is otherwise in good condition. If the valve
3. Cylinder head deck for corrosion, sand particles face cannot be grounded within the limits given,
in head, and porosity. it must be replaced. Refer to "Engine
Specifications" in this section.
[I] Important 15. Valve spring dampers (127 and 134) for broken
• Do not attempt to weld the cylinder head, pieces or cracks. Replace if damaged.
replace it.
6A2B-36 3.4 LITER V-6 VIN CODE S UNIT REPAIR

16. Valve springs (128 and 135).

• Free length.
• Spring ends. If they are not parallel, the
spring is bent and must be replaced.
• Spring tension (load open and load
cfosed). If below specification, replace.
• For cracks or breaks.
17. Valve spring seating surface of the spring caps
for wear, cracks or gouging. Replace as
required.

A B

MC0044-6A7-W-RA

Figure 54 Checking Valve Spring Tension

l@I Measure
1. Valve margin after grinding valves. If the
margin is less than the minimum recommended
B STRAIGHT EDGE margin, replace the valve.
RC0021·6A2B-F-RA
2. Valve seat margin and runout. If the margin is
Figure 52 Checking Cylinder Head Flatness less than the minimum recommended margin,
replace the cylinder head.
3. Valve guide clearance.
• Insert the valve into its guide. Lift it 2 mm
(118 inch) off the seat and move it side to
side, measuring the amount of movement
with a dial indicator, or
NOT MORE THAN 1116" •• ·.·
VARIANCE WHILE • With a hole gage, measure the valve guide
ROTATING SPRING ID, then measure the valve stem with a
micrometer and compare the clearance.
• Refer to "Engine Specifications" in this
section for allowable clearances.
NOTICE: Avoid breaking reamer flutes or jam-
ming the reamer into the valve guide due to pack-
ing of chips or carbon. Clean the valve guides
before reaming.
• The valve guides may be reamed oversize and an
K37898-6A7-JN oversized valve installed (Figure 56).
Figure 53 Checking Valve Springs
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-37

• Clean all traces of Prussian blue. Apply a

dab of Prussian blue on the valve seat and
repeat the check. The traces of Prussian
blue transferred to the valve indicates
valve run-out. Recondition valve seat/face
or replace valves as required.
5. Intake valve stem oil seals (126).

m •
Important
Push the valve stem seals down as far as
possible. If oversize valves have been
mstalled, oversized valve stem must be
used.
Fi.gure 55 Measuring Valve Guide Clearance A. Use plastic sleeve provided.
B. Press over valve guide boss.
6. Spring shim (133), if required.
7. Valve stem 0-rings (129 and 136).
J 37377, J 37378, 8. Valve spring dampers (127 and 13~) and springs
OR J 37379 ~-~ (128 and 135).
9. Exhaust valve oil shedders (137).
10. Valve caps (123 and 138).
11. Compress the valve springs (128 and 135) using
J 38606.
12. Valve locks (131 and 139).
• If necessary, hold valve locks in place
with grease.
13. Release valve springs (128 and 135).

ll•l Inspect
• Make sure valve locks are seated.
Figure 56 Reaming Valve Guide
14. Rocker cover studs (196).
!+:+I Assemble .
l~I Tighten
1. Lightly lap the reconditioned valves into the
valve seat. • Studs (196) to 6 N·m (106 lb. in.).
2. Cooling jacket plugs. Coat plugs with sealer 15. Intake manifold mounting studs (140).
GM p/n 1050026 (or equivalent).
~ Tighten
l~J Tighten • Studs (140) to 10 N·m (89 lb. in.).
• Plug to 21 N·m (15 lb: ft.).
16. Right cylinder head engine lift hook (200) and
3. Pushrod guide plates and rocker arm studs bolts (201).
(121).

l~I Tighten
l~I Tighten
• Bolts (201) to 32 N·m (24 lb. ft.).
• Studs (121) to 46 N·m (35 lb. ft.).
NOTICE: To avoid damage, install spark plugs
4. Valves (125 and 132). (221) after the cylinder head has been installed on
lCI Measure
the engine block assembly.
• Valve run-out. Lift the valve off its seat
and apply a dab of Prussian blue on the
valve face. Seat the .valve and carefully
rotate it. The Prussian blue traces
transferred to the valve seat are an
indication of concentricity of the valve
seat.
6A2B·38 3.4 LITER V-6 VIN CODES UNIT REPAIR

CAMSHAFT INSPECTION
A CAMSHAFT JOURNALS
Figure 57 and 58 B MICROMETER
Tool Required:
J 26900-12 Dial Indicator
J 26900-13 Magnetic Base

IL•I Inspect A
• Sprocket.
• Keyway and threads.
• Bearing surfaces and lobes for:
Wear.
Galling.
Gouges. P0036-6A2B-F-RA
Overheating (Discoloration).
Figure 57 Measuring Camshaft Journals
(J] Important
• Do not attempt to repair the camshaft, replace it
if damaged.
• If a new camshaft is installed, all valve lifters
must be replaced.

1@1 Measure
1. Bearing journals.
• With a micrometer, measure diameter and
run-out. If out of specification, replace
the camshaft.
A CAMSHAFT JOURNALS
2. Camshaft lift.
A. Lubricate the camshaft bearings with GM Figure 58 Measuring Cam Lift and Journal Runout
Camshaft and Lifter Prelube p/n 1052365
(or equivalent). TIMING CHAIN AND SPROCKETS
B. Carefully set the camshaft on "V" blocks
or between camshaft centers. Figure 71
C. Install J 26900-12 and J 26900-13.
D. Measure camshaft journal runout and lobe
!L•! Inspect
lift (Figure 57 and 58). If out of • Camshaft and crankshaft sprockets (98 and 26)
specification, replace the camshaft. for wear or knicks.
• Key and crankshaft keyway for wear or knicks.
(J] Important • Timing chain (25) for wear or binding.
• If a new camshaft is being installed, add
Camshaft and Lifter Prelube GM p/n 1052365 ENGINE FRONT COVER
(or equivalent) to the engine oil. Figure 73
• Coat cam lobes with Camshaft and Lifter
Prelube GM p/n 1052365 (or equivalent). Tool Required:
J 34995 Oil Seal Installer

EE Disassemble
1. Crankshaft position sensor screws (56).
2. Crankshaft position sensor (57).
3. Front cover oil seal (58).
• Pry out carefully with a suitable tool.
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A28-39

~ Clean VALVE LIFTERS

• Engine front cover mating surfaces. Figure 59
Valve lifters should be kept in order so they may
IL•I Inspect be installed in their original position.
• Front cover oil seal (58) for damage. If the lifters are removed, they must be installed
in their original location. If replacement is necessary,
• Cracks or knicks. use lifters with a narrow flat ground along the lower
3/4 of lifter. These flats provide additional oil to the
j+:+I Assemble cam lobe and lifter surfaces. ·
1. Front cover oil seal (58) using J 34995.
2. Crankshaft position sensor (57). IL•I Inspect
3. Crankshaft position sensor screws (56). • Lifter body for wear and scuffing.
• Lifter bore for wear.
l~I Tighten • Lifter pushrod seat for wear.
• Sensor screws (56) to 9 N·m (89 lb. in.).
II] Important
OIL PAN • Whenever new valve lifters are being
installed, coat foot of valve lifters with
Figure 17 camshaft and lifter prelube GM p/n
1052365 (or equivalent).
F:3 Disassemble
1. Low oil level indicator (15).

~ Clean
• Oil ran (1) in solvent. Remove all sludge and
varnish.
• Gasket surfaces.

IL•I Inspect
• Gasket flanges for bending or damage.
• Oil pan (1) for cracks or dents.

j+:+I Assemble
1. Low oil level indicator (sensor) (15).

l~I Tighten
• Indicator (sensor) (15) to 22 N·m
(16 lb. ft.). A PLUNGER
B LIFTER BODY
2. Oil drain plug (9) and washer (8). C CHECK BALL SPRING

l~I Tighten
D
E
PLUNGER RETURN SPRING
CHECK BALL (CLOSED)
• Oil drain plug (9) to 25 N·m (18 lb. ft.). F CHECK BALL (OPEN)
93 PUSHROD
COOLANT PUMP
P0038-6A2B·F·RA
Figure 74
Figure 59 Valve Lifter Operation
~ Clean VALVE ROCKER ARMS AND PUSHRODS
• Coolant pump (54) mating surface. Figure 13

IL•I Inspect IL•I Inspect

• Rocker arms (122) and balls (123) for wear at
• Coolant pump shaft for looseness. rotation surfaces.
• Pushrod (93) ends for wear.
• Pushrod (93) for bends.
6A2B-40 3.4 LITER V-6 VIN CODE S UNIT REPAIR

VALVE ROCKER COVERS 3. Canister purge solenoid (178).

Figure 12 4. Emission control vacuum harness assembly
1±1 Disassemble
5,
(172).
Vacuum tee.
1. Oil fill tube bolt (189) and oil fill tube (188).
2. Rubber grommets. ~ Clean

~ Clean
• Gasket surfaces.
• Manifold bolts and studs.
• Valve rocker cover gasket surfaces.
IL•I Inspect l•i+I Assemble
• Gasket flanges for damage. 1. Vacuum tee.
• Rubber grommets for deterioration.
2. Emission control vacuum harness assembly
l•i+I Assemble (172).
1. Rubber grommets. 3. Canister purge solenoid (178).
2. Oil fill tube (188) and bolt (189). 4. MAP sensor screws (160) and MAP sensor
l~I Tighten 5.
(158).
Throttle body gasket (163), throttle body (164)
• Oil fill tube bolt (189) to 8 N·m and bolts (165).
(71 lb. in.).
UPPER INTAKE MANIFOLD
l~I Tighten
• Apply sealer GM p/n 1052080 to threads
Figures 11 and 60 of throttle body bolts.
1±1 Disassemble • Throttle body bolts (165) to 25 N·m (18
lb. ft.).
1. Throttle body bolts (165), throttle body (164)
and gasket (163).
2. MAP sensor screws (160) and MAP sensor
(158).
155

155 MANIFOLD, UPPER INTAKE

163 GASKET, THROTTLE BODY
164 BODY, THROTTLE
165 BOLT, THROTTLE BODY
RC0008-6A2B·F·RA

Figure 60 Throttle Body

 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-41

LOWER INTAKE MANIFOLD • Lifter valley oil gallery plugs (64) to

15 N·m (11 lb. ft.).
Figure 14
2. Coolant drain plugs (69 and 70).
1±1 Disassemble
!~! Tighten
1. Rocker cover studs (196).
2. Thermostat housing bolts (146). • Apply teflon sealant GM p/n 1052080 to
threads of plugs.
3. Thermostat housing (147) and gasket.
4. Thermostat (148). • Coolant drain plugs to 19 N·m (14 lb. ft.).
5. Engine coolant temperature sensor (145). 3. Coolant plugs (74).
6. Heater inlet hose nipple (149). • Apply sealant GM p/n 12345493 to
outside edge of coolant expansion plugs
~ Clean (74).
• Intake manifold gasket surfaces. 4. Camshaft position sensor (96).
• Injector bores. 5. Camshaft position sensor retaining bolt (95).
• Intake manifold bolts and studs.
!~! Tighten
l•t•! Assemble • Bolt (95) to 10 N·m (89 lb. in.).
1. Heater inlet hose nipple (149). 6. Ignition timing sensor (67) and retaining bolt
(66).
!~! Tighten
• Apply teflon sealant to threads of pipe !~! Tighten
nipple (149). • Bolt (66) to 9 N·m (89 lb. in.).
• Pipe nipple (149) to 30 N·m (22 lb. ft.).
7. Knock sensor (68).
2. Engine coolant temperature sensor (145).
~ Tighten
!~! Tighten
• Apply teflon sealant GM p/n 1052080 to • Apply sealer GM p/n 1052080 to threads
of knock sensor.
threads of sensor (145).
• Sensor (145) to 16 N·m (12 lb. ft.). • Knock sensor (68) to 19 N·m (14 lb. ft.).
3. Thermostat (148). 8. Oil filter adapter (41) and gasket (40).
4. Thermostat housing gasket and housing (147). 9. Oil filter adapter bolt (43).
5. Thermostat housing bolts (146).
I~! Tighten
~ Tighten • Bolt (43) to 68 N·m (50 lb. ft.).
• Thermostat housing bolts (146) to 21 N·m 10. Oil filter (45).
(15 lb. ft.).
6. Rocker cover studs (196). !~! Tighten
~ Tighten • Filter (45) to 13 N·m (115 lb. in.) or 1-1/2
turns past seal contact.
• Studs (196) to 6 N·m (106 lb. in.).
ASSEMBLY CAMSHAFT BEARINGS
CYLINDER BLOCK Figure 61
Figure 1 Tool Required:
J 33049 Camshaft Bearing
E3 Install or Connect Remover/Installer
1. Oil gallery plugs (64 and 65).
~ Tighten
E3 Install or Connect
1. New camshaft bearings (101).
• Apply teflon sealant GM p/n 1052080 to
threads of plugs. A. Select front, rear and intermediate
• Front and rear oil gallery plugs (79) to camshaft bearings.
33 N·m (24 lb. ft.). B. Select the proper expander assembly and
• Front and rear oil gallery plugs (65 and driving washer.
78) to 19 N·m (14 1b. ft.). C. Assemble J 33049.
6A2B-42 3.4 LITER V-6 VIN CODE S UNIT REPAIR
D. Place intermediate camshaft bearing onto
J 33049 and index the oil hole at 4 o'clock
when looking from the front of the engine
block. Drive the intermediate camshaft
bearings into place.
E. Instal! #4 camshaft ,bearing with the oil
hole mdexed at 4 o clock when looking
from the front of the engine block using
J 33049. ' 2.
F. Install # 1 camshaft bearing with the oil
hole indexed at 4 and 7 o'clock when
looking from the front of the engine block
using J 33049. '
IL•I Inspect
• With a piece of 3/32 inch brass rod with a 90°
ben_d at the end, probe the bearing oil holes and
venfy that they are properly aligned (Figure 61).
N~TICE: P~ol?er alignment of the oil holes is
critical. Restnctlon of the oil flow will cause se-
vere engine damage.
2. Camshaft cover gasket (75), cover (76) and
bolts (77).
l~I Tighten
• Bolts (77) to 10 N·m (89 lb. in.).
0 7.
~ installed and cap bolts started, thrust crankshaft
A 90° BEND
CHECKING OIL HOLE ALIGNMENT WITH
BRASS ROD. MAKE ROD AS SHOWN
USING 3/32" ROD ABOUT 762mm (30") LONG
P0040·6A2B·F-RA
Figure 61 Checking Camshaft Bearing Oil
Hole Alignment
CRANKSHAFT
Figure 62 and 63
I•+! Install or Connect
NOTICE: Bearing inserts must not be
~himmed, scraped o~ flled. ~o not touch the bear-
mg surface of the msert with the bare fingers.
Skin oil and acids will etch the bearing surface.
II] Important
• Make sure the bearing cap bolt holes and
the cap mating surfaces are clean and dry.
1. Dip bearing cap bolts (19) in clean engine oil.
NOTICE: Upper and lower inserts may be dif-
ferent. Do not obstruct any oil passages.
Place bearing inserts (23) into the bearing cap
(20) and into the engme block (71). Refer to
"Main. B~a!ing .and ~onnecting Rod Bearing
Select10n m this section.
II] Important
• The inserts will project slightly when put
into place. Make sure tl:iey project an
equal distance on both sides. Make sure
the insert tangs are engaged.
3. !n the case of a thrust bearing type main bearing
msert, coat the thrust surface with GM EOS p/n
1052368 (or equivalent).
4. L~bricate the bearing surface with clean engine
011.
5. Crankshaft (22).
NOTICE: In order to prevent the possibility of
cylinde_r bloc~ and/or main bearing cap damage,
the mam bearmg caps are to be tapped into their
cylinder block cavity using a brass or leather mal-
let bef~re attaching bolts are installed. Do not use
att~chmg bolts to pull main bearing caps into
theu seats. Failure to observe this mformation
may damage a cylinder block or bearing cap.
6. B~aring cap (20). Tap gently into place with a
smtable tool.
• Apply a small amount of sealer GM p/n
1052942 to the rear of rear bearing cap
sealing surface.
With crankshaft bearing and bearing caps
rearward to set and align bearing caps, then
thrust crankshaft forward to align rear face of
thrust main bearing (Figure 62).
8. Main bearing cap bolts (19).
l~I Tighten
• Main bearing cap bolts (19) evenly to
50 N·m (37 lb. ft.).
• Turn main bearing cap bolts (19) evenly
an additional 77° using J 36660.
lGI Measure
• Crankshaft end play (Figure 63).
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A2B-43

B. Turn "T" handle of J 34686 so the collar

pushes the seal into the bore. Turn handle
until the collar is tight against the cylinder
case, this will ensure the seal is seated
properly.
C. Loosen the "T" handle of J 34686 until it
comes to a stop.
D. Remove J 34686 attaching screws.

!L•I Inspect
• Check to ensure seal is seated squarely
in bore.

SPRING SIDE DUST LIP SIDE

Figure 62 Seating the Crankshaft Thrust Bearing

I J-34686

SEAL BORE TO SEAL SURFACE

TO BE LUBRICATED
WITH ENGINE OIL BEFORE
ASSEMBLY MC0018-6A4-A-RA

Figure 64 Rear Main Seal and Tool

ALIGNMENT HOLE

DUST
LIP

Figure 63 Measuring Crankshaft End Play

REAR MAIN OIL SEAL

Tool Required:
J 34686 Rear Main Oil Seal Installer
Figures 64 and 65

!++! Install or Connect

1. Apply engine oil to ID and OD of new seal.
Sfiae seal over mandrel until back of seal
bottoms sguarely against collar of tool (Figures MC0019-6A4-A-RA
64 and 65). Figure 65 Installing Rear Main Seal
2. Rear main oil seal (32).
A. Align dowel pin of J 34686 with dowel
pin in crankshaft and attach J 34686 to
crankshaft by hand or tighten attaching
screws to 5 N·m (44 lb. in.).
6A2B-44 3.4 LITER V-6 VIN CODES UNIT REPAIR

PISTONS AND CONNECTING RODS

Figures 66 and 67
Tool Required:
J 8037 Piston Ring Compressor

l++I Install or Connect

1. Lubricate cylinder wall and piston rings with
clean engine oil.
2. Turn crankshaft to bottom dead center.
3. Connecting rod stud thread protector
(Figure 22).
4. J 8037 Piston ring compressor (Figure 66).
A ARROW TOWARDS FRONT OF ENGINE
NOTICE: Guide the lower connecting rod end
86 PISTON
carefully to avoid damaging the crankshaft jour- RC0010·6A5B-ALNW·RA
nal.
5. Piston (86) and connecting rod (83) assembly. Figure 66 Piston Ring Compressor

(II Important
• Make sure that the arrow on top of the
piston faces towards the front of the
engine (Figure 66).
6. Remove thread protectors.
7. Connecting rod bearings (82). Refer to "Main
Bearing and Connecting Rod Bearing
Selection" in this section.
NOTICE: In order to prevent the possibility of
rod bolt or bearing cap damage, the bearing caps
may need to be tappeo into position with a brass
or leather mallet before attaching nuts are in-
stalled. Do not use attaching nuts to pull bearing
caps onto rod. Failure to observe this information
may damage a rod bolt or bearing cap.
8. Seat the bearing caps (81) by pushing on by
hand or by carefully tappmg it lightly with a Figure 67 Measuring Connecting Rod Side Clearance
suitable tool.
9. Bearing cap nuts (80). OIL PUMP
~ Tighten Figure 21
• Cap nuts (80) to 50 N·m (38 lb. ft.).
l••I Install or Connect
IL•I Inspect 1. Oil pump (17) and drive rod (18).
• Pry the connecting rod back and forth 2. Oil pump bolt (16).
with a suitable tool and check for binding.
If necessary, loosen and retighten the I~! Tighten
bearing cap. • Bolt (16) to 41 N·m (30 lb. ft.).
ICil Measure
• Connecting rod side clearance
(Figure 67).
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-45

CYLINDER HEAD 4. Pencil brace bracket bolts.

Tool Required: Left
J 36660 Torque Angle Meter Figure 68

Right I++! Install or Connect

Figure 68 1. Cylinder head gasket (112).
2. Cylinder head (113).
I••! Install or Connect 3. Cylinder head bolts (115).
1. Cylinder head gasket (112).
2. Cylinder head (113). l~I Tighten
3. Cylinder head bolts (115). • Bolts (115) in sequence to 45 N·m
(41 lb. ft.). Figure 68.
~ Tighten • Turn bolts (115) in sequence an additional
• Bolts (115) in sequence to 45 N·m 90° using 1 36660. Figure 68.
(41 lb. ft.). Figure 68.
• Turn bolts (115) in se9.uence an additional
90° using 1 36660. Figure 68.

115

.FRT

0 02 03 07 113
6

~
4 8

112 115

A TIGHTENING SEQUENCE
71 BLOCK, ENGINE
112 GASKET, CYLINDER HEAD
113 HEAD, CYLINDER
71 115 BOLT/STUD, CYLINDER HEAD

P0043-6A2B-F-RA

Figure 68 Cylinder Head Installation

6A2B-46 3.4 LITER V-6 VIN CODE S UNIT REPAIR

4. Engine coolant temperature sensor (114).

l~I Tighten
A BOLTS
100 CAMSHAFT
A

• Apply teflon sealant GM p/n 1052080 to

threads of sensor (114).
• Coolant temperature sensor (114) to
16 N·m (12 lb. ft.).
5. Engine lift bracket (200) and bolts (201).

l~I Tighten
• Bolts (201) to 50 N·m (37 lb. ft.).
6. Oil level indicator tube nut (47).
l~I Tighten
• Nut (47) to 21 N·m (15 lb. ft.).
7. Power steering pump brace (38), nut (39) and
stud (37).
~ Tighten
• Stud (37) to 25 N·m (18 lb. ft.).
• Nut (39) to 50 N·m (37 lb. ft.).
8. Power steering pump bracket (224) and stud.
CAMSHAFT P0044·6A2B-F-RA

Figure 69 Figure 69 Installing Camshaft

l++I Install or Connect TIMING CHAIN AND SPROCKETS

NOTICE: Camshaft journals are all the same
diameter so care must tie used when installing the
camshaft to avoid bearing damage.
• Coat camshaft journals with engine oil or its
equivalent.
• Coat camshaft lobes with prelube GM p/n
1052365.
1. Camshaft (100).
• Install three 4-inch bolts in the camshaft
bolt holes.
• Carefully rotate and install the camshaft
(100) into the camshaft bearings.
2. Oil pump driven gear assembly (90).
• Lubricate driven gear with prelube GM
p/n 1052365.
• Lubricate assembly with engine oil for
ease of installation.
3. Oil pump driven gear hold down clamp (92) and
bolt (91).
~ Tighten
• Bolt (91) to 34 N·m (25 lb. ft.).
Figure 70 through 72
Tool Required:
J 38612 Crankshaft Sprocket Installer
l++I Install or Connect
1. Crankshaft sprocket (26) using J 38612.
2. Remove J 38612.
• Coat crankshaft and camshaft sprocket
teeth with engine oil.
• Coat rear face of camshaft sprocket with
engine oil.
3. Camshaft sprocket (98) and timing chain (25).
• Align timing marks on crankshaft and
camshaft sprockets with cast timing marks
on engine block or timing marks on
timing chain damper.
4. Camshaft sprocket bolts (97).
~ Tighten
• Bolts (97) to 24 N·m (18 lb. ft.).
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-47

I I I

A TIMING ALIGNMENT MARKS

22 CRANKSHAFT
24 KEY, CRANKSHAFT
26 SPROCKET, CRANKSHAFT
71 BLOCK, ENGINE

24
J 38612

22

P0045-6A2B-F-RA

Figure 70 Crankshaft Sprocket Installation

A ALIGNMENT MARKS I I
I I I \
25 CHAIN, TIMING
26 SPROCKET,CRANKSHAFT
71 BLOCK, ENGINE
97 BOLT, CAMSHAFT SPROCKET
98 SPROCKET, CAMSHAFT
100 CAMSHAFT

100

26 71

P0046-6A2B-F-RA

Figure 71 Camshaft Sprocket and Timing Chain Installation

6A2B-48 3.4 LITER V-6 VIN CODES UNIT REPAIR

5. Timing chain damper (63) and bolts (62). ENGINE FRONT COVER
l~I Tighten Figure 73
• Bolts (62) to 21 N·m (18 lb. ft.).
l·u·I Install or Connect
1. Front cover gasket (61).
• Uniformly coat both sides of the lower
tabs of the front cover gasket (61) with
sealer GM p/n 1052080.
2. Front cover (60).
3. Front cover bolts (59).

l~I Tighten
• Bolts (59) to 21 N·m (15 lb. ft.).

COOLANT PUMP
Figure 74

62 l••I Install or Connect

A TIMING ALIGNMENT MARKS
1. Coolant pump gasket (55).
62 BOLT, TIMING CHAIN DAMPER
63 DAMPER, TIMING CHAIN • Apply sealer GM p/n 1052080 to the threads of
71 BLOCK, ENGINE the coolant pump retaining bolts (51, 52 and 53).
P0047·6A2B-F-RA
2. Coolant pump (54) and retaining bolts (51, 52
Figure 72 Timing Chain Damper
and 53).

71

54

A APPLY SEALANT
52 BOLT, COOLANT PUMP (LARGE)
53 BOLT, COOLANT PUMP (MEDIUM)
54 PUMP, COOLANT
55 GASKET, COOLANT PUMP
58 SEAL, FRONT COVER OIL
59 BOLT, COVER
58 60 COVER, ENGINE FRONT
52 53 61 GASKET, ENGINE FRONT COVER
71 BLOCK, ENGINE Rcooog.6A2B·F·RA

Figure 73 Engine Front Cover

 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-49

51 BOLT, COOLANT PUMP (SMALL)

53 BOLT, COOLANT PUMP (MEDIUM)
54 PUMP, COOLANT
55 GASKET, COOLANT PUMP
60 COVER, ENGINE FRONT

RC0010-6A2B·f-RA

Figure 74 Coolant Pump

!~! Tighten
• Large bolts (52) to 47 N·m (35 lb. ft.).
• Medium bolts (53) to 21 N·m (15 lb. ft.).
• Small bolts (51) to 10 N·m (89 lb. in.).
3. Coolant pump pulley .(50) and retaining bolts
(49).

!~! Tighten
• Bolts (49) to 25 N·m (18 lb. ft.).
4. Power steerin__g pump mounting bracket (227)
and bolts (22~) .

TORSIONAL DAMPER
27 DAMPER, TORSIONAL
Figure 75 P0050-6A2B-F-RA

Tool Required: Figure 75 Torsional Damper Installation

J 29113 Torsional Damper Installer
ELECTRONIC IGNITION MODULE
!++! Install or Connect Figure 18
1. Torsional damper (27) using J 29113. Tool Required:
J 25033-B Power Steering Pump Pulley
• Apply sealant GM _p/n 1~34573_9 to Installer
keyway of damper pnor to mstallation.
2. Remove J 29113. !++! Install or Connect
3. Crankshaft pulley (28) and retaining bolts (31). 1. Electronic ignition module (222) and retaining
nuts (226).
!~! Tighten
!~I Tighten
• Bolts (31) to 50 N·m (37 .lb. ft.).
• Nuts (226) to 10 N·m (89 lb. in.)
4. Torsional damper washer (29) and bolt (30). 2. Power steering pump (225) and retaining bolts
(228).
~ Tighten 3. Power steering pump to rear bracket retaining
• Bolt (30) to 79 N·m (58 lb. ft.). bolts.
6A2B-50 3.4 LITER V-6 VIN CODE S UNIT REPAIR

4. Power steering pump pulley (229) using 3. Exhaust manifold retaining bolts (102 and 202).
J 25033-B.
• Install pulley (229) until fully seated. l~I Tighten
• Bolts (102 and 202) to 25 N·m (18 lb. ft.).
OIL PAN
4. Secondary air injection pipe assembly, if
Figure 17 equipped.
5. AIR pipe fitting to right exhaust manifold, if
l++I Install or Connect equipped.
1. Oil pan gasket ( 1). 6. AIR pipe retaining nut (184) and bolt (183), if
equipped.
• Apply sealant GM p/n 12345739 where
the oil pan gasket tabs seat on rear main 7. A/C compressor and generator mounting
bearing cap groove. bracket.
8. A/C compressor and generator mounting
2. Oil pan (1). bracket bolts.
3. Oil pan reinforcements (10), nuts (11), bolts 9. Generator pencil brace bolts and braces.
(12 and 14) and studs (13).
10. Rear NC compressor bracket mounting bolts
l~I Tighten
11.
and bracket.
Serpentine drive belt.
• Nuts (11) to 10 N·m (89 lb. in.).
• Two rear bolts (14) to 25 N·m (18 lb. ft.). VALVE LIFTERS
• Remaining bolts (12) to 10 N·m Figure 13
(89 lb. in.).
• Studs (13) to 6 N·m. I•+!Install or Connect
• Install lifters in their original locations.
EXHAUST MANIFOLD
1. Coat lifters with prelube, GM p/n 1052365.
Figures 15 and 16
2. Valve lifters (94).
Transfer Parts VALVE ROCKER ARM AND PUSHROD
If replacing an exhaust manifold, transfer the Figure 13
following:
1. Oxygen sensor ( 111 and 217). I++! Install or Connect

l~I Tighten
1. Pushrods (93).
• Install pushrods in their original location.
• Oxygen sensor (110 and 218) to 42 N·m
(31 lb. ft.). • Coat the ends of the pushrods with
prelube GM p/n 1052365.
2. Right manifold EGR adapter pipe (209) and 2. Rocker arms (122) and balls (123).
studs (210).
• Install rocker arms and balls in their
l~I Tighten original location.
• Coat rocker arm balls and friction surfaces
• Studs (210) to 26 N·m (23 lb. ft.).
of rocker arms with prelube GM p/n
3. Right manifold EGR gasket (208), EGR (206) 1052365.
ana bolts (207) .
3. Rocker arm nuts (124).
l~I Tighten
(ll Adjust
• Bolts (207) to 35 N·m (22 lb. ft.).
• Valves when lifter is on base circle of camshaft
4. Right manifold EGR flexible adapter pipe lobe:
gasket (211 ), EGR flexible adapter pipe (212) A. The engine should be in the #1 firing
and bolts (214). position. This may be determined by
l~I Tighten
placing fingers on the # 1 rocker arms as
the engine assembly timing mark on the
• Bolts (214) to 26 N·m (19 lb. ft.). torsional damper aligns witli the crankshaft
position sensor bolt located on the front
l•+I Install or Connect cover. If the valves are not moving, the
engine is in the #1 firing position. lf the
1. Exhaust manifold gasket (106 and 216). valves move the engine is in #4 firing
2. Exhaust manifold (105 and 215) and heat position and should be rotated one
shields (103, 104 and 205). revolution to reach the #1 position.
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-51

B. With the engine in the #1 firing position, 2. Reinforcement (193) and nuts (192).
the following valves should be adjusted:
Exhaust - 1, 2, 3 !~I Tighten
Intake - 1, 5, 6 • Nuts (192) to 9 N·m (89 lb. in.).
C. Tighten the adjusting nut until there is zero UPPER INTAKE MANIFOLD
lash + 1-1/2 turns.
(This can be determined by rotating Figure 10 and 11
pushrod while turning adjusting nut).
When lash has been removed, turn
adjusting nut in 1-1/2 additional turns (to
l••I Install or Connect
center hfter plunger). 1. Upper intake manifold gasket (154) and
manifold (155).
D. Crank the engine one crankshaft
revolution. This 1s the #4 firing position. 2. Upper intake manifold bolts (156).
With the engine in this pos1tion, the
following valves should be adjusted to zero I~! Tighten
lash + 1-1/2 turns: • Upper intake manifold bolts (156) to
Exhaust - 4, 5, 6 25 N·m (18 lb. ft.).
Intake - 2, 3, 4 3. MAP sensor electrical connector.
4. EGR flexible adapter pipe gasket (213), pipe
LOWER INTAKE MANIFOLD and bolts (212) at upper manifold (155).
Figure 14
I~! Tighten
I••! Install or Connect • Apply teflon sealant GM p/n 1052080 to
threads of bolts (212).
1. Cut lower manifold gasket where it says "Cut
Out". • Gasket must be installed with text "tube
side" facing the pipe.
• This will allow you to put the manifold • EGR flexible adapter pipe bolts to 26 N·m
gasket on with pushrods already installed. (19 lb. ft.).
2. Lower intake manifold gasket (141). 5. PCV valve (190).
3. Apply sealant GM p/n 12345739 at both ends
where the intake manifold mates the engine
block. Bead should be 2.0-3.0 mm wide and
m•
Important
Do not press on the regulator cover or piedmont
3.0-5.0 mm thick.
4. Lower intake manifold (142). valve when installing fuel injector rail assembly.
5. Retaining bolts (144) and nuts (143). 6. Fuel injector rail assembly (166).

I~! Tighten
A. Lightly lubricate fuel injector 0-rings with
engine oil.
• Bolts (144) and nuts (143) in sequence, B. Install injectors of fuel rail assembly into
refer to Figure 14. bores of manifold.
• First, bolts (144) and nuts ( 143) in C. Carefully press on injector rail (166) with
sequence, to 5 N·m (44 lb. in.). palms of both hands until injectors are
• Then, bolts (144) and nuts (143) in fully seated.
sequence, to 20 N·m (15 lb. ft.). 7. Fuel rail stud (169).
• Finally, bolts (144) and nuts (143) in
sequence, to 30 N·m (22 lb. ft.). I~! Tighten
VALVE ROCKER COVER • Fuel rail stud (169) to 25 N·m (18 lb. ft.).
Figure 12 8. Coolant sensor electrical connector.
9. Fuel pressure regulator vacuum hose (173).
!••! Install or Connect 10. Fuel injection harness retaining nut.
1. Valve rocker cover gasket (195) and cover 11. Fuel lines (175) to fuel injection rail (166).
(194). • Slide fuel line hold down plate (168) over
• Apply sealant GM p/n 12345739 at fuel lines.
cylmder head to lower manifold joint.
6A2B·52 3.4 LITER V-6 VIN CODES UNIT REPAIR

12. Fuel line hold down plate bolt (167). FLYWHEEL

l~I Tighten Figure 9
• Apply teflon sealant GM p/n 1052080 to
threads of bolt (167). !++! Install or Connect
• Bolt (167) to 25 N·m (18 lb. ft.). 1 Flywheel (33).
13. Fuel line clamp bolts (176 and 177). 2. Retainer bolts (36).

!~I Tighten
• Bolts (36) to 83 N·m (61 lb. ft.).

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
AIR Check Valve Assembly .................................................................................. 19 N·m (14 lb. ft.)
AIR Pipe Fitting to Manifold ................................................................................. 25 N·m (18 lb. ft.)
AIR Pipe Assembly Nut ....................................................................................... 25 N·m (18 lb. ft.)
AIR Pipe Assembly to Cylinder Head Screw .............................................................50 N·m (37 lb. ft.)
Camshaft Rear Cover Bolts ................................................................................... 10 N·m (89 lb. in.)
Camshaft Position Sensor Screw ............................................................................ 10 N·m (89 lb. in.)
Camshaft Sprocket Bolt ........................................................................................ 24 N·m (18 lb. ft.)
Cannister Purge Solenoid Valve Bolt/Screw ... ;., ......................................................... 10 N·m (89 lb. in.)
Connecting Rod Cap Nut ......................................................................................50 N·m (37 lb. ft.)
Coolant Drain Plug ............................................................................................. 19 N·m (14 lb. ft.)
Coolant Pump Bolt - Large .................................................................................. .47 N·m (35 lb. ft.)
Coolant Pump Bolt - Medium ................................................... .', ........................... 21 N·m (15 lb. ft.)
Coolant Pump Bolt - Small ................................................................................... 10 N·m (89 lb. in.)
Coolant Pump Pulley Bolt.. ................................................................................... 25 N·m (18 lb. ft.)
Coolant Temperature Sensor .................................................................................. 16 N·m (12 lb. ft.)
Coolant Temperature Gage Sensor. ........................................................................ 13 N·m (115 lb. in.)
Crankshaft Pulley Bolt ......................................................................................... 50 N·m (37 lb. ft.)
Crankshaft Position Sensor Screw ............................................................................ 9 N·m (80 lb. in.)
Cylinder Head Bolt ......................................................................... .45 N·m + 90° (33 lb. ft. + 90°)
Cylinder Head Bolt Tightening Sequence ........................................................................... Refer to A
Cylinder Head Coolant Plug .................................................................................. 23 N·m (17 lb. ft.)
Electronic Ignition Module Nut .............................................................................. 10 N·m (89 lb. in.)
EGR Adapter Pipe to Exhaust Manifold Bolt ............................................................. 35 N·m (26 lb. ft.)
EGR Flexible Adapter Pipe to
EGR Adapter Pipe Bolt ..................................................................................... 26 N·m (19 lb. ft.)
.EGR Flexible Adapter Pipe to
Upper Intake Manifold Bolt ................................................................................ 26 N·m (19 lb. ft.)
EGR Stud ......................................................................................................... 26 N·m (19 lb. ft.)
EGR to Adapter Pipe Bolt .................................................................................... 35 N·m (26 lb. ft.)
Engine Front Cover Bolt ....................................................................................... 21 N·m (15 lb. ft.)
Exhaust Manifold Bolt ......................................................................................... 25 N·m (18 lb. ft.)
Exhaust Manifold Heat Shield Nut ........................................................................... 8 N·m (71 lb. in.)
Exhaust Manifold Pipe Stud .................................................................................. 35 N·m (26 lb. ft.)
Flywheel Bolt .................................................................................................... 83 N·m (61 lb. ft.)
Front Engine Lift Bracket Bolt ............................................................................... 50 N·m (37 lb. ft.)
Fuel Injector Rail Stud ......................................................................................... 25 N·m (18 lb. ft.)
Fuel Line Hold Down Plate Bolt ............................................................................ 25 N·m (18 lb. ft.)
Generator Rear Support Bolt.. ................................................................................ 50 N·m (37 lb. ft.)
Heater Inlet Hose Nipple ...................................................................................... 30 N·m (22 lb. ft.)
Heater Inlet Pipe Assembly Bolt/Screw .................................................................... 10 N·m (89 lb. in.)
Ignition Timing Sensor Screw ................................................................................. 9 N·m (80 lb. ft.)
Knock Sensor .................................................................................................... 19 N·m (14 lb. ft.)
Lower Intake Manifold Stud .................................................................................. 10 N·m (89 lb. in.)
 3.4 LITER V-6 VIN CODES UNIT REPAIR 6A28-53

Lower Intake Manifold Bolt ................................................................................. .30 N·m (22 lb. ft.)
Lower Intake Manifold Tightening Sequence ...................................................................... Refer to B
Lower Intake Manifold Nut .................................................................................. .30 N·m (22 lb. ft.)
Main Bearing Cap Bolts .................................................................... 50 N·m + 77° (37 lb. ft. + 77°)
MAP Sensor Bolt/Screw ....................................................................................... .4 N·m (35 lb. in.)
Oil Drain Plug ................................................................................................... 25 N·m (18 lb. ft.)
Oil Gallery Plug - 1/8" ......................................................................................... 15 N·m (11 lb. ft.)
Oil Gallery Plug - 1/4" ......................................................................................... 19 N·m (14 lb. ft.)
Oil Gallery Plug - 3/8" .........................................................................................33 N·m (24 lb. ft.)
Oil Fill Tube Retaining Screw ................................................................................ 8 N·m (71 lb. in.)
Oil Filter ........................................................................................................ 13 N·m (115 lb. in.)
O!l Filter Ad~pter Bolt ......................................................................................... 68 N·m [50 lb. ft.)
Oii Level Indicator Nut ........................................................................................ 21 N·m 15 lb. ft.)
Oil Level Sensor ................................................................................................ 22· N·m 16 lb. ft.)
Oil Pan Bolt (2 Rear) .......................................................................................... 25 N·m (18 lb. ft.)
O!l Pan Bolt ..................................................................................................... 10 N·m (89 lb. !n.)
Oii Pan Nut ...................................................................................................... 10 N·m (89 lb. 1n.)
Oil Pan Stud ....................................................................••................................ 6 N·m (53 lb. in.)
Oil Pressure Sensor ........................................................................................... 13 N·m (115 lb. in.)
Oil Pump Bolt ................................................................... ·................................ 41 N·m (30 lb. ft.)
Oil Pump Cover Bolt .......................................................................................... 10 N·m (89 lb. in.)
Oil Pump Drive Assembly Bolt ............................................................................. .34 N·m (25 lb. ft.)
Oxygen Sensor ................................................................................................... 42 N·m (31 lb. ft.)
Power Steering Pump Bracket Assembly Bolt.. ........................................................... 50 N·m (37 lb. ft.)
Power Steering Pump Rear Brace Nut ......................................................................50 N·m (37 lb. ft.)
Power Steering Pump Rear Brace Stud ..................................................................... 25 N·m (18 lb. ft.)
Pressure Plate Bolt ........................................................................... 20 N·m + 45° (15 lb. ft. + 45°)
Rear Engine Lift Bracket Bolt.. ..............................................................................50 N·m (37 lb. ft.)
Rocker Cover Stud .............................................................................................. 6 N·m (53 lb. in.)
Rocker Cover Nut. ............................................................................................... 9 N·m (80 lb. in.)
Rocker Arm Nut. ................................................................................................ 25 N·m (18 lb. ft.)
Rocker Arm Stud ................................................................................................ 46 N·m (35 lb. ft.)
Spark Plug ........................................................................................................ 31 N·m (23 lb. ft.)
Thermostat Housing Bolt ...................................................................................... 21 N·m (15 lb. ft.)
T~r~ttle Bo~y Retaining Bolt ................................................................................. 25 N·m (18 lb. ft.)
T1mmg Cham Damper Bolt ................................................................................... 21 N·m (15 lb. ft.)
Torsional Damper _Bolt ......................................................................................... 79 N·m (58 lb. ft.)
Upper Intake Mamfold Bolt.. ................................................................................. 25 N·m (18 lb. ft.)
(A) Refer to "Cylinder Head" under Assembly in this section.
(B) Refer to "Lower Intake Manifold" under Assembly in this section.

ENGINE SPECIFICATIONS
General Specifications
Type ............................................................................................................................... 60°V-6
Displacement .............................................................................................................. 204 Cu. In.
Liter (VIN) ...................................................................................................................... 3.4 (S)
RPO ................................................................................................................................... L32
Bore ............................................................................................................... 92 mm (3.622 inch)
Stroke ........................................................................................................... 84 mm (3.3122 inch)
Compression Ratio ................................................................................................................ 9.0:1
Firing Order ................................................................................................................ 1-2-3-4-5-6
Oil Pressure @ Operating
Temperature ...................................................................... 103 kPa (15 psi) @ 1100 rpm - minimum
6A2B-54 3.4 LITER V-6 VIN CODE S UNIT REPAIR

Cylinder Bore
Diameter .............................................................................. 92.020 mm-92.038 mm (3.6228"-3.6235")
Out-of-Round - Max ......................................................................................... 0.014 mm (0.0006 ")

Piston
Diameter .............................................................................. 91.977 mm-91.992 mm (3.6211"-3.6217")
Clearance ................................................................................ 0.028 mm-0.061 mm (0.0011"-0.0024")

Piston Ring
Compression
Groove Clearance
lst. .......................................................................................... 0.05 mm-0.09 mm (0.002"-0.0035")
2nd .......................................................................................... 0.05 mm-0.09 mm (0.002"-0.0035")
Gap (at gage dia.)
1st ............................................................................................ 0.18 mm-0.41 mm (0.007"-0.016")
2nd ........................................................................................... 0.48 mm-0.74 mm (0.019"-0.029")
Oil Groove Clearance - Max ................................................................................... 0.20 mm (0.008")
Gap (Segment at gage dia.) ............................................................... 0.25 mm-0.76 mm (0.010"-0.030")

Piston Pin
Diameter ............................................................................... 22.9915 mm-22.9964 mm (.9052".9054")
Clearance ............................................................................. 0.0116 mm-0.0218 mm (0.0005"-0.0009")
Fit in Rod - Press ................................................................. 0.0165 mm-0.0464 mm (0.00065"-0.0018")

Crankshaft
Main Journal
Diameter - All .................................................................... 67.239 mm-67.257 mm (2.6473"-2.6483")
Taper - Max .................................................................................................. 0.005 mm (0.0002;'.)
Out-of-Round - Max ........................................................................................ 0.005 mm (0.0002 )
Main Bearing Clearance .............................................................. 0.032 mm-0.077 mm (0.0012"-0.0030")
Main Thrust Bearing
Clearance ............................................................................. 0.032 mm-0.077 mm (0.0012"-0.0030")
Crankshaft End Play ..................................................................... 0.06 mm-0.21 mm (0.0024"-0.0083")

Crankpin
Diameter .............................................................................. 50.768 mm-50.784 mm (1.9987"-1.9994")
Taper - Max .................................................................................................... 0.005 mm (0.0002")
Out-of-Round - Max .......................................................................................... 0.005 mm (0.0002")
Rod Bearing Clearance ............................................................... 0.028 mm-0.082 mm (0.0011"-0.0032")
Rod Side Clearance ......................................................................... 0.18 mm-0.44 mm (0.007"-0.017")

Camshaft
Lobe Lift
Intake ............................................................................................................ 6.67 mm (0.2626")
Exhaust .......................................................................................................... 6.94 mm (0.2732")
Journal Diameter ......................................................................... .47.44 mm-47.52 mm (l.868"-1.871")
Bearing Inside
Diameter ............................................................................. .47.523 mm-47.549 mm (l.871"-1.872")
Journal Clearance ......................................................................... 0.026 mm-0.101 mm (0.001"-0.004")
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B·55

Valve System
Lifter ........................................................................................................................... Hydraulic
Rocker Arm Ratio ............................................................................................................... 1.50: 1
Face Angle ............................................................................................................................ 45°
Seat Angle ............................................................................................................................ 46°
Seat Runout - Max .............................................................................................. 0.025 mm (0.001")
Seat Width
Intake ........................................................................................ 1.55 mm-1.85 mm (0.061"-0.073")
Exhaust ...................................................................................... 1. 70 mm-2.0 mm (0.067" -0.079")
Stem Clearance
Intake .............................................................................. 0.0356 mm-0.0686 mm (0.0014" -0.0027")
Exhaust ............................................................................ 0.0381 mm-0.0737 mm (0.0015" -0.0029")

Valve Spring
Free Length ......................................... , ................................................................ 48.5 mm (1.91")
Load - Closed ...........................................................................356 N @ 40.9 mm (80 Lbs. @ 1.61")
Load -Open ........................................................................... 841 N@ 30.5 mm (190 Lbs. @ 1.20")
Installed Height ..................................................................................................... 40.9 mm (1.61")
Approx. # of Coils ................................................................................................................... 4

Oil Pump
Gear Lash ............................................................................... 0.094 mm-0.195 mm (0.0037"-0.0077")
Gear Pocket
Depth ..................................................................................... 30.53 mm-30.61 mm (1.202"-1.205")
Diameter .............................................................................. 38.202 mm-38.252 mm (1.504"-1.506")
Gear
Length ............................................... , .................................... 30.45 mm-30.48 mm (1.199"-1.200")
Diameter ................................................................................. 38.05 mm-38.10 mm (1.498"-1.500")
Side Clearance ............................................................................... 0.08 mm-0.10 mm (0.003"-0.004")
End Clearance .............................................................................. 0.05 mm-0.152 mm (0.002"-0.006")
Valve to Bore Clearance ............................................................. 0.038 mm-0.089 mm (0.0015"-0.0035")
6A2B-56 3.4 LITER V-6 VIN CODE S UNIT REPAIR

SPECIAL TOOLS
J 9666
J8001 ~ J 8037

~~,1( 2 3

J0087.
J 8062

J 8101
00.....__
5
4

J 24086-B
J 21882 J 24420-B

7
9
8

J 26900-12 J 26900-13

J 5825-A

10

11 12
J 29113

13

1 DIAL INDICATOR SET 8 PISTON PIN REMOVER AND

2 PISTON RING COMPRESSOR INSTALLER SET
3 VALVE SPRING TESTER 9 TORSIONAL DAMPER REMOVER
4 CYLINDER BORE CHECKING GAGE 10 CRANKSHAFT SPROCKET REMOVER
5 VALVE GUIDE CLEANER 11 DIAL INDICATOR
6 VALVE SPRING COMPRESSOR 12 MAGNETIC BASE
7 OIL SUCTION PIPE INSTALLER 13 TORSIONAL DAMPER INSTALLER

RC0013·6A5B·ALNW-RA
 3.4 LITER V-6 VIN CODE S UNIT REPAIR 6A2B-57

SPECIAL TOOLS (CONT.)

J 38612

J 34995

J 25033-B
1 CAMSHAFT BEARING REMOVER 6 VALVE GUIDE REAMER
AND INSTALLER 7 POWER STEERING PUMP PULLEY
2 TORQUE ANGLE METER INSTALLER
3 CRANKSHAFT SPROCKET 8 POWER STEERING PUMP PULLEY
INSTALLER REMOVER
4 REAR MAIN OIL SEAL INSTALLER
5 FRONT COVER OIL SEAL
J 25034-B INSTALLER
RC0015-6A2B-F-RA
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·1

SECTION 6A3A

5.7 LITER VS ENGINE

ON-VEHICLE SERVICE
RPO LT1 - VIN P
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J-B under "On-Vehicle Service" and the SIR Components and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" or "hot at all times" exposed electrical terminals,
disconnect the battery negative cable to help prevent personal injury and/or damage to the
vehicle or components. Unless instructed otherwise, the ignition switch must be in the
"OFF" or "LOCK" position.

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

CONTENTS
General Description .......... Refer to Section 6A3B
On-Vehicle Service ...................... 6A3A- l
Fuel System Pressure Relief ............. 6A3A- I
Serpentine Drive Belt and Tensioner
Assembly .......................... 6A3A-2
Engine Mount Assemblies and Brackets .... 6A3A-3
Oil Level Indicator and Tube Assemblies ... 6A3A-4
Intake Manifold Assembly ............... 6A3A-5
Exhaust Manifold Assemblies ............ 6A3A-7
Valve Rocker Arm Cover Assemblies ...... 6A3A-9
Valve Rocker Arms and Pushrod
Assemblies ........................ 6A3A-IO
Rocker Arm Studs .................... 6A3A-l l
Valve Lifter Assemblies ................ 6A3A-1 l
Water Pump Assembly ................. 6A3A-12
Crankshaft Balancer Assembly and Hub ... 6A3A-12
Distributor Assembly , ................. 6A3A-12
Engine Front Cover Assembly ........... 6A3A-13
Timing Chain Assembly, Crankshaft and
Camshaft Sprockets, and Water Pump
Driveshaft Assembly ................ 6A3A- l 3
Camshaft Assembly ................... 6A3A-15
Valve Spring and Stem Seal ............. 6A3A-16
Cylinder Head Assembly and Gasket ..... 6A3A-17
Engine Oil Cooler and Hose Assembly .... 6A3A-20
Oil Pan Assembly .................... 6A3A-20
Oil Pump Assembly ................... 6A3A-22
Connecting Rod Bearings .............. 6A3A-23
Piston and Connecting Rod Assemblies ... 6A3A-24
Crankshaft Bearings ................... 6A3A-25
Flywheel Assembly ................... 6A3A-27
Crankshaft Rear Oil Seal Assembly ...... 6A3A-28
Crankshaft Rear Oil Seal Housing Assembly
and Gasket ........................ 6A3A-29
Engine Assembly ..................... 6A3A-29
Thread Repair ....................... 6A3A-31
Specifications .......................... 6A3A-32
Fastener Tightening Specifications ....... 6A3A-32
Engine Assembly Specifications
5.7L (LTl) ........................ 6A3A-33
Special Tools .......................... 6A3A-36

ON-VEHICLE SERVICE • After relieving system pressure, a small

FUEL SYSTEM PRESSURE RELIEF
CAUTION:
• To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel
system pressure before servicing fuel
system components.
amount of fuel may be released when
servicing fuel lines or connections. In
order to reduce the chance of personal
injury, cover fuel pipe fittings with a
shop towel before disconnecting, to
catch any fuel that may leak out. Place
the towel in an approved container
when disconnect is completed.
6A3A-2 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

Tool Required: The indicator on the movable portion of the tension-

J 34730-1 Fuel Pressure Gage
1. Disconnect battery negative cable assembly termi-
nal to avoid possible fuel discharge if an additional
attempt is made to start the engine.
2. Loosen fuel filler cap to relieve tank vapor pressure.
3. Connect gage J 34 730-1 to fuel pressure connection.
Wrap a shop towel around fitting while connecting
gage to avoid spilling.
4. Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel connec-
tions are now safe for servicing.
5. Drain any fuel remaining in gage into an approved
container.
SERPENTINE DRIVE BELT AND TENSIONER
ASSEMBLY
Figures 1 and 2
NOTICE: Routine inspection of the belt may reveal
cracks in the belt ribs. These cracks will not impair
belt perfonnance and therefore should not be con-
sidered a problem requiTing belt replacement. How-
ever, the belt should be replaced if belt slip occurs or
if sections of the belt ribs are missing.
A single serpentine drive belt is used to drive all en-
gine accessories. All belt driven accessories are rigidly
mounted with belt tension maintained by a spring loaded
tensioner assembly.
er assembly must be within the limits of the marks of the
stationary portion of the tensioner assembly. Any reading
outside of these limits indicates either a defective belt or
tensioner assembly.
Drive Belt
IL"'I Inspect
• Belt length scale on the drive belt tensioner assem-
bly for the proper installed length. If the belt length
scale does not indicate the proper il).stalled length,
install a new drive belt.
l++I Remove or Disconnect
CAUTION: See ''Caution" on page
6A3A-1 of this section.
I. Battery negative cable assembly.
2. Lift drive belt tensioner assembly (145) downward
(clockwise) off drive belt (148) using a socket and
handle on tensioner pulley bolt/screw.
3. Drive belt (148).
lS,I Clean
• Accessory drive belt surfaces.
l++I Install or Connect
I. Drive belt (148) over tensioner pulley by pushing
down on drive belt tensioner assembly (145).

145
A INDICATOR MARK
B READING FOR REPLACING BELT IN SERVICE
C DEFECTIVE PARTS CHECK RANGE
D MAXIMUM TOLERANCE BELT READING
E MINIMUM TOLERANCE BELT READING
42 BALANCER ASSEMBLY, CRANKSHAFT
145 TENSIONER ASSEMBLY, DRIVE BELT
146 PUMP ASSEMBLY, POWER STEERING
147 GENERATOR ASSEMBLY
148 BELT, SERPENTINE DRIVE
149 COMPRESSOR ASSEMBLY, AIR CONDITIONING
150 PULLEY, DRIVE BELT IDLER

Figure 1 - Serpentine Drive Belt

 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·3

- Be sure drive belt (148) is aligned into proper 2. Idler pulley bolts/screws (151 ).
grooves of accessory drive pulleys.
3. Drive belt idler pulley (150).
2. Battery negative cable assembly.

Drive Belt Tensioner Assembly l++l tnstall or Connect

NOTICE: See "Notice" on page 6A3A-l of this
l++I Remove or Disconnect section.
1. Drive belt (148). 1. Drive belt idl~r pulley (150).
2. Drive belt tensioner bolts/screws (I 52). 2. Idler pulley bolts/screws ( 151 ).
3. Drive belt tensioner assembly (145).

j++l tnstall or Connect I~! Tighten

• Idler pulley bolts/screws (151) to 50 N•m
NOTICE: See "Notice" on page 6A3A-1 of this (37 lb. ft.).
section.
3. Drive belt (148).
1. Drive belt tensioner assembly (145).
2. Drive belt tensioner bolts/screws (152).
ENGINE MOUNT ASSEMBLIES AND
!~I Tighten BRACKETS
• Drive belt tensioner bolts/screws (152) to
33 N•m (24 lb. ft.). Figure 3
3. Drive belt (148).
NOTICE: When raising or supporting the engine for
Drive Belt Idler Pulley any reason, do not use a jack under the oil pan,
The drive belt idler pulley is used in place of the A/C crankshaft pulley, or any sheet metal. Due to small
compressor when the vehicle is not equipped with air clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
conditioning.
bent against the pump screen resulting in a damaged
j++j Remove or Disconnect oil pickup unit.

1. Drive belt (148). ll'i'! tnspect

• Engine mounts for damage to the rubber portions of
the mount.
- Rubber surface covered with heat check
cracks.
Rubber cushion separated from the plate of the
mount.
Rubber cushion split through the center.

I++! Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Engine mount through-bolts/screws ( 130) and nuts
( 125).
3. Raise engine with a jacking fixture.
4. Engine mount bolts/screws (128) and engine mount
152 assemblies (127).
5. Engine bracket bolts/screws (126) and engine brack-
145 TENSIONER ASSEMBLY, DRIVE BELT ets (124).
150 PULLEY, DRIVE BELT IDLER
151
152
BOLT/SCREW, DRIVE BELT IDLER PULLEY
BOLT/SCREW, DRIVE BELT TENSIONER j++l tnstall or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
PC0061-8A3A·F·RP 1. Engine brackets ( 124) and engine bracket bolts/
Figure 2 - Drive Belt Tensioner Assembly and Idler Pulley screws (126).
6A3A-4 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

!VIEW Al

124 BRACKET, ENGINE

125 NUT, ENGINE MOUNT
126 BOL,T/SCREW, ENGINE BRACKET
127 MOUNT ASSEMBLY, ENGINE
128 BOLT/SCREW, ENGINE MOUNT
130 BOLT/SCREW, ENGINE MOUNT

PC0062-6A3A·F-RP

Figure 3 - Engine Mount Assemblies and Brackets

2. Engine mount assemblies ( 127) and engine mount OIL LEVEL INDICATOR AND TUBE
bolts/screws ( 128). ASSEMBLIES
l~I Tighten f++I Remove or Disconnect
• Engine mount and bracket bolts/screws (126 1. Nut securing tube bracket to right exhaust manifold
and 128) to 58 N•m (43 lb. ft.). stud bolt.
3. Lower engine. 2. Level indicator and tube assemblies from engine
block.
4. Engine mount through-bolts/screws ( 130) and nuts
( 125). f++! tnstall or Connect
l~I Tighten
NOTICE: See "Notice" on page 6A3A-l of this
section.
• Engine mount through-bolt/screw nuts ( 125) to 1. Clean tube assembly and apply sealant, GM P/N
80 N•m (59 lb. ft.). 12345493 or equivalent, around tube 12.7 mm (0.50
inch) below bead.
-or-
2. Tube assembly into engine block and rotate into
• Engine mount through-bolts/screws ( 130) to position.
95 N•m (70 lb. ft.). 3. Nut securing tube bracket.
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·5

·--i I 1 BOLT/SCREW, FUEL INJECTION FUEL RAIL

2 RAIL ASSEMBLY, MULTIPORT FUEL INJECTION FUEL
3 BODY ASSEMBLY, THROTTLE
4 BOLT/SCREW, THROTTLE BODY
5 GASKET, THROTTLE BODY
6 MANIFOLD ASSEMBLY, INTAKE
7 TUBE ASSEMBLY, FUEL PRESSURE REGULATOR VACUUM

RC0001-6A3A·f·RP

Figure 4 - Fuel Rail and Throttle Body Assemblies

14. Vacuum and crankcase vent hoses.

!~! Tighten 15. Exhaust gas recirculation (EGR) control valve relay
nut and control valve relay.
• Oil level indicator tube nut to 34 N•m
(25 lb. ft.). 16. Emission canister purge solenoid bracket nut and
solenoid.
4. Level indicator.
17. EGR valve nuts and valve assembly.
INTAKE MANIFOLD ASSEMBLY 18. Secondary air injection pipe fitting, nuts and pipe
assembly from intake and right exhaust manifold
Figures 4 through 6 assemblies.
19. Generator rear brace. Refer to SECTION 603.
!++j Remove or Disconnect 20. Coolant hoses from throttle body assembly (3).
CAUTION: See "Caution" on page 21. Throttle body bolts/screws (4), throttle body assem-
6A3A-1 of this section. bly (3) and gasket (5).
1. Battery negative cable assembly. 22. Intake manifold bolts/screws (8) and studs (9).
2. Drain coolant. Refer to SECTION 68. 23. Intake manifold assembly (6) and gaskets (10).
3. Throttle body air duct. • Discard gaskets ( 10).
4.
5.
Wiring harness connectors from fuel injectors.
Left and right wiring harnesses and lay aside.
!t:'! Clean
• Intake manifold bolts/screws (8) and studs (9).
6. Accelerator cable bracket bolts/screws, bracket and
cables from throttle body assembly (3). • Cylinder head assembly, engine block and intake
manifold sealing surfaces.
7. Accelerator control/cruise control servo cable
adjuster assembly, if equipped. Refer to SECTION
5E2. !++! Install or Connect
8. Relieve fuel system pressure. Refer to "Fuel System NOTICE: See "NOTICE" on page 6A3A-1 of this
Pressure Relief" in this section. section.
9. Secondary air injection diverter valve hoses. 1. Apply a 5 mm (3/16 inch) bead of RTV sealer, GM
P/N 1052366 or equivalent, to the front and rear of
10. Fuel pipe connectors from fuel rail assembly (2). the engine block. Extend the bead 13 mm ( 1/2 inch)
11. Fuel rail bolts/screws (1 ). up each cylinder head assembly to seal and retain the
12. Fuel pressure regulator vacuum tube assembly (7). gaskets.
13. Fuel rail assembly (2) from intake manifold assem- 2. Intake manifold assembly (6) with new gaskets (10).
bly (6) and lay aside. 3. Intake manifold bolts/screws (8) and studs (9).
6A3A·6 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

3 2 7
0 0 0
6 MANIFOLD ASSEMBLY, INTAKE PC0055-6A3B-F-RP

Figure 6 - Intake Manifold Tightening Sequence

!~I Tighten
• Intake manifold bolts/screws (8) and studs (9)
9 in a first pass to 8 N•m (71 lb. in.) in sequence
as shown in Figure 6. Tighten in sequence in a
second pass to final specifications of 48 N•m
(35 lb. ft.).
4. Throttle body assembly (3), gasket (5) and throttle
body bolts/screws (4).

l~I Tighten
• Throttle body bolts/screws (4) to 26 N•m
(19 lb. ft.).
5. Coolant hoses to throttle body assembly (3).
6. Generator rear brace. Refer to SECTION 603.
7. Accelerator control/cruise control servo cable
adjuster assembly, if equipped. Refer to SECTION
5E2.
8. Accelerator cable bracket, bolts/screws and cables.

l~I Tighten
• Accelerator cable bracket bolts/screws to
10 N•m (90 lb. in.).
9. Secondary air injection pipe assembly and nuts.

!~I Tighten
• Secondary air injection pipe exhaust manifold
fitting to 34 N•m (25 lb. ft.).
• Secondary air injection pipe flange nuts to
intake manifold assembly to 25 N•m (19 lb.
ft.).
I 0. EGR valve assembly and nuts.
A SEALER 11. EGR control valve relay and nut.
6
8
9
MANIFOLD ASSEMBLY, INTAKE
BOLT/SCREW, INTAKE MANIFOLD
STUD, INTAKE MANIFOLD
!~I Tighten
10 GASKET, INTAKE MANIFOLD • EGR valve nuts to 22 N•m (16 lb. ft.).
• EGR control valve relay nut to 22 N•m (16 lb.
ft.).
PC001Cl-8A3B·F·RP
12. Emission canister purge solenoid and bracket bolt/
Figure 5 - Intake Manifold Assembly screw.
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·7

l~I Tighten !~I Clean

• Emission canister purge solenoid bracket bolt/ • Exhaust manifold and cylinder head sealing
screw to 6 N•m (53 lb. in.). surfaces.
13. Vacuum and crankcase vent hoses.
14. Fuel rail assembly (2) to intake manifold assembly
!++-I Install or Connect
(6). NOTICE: See "NOTICE" on page 6A3A-1 of this
section.
15. Fuel pressure regulator vacuum tube assembly (7).
1. Exhaust manifold gasket (18) and exhaust manifold
16. Fuel rail bolts/screws ( 1). assembly (19).

l~I Tighten
2. Front three exhaust manifold studs (20) and bolt/
screw (21).
• Fuel rail bolts/screws ( 1) to 20 N •m ( 15 lb. ft.). 3. Generator and rear lower brace. Refer to SECTION
17. Fuel pipe connectors to fuel rail assembly (2). 603.
4. Raise and suitably support vehicle. Refer to SEC-
18. Secondary air injection diverter valve hoses. TION OA.
19. Left and right wiring harnesses. 5. Remaining exhaust manifold bolts/screws (21).
20. Wiring harness connectors to fuel injectors.
21. Throttle body air duct. l~I Tighten
22. Battery negative cable assembly. • Exhaust manifold studs (20) and bolts/screws
(21) to 35 N•m (26 lb. ft.).
23. Refill with coolant. Refer to SECTION 6B.
6. Oxygen sensor electrical connector.
7. Oil level indicator and tube assemblies. Refer to
EXHAUST MANIFOLD ASSEMBLIES "Oil Level Indicator and Tube Assemblies" in this
section.
Figures 7 and 8 8. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
Right Exhaust Manifold Assembly 9. Exhaust crossover pipe. Refer to SECTION 6F.
10. Lower vehicle.
!+-+! Remove or Disconnect 11. EGR valve pipe assembly. Refer to SECTION 6E3.
CAUTION: See "Caution" on page 12. Secondary air injection pipe assembly fitting to
6A3A-1 of this section. exhaust manifold assembly. Refer to SECTION
I. Battery negative cable assembly. 6E3.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA. !~! Tighten
3. Exhaust crossover pipe. Refer to SECTION 6F. • Secondary air injection pipe assembly fitting to
34 N•m (25 lb. ft.).
4. Serpentine drive belt. Refer to "Serpentine Drive 13. Battery negative cable assembly.
Belt and Tensioner Assembly" in this section.
5. Oil level indicator and tube assemblies. Refer to Left Exhaust Manifold Assembly
"Oil Level Indicator and Tube Assemblies" in this
section. !++J Remove or Disconnect
6. Oxygen sensor electrical connector. CAUTION: See "Caution" on page
7. Three rear exhaust manifold assembly bolts/screws 6A3A-1 of this section.
(21). 1. Battery negative cable assembly.
8. Lower vehicle. 2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
9. Secondary air injection pipe fitting from exhaust
manifold assembly. Refer to SECTION 6E3. 3. Crossover pipe from exhaust manifold assembly.
Refer to SECTION 6F.
I 0. EGR valve pipe assembly. Refer to SECTION 6E3. 4. Lower vehicle.
11. Generator and rear lower brace. Refer to SECTION 5. Brake booster vacuum hose.
603. 6. Secondary air injection pipe fitting from exhaust
12. Remaining exhaust manifold studs (20) and bolt/ manifold assembly. Refer to SECTION 6E3.
screw (21). 7. Accelerator control/cruise control servo cable
13. Exhaust manifold assembly (19) and exhaust man- adjuster assembly, if equipped. Refer to SECTION
ifold gasket ( 18). 5E2.
 11 VALVE
PIPE ASA SSEMBLY, SECO
!! ~1~D, E~ERMJ.!-{vi'~~ VA~.JtRY AIR INJECTION CHECK
12

15 PIPE'ii'sRE:LVE PIPE E
2 GASKET BLY, SECONDA
12 229
2 BOLT/SCREEGR VALVE PIPE RY AIR INJECTION

________ -Flgu~~~:;::=-~---
'f~' W, EGR VALVE PIPE
,pe Assembl;es _ _ _o_z_·&A-3A--F~·R::_P I
Figure 7- s econdary
" A',r Injection an~EE~~!Va~Pic;-;::::--:----
Valve p· ""'

r
16

16 GA
17 MANI FOLD ASSEMB
18 GASSKET, EXHAUST MLVA, EXHAUST
KET, EXHA NIFOLD
~~ MANIFOLD ASS~ST MANIFOLD
21 ~6~~js~~~~ST ~~~j:~~~AUST
' EXHAUST MANIFOLD

19
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·9

8. Oxygen sensor electrical connector. 6. Crankcase vent hose.

9. Exhaust manifold bolts/screws (21). 7. Generator and rear generator brace. Refer to SEC-
10. Exhaust manifold assembly (16) and exhaust man- TION 603.
ifold gasket (17). 8. Secondary air injection pipe fitting from exhaust
manifold assembly. Refer to SECTION 6D3.
1-:,f Clean 9. Rocker arm cover bolts/screws (24).
• Exhaust manifold and cylinder head sealing sur- 10. Rocker arm cover assembly (23) and gasket (25).
faces.

l++I Install or Connect 1-:,1 Clean

NOTICE: See "NOTICE" on page 6A3A-1 of this
section.
I. Exhaust manifold gasket ( 17) and exhaust manifold
assembly (16).
l++I Install or Connect
2. Exhaust manifold bolts/screws (21).
l~J Tighten
• Exhaust manifold bolts/screws (21) to 35 N•m
(26 lb. ft.).
3. Oxygen sensor electrical connector.
4. Accelerator control/cruise control servo cable
adjuster assembly, if equipped. Refer to SECTION
5E2.
5. Secondary air injection pipe fitting from exhaust
manifold assembly. Refer to SECTION 6E3.
• Rocker arm cover assembly and cylinder head gas-
ket surfaces.
NOTICE: See "NOTICE" on page 6A3A-1 of this
section.
1. Gasket (25) and rocker arm cover assembly (23).
2. Rocker arm cover bolts/screws (24).
l~I Tighten
• Rocker arm cover bolts/screws (24) to 11 N •m
(100 lb. in.).
3. Secondary air injection pipe fitting to exhaust man-
ifold assembly. Refer to SECTION 6D3.
4. Generator and rear generator brace. Refer to SEC-

I~! Tighten
TION 603.
5. Crankcase vent hose.
• Secondary air injection pipe fitting to 34 N•m 6. Raise and suitably support vehicle. Refer to SEC-
(25 lb. ft.). TION OA.
6. Brake booster vacuum hose. 7. Transmission fluid level indicator tube assembly to
7. Raise and suitably support vehicle. Refer to SEC- transmission housing (automatic transmission only.)
TION OA.
8. Serpentine drive belt. Refer to "Serpentine Drive
8. Crossover pipe to exhaust manifold assembly. Refer Belt and Tensioner Assembly" in this section.
to SECTION 6F.
9. Lower vehicle.
9. Lower vehicle.
10. Battery negative cable assembly.
I 0. Battery negative cable assembly.

VALVE ROCKER ARM COVER ASSEMBLIES Left Cover Assembly

Figure 9 l++I Remove or Disconnect

1. Brake booster vacuum hose.
Right Cover Assembly
2. Secondary air injection hose from pump to check
l++I Remove or Disconnect valve assembly.
3. Secondary air injection pipe fitting from exhaust
CAUTION: See "Caution" on page
manifold assembly. Refer to SECTION 6E3.
6A3A-1 of this section.
I. Battery negative cable assembly. 4. Accelerator control/cruise control servo cable
adjuster assembly, if equipped. Refer to SECTION
2. Raise and suitably support vehicle. Refer to SEC- 5E2.
TION OA.
5. Rocker arm cover bolts/screws (24).
3. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section. 6. Rocker arm cover assembly (23) and gasket (25).
4. Transmission fluid level indicator tube assembly
bracket from transmission housing (automatic trans- !-:,I Clean
mission only.) • Rocker arm cover assembly and cylinder head gas-
5. Lower vehicle. ket surfaces.
6A3A-10 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

27 PUSHROD ASSEMBLY, VALVE

28 STUD, VALVE ROCKER ARM BALL
29 ARM, VALVE ROCKER
30 BALL, VALVE ROCKER ARM
31 NUT, VALVE ROCKER ARM

PC0014-6A3B-F-RP

Figure 10 - Valve Rocker Arms and Pushrod Assemblies

23 COVER ASSEMBLY, VALVE ROCKER ARM
24 BOLT/SCREW, VALVE ROCKER ARM COVER 3. Rocker arms (29) and pushrod assemblies (27).
25 GASKET, VALVE ROCKER ARM COVER
• Place the roci<er arms (29), rocker arm balls
PC0013-6A3B-F-RP
(30) and pushrod assemblies (27) in a rack so
that they can be reinstalled in the same loca-
Figure 9 - Valve Rocker Arm Cover Assemblies
tions from which they were removed.

!-++I Install or Connect

m Important
• Refer to SECTION 6A3B for inspection of the rock-
NOTICE: See "Notice" on page 6A3A-1 of this er arms, studs and pushrod assemblies.
section.
1. Gasket (25) and rocker arm cover assembly (23). !-++I Install or Connect
2. Rocker arm cover bolts/screws (24). NOTICE: See "Notice" on page 6A3A-l of this
section.
l~I Tighten
• Rocker arm cover bolts/screws (24) to 11 N •m
rn Important
• When installing rocker arms (29) and rocker
(100 lb. in.).
arm balls (30), coat their bearing surfaces with
3. Accelerator control/cruise control servo cable
adjuster assembly, if equipped. Refer to SECTION prelube, GM PIN 1052365 or equivalent.
Install these components and the pushrod
5E2.
assemblies (27) in the locations from which
4. Secondary air injection pipe fitting to exhaust man- they were removed.
ifold assembly. Refer to SECTION 6E3.
1. Pushrod assemblies (27). Make sure pushrod assem-
5. Secondary air injection hose to pump and check blies (27) seat in lifter sockets.
valve assembly.
2. Rocker arms (29).
6. Brake booster vacuum hose.
3. Rocker arm balls (30) and rocker arm nuts (31 ).
VALVE ROCKER ARMS AND PUSHROD
ASSEMBLIES l~I Tighten
• Rocker arm nuts (31) until all lash is elimi-
Figure 10 nated.

l+-+I Remove or Disconnect ~ Adjust

I. Valve rocker arm cover assemblies. Refer to "Valve 1. Turn crankshaft assembly until cast arrow on crank-
Rocker Arm Cover Assemblies" in this section. shaft hub is in 12 o'clock position and number 1
2. Rocker arm nuts (31) and rocker arm balls (30). cylinder is in firing position (top dead center).
 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·11

• Watch number 1 cylinder valves as crankshaft VALVE LIFTER ASSEMBLIES

hub arrow approaches 12 o'clock position. If a
valve moves as the arrow moves to position,
the engine is in number 6 cylinder firing posi-
tion. Crankshaft assembly must then be turned
one more time to reach number 1 cylinder fir-
ing position.
2. With engine in number 1 cylinder firing position, the
following valves can be adjusted:
• Exhaust 1, 3,4, 8
• Intake 1, 2, 5, 7
3. Back off rocker arm nut (31) until lash is felt in
pushrod assembly (27). Then tighten rocker arm nut
(31) until all lash is removed. Zero lash can be felt
by moving pushrod assembly (27) up and down
using thumb and forefinger until there is no more
movement.
4. When all free play has been removed, tighten rocker
arm nut (31) one additional turn.
5. Turn crankshaft assembly one revolution until hub
arrow is again at 12 o'clock position. This is number
6 cylinder firing position. The following valves can
now be adjusted:
• Exhaust 2, 5,6, 7
• Intake 3, 4, 6, 8
6. Install valve rocker arm cover assemblies. Refer to
"Valve Rocker Arm Cover Assemblies" in this sec-
tion.
Figure 11
Tools Required:
J 3049 Hydraulic Valve Lifter Remover (Plier
Type)
J 9290-01 Hydraulic Valve Lifter Remover
(Slide Hammer Type)
No service parts are available for valve lifter assem-
blies. They are replaced as a unit when worn and when a
new camshaft assembly is installed.
++! Remove or Disconnect
f
1. Intake manifold assembly. Refer to "Intake Man-
ifold Assembly" in this section.
2. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
3. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
4. Valve lifter guide retainer (33) and bolts/screws
(32).
5. Valve lifter guide (35) and valve lifter assembly
(36).
• Some valve lifter assemblies (36) may be stuck
in their bores because of gum or varnish depos-
its. These valve lifter assemblies (36) can be
removed using J 3049 or J 9290-01.

ROCKER ARM STUDS

Figure 10
Rocker ann studs that have damaged threads should
be replaced with new studs.

!++! Remove or Disconnect

1. Valve rocker arm cover assembly. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
2. Valve rocker arm. Refer to "Valve Rocker Arms and
Pushrod Assemblies" in this section.
3. Rocker arm stud (28).

!++! Install or Connect

NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Apply sealer, GM PIN 1052080 or equivalent, to
threads of new rocker arm stud.
2. Rocker arm stud (28). 27 PUSHROD ASSEMBLY, VALVE
32 BOLT/SCREW, VALVE LIFTER GUIDE RETAINER
l~.J Tighten 33
34
RETAINER, VALVE LIFTER GUIDE
HEAD ASSEMBLY, CYLINDER
• Rocker arm stud (28) to 68 N•m (50 lb. ft.). 35 GUIDE, VALVE LIFTER
36 LIFTER ASSEMBLY, VALVE
3. Valve rocker arms. Refer to "Valve Rocker Arms
and Pushrod Assemblies" in this section. PC0015-6A3B·f·RP

4. Valve rocker arm cover assembly. Refer to "Valve Figure 11 - Valve Lifter Assemblies
Rocker Arm Cover Assemblies" in this section.
6A3A-12 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
m Important
• Refer to SECTION 6A3B for inspection of the valve
lifter assemblies.
!-t+I Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Coat valve lifter rollers with .prelube, GM P/N
1052365 or equivalent.
2. Valve lifter assemblies (36) in the same location
from which they were removed.
3. Valve lifter guides (35), valve. lifter guide retainer
(33) and bolts/screws (32).
l~I Tighten
• Bolts/screws (32) to 20 N•m (15 lb. ft.).
4. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
5. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
6. Intake manifold assembly. Refer to "Intake Man-
ifold Assembly" in this section.
WATER PUMP ASSEMBLY
The water pump assembly is directly driven by the
pump shaft which is coupled to a bearing, gear and shaft
assembly driven by the camshaft sprocket. Refer to SEC-
TION 6B for water pump assembly service procedures.
CRANKSHAFT BALANCER ASSEMBLY AND
HUB
Figure 12
Tool Required:
J 39046 Crankshaft Hub Remover/Installer
l+-tl Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Serpentine drive belt Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
3. Balancer bolts/screws (46) and balancer assembly
(42).
4. Matchmark crankshaft hub (45) to engine front
cover assembly.
• Do not crank engine over after match-marking
crankshaft hub and engine front cover assem-
bly. Rotating crankshaft assembly will mis-
align installation of balancer assembly to
crankshaft assembly possibly resulting in en-
gine imbalance.
5. Crankshaft hub bolt/screw and washer.
6. Crankshaft hub (45) using J 39046.
42 BALANCER ASSEMBLY, CRANKSHAFT
45 HUB, CRANKSHAFT BALANCER
46 BOLT/SCREW, CRANKSHAFT BALANCER
77 WEIGHT, CRANKSHAFT BALANCER
PC0017-6A3B-F-RP
Figure 12 - Crankshaft Balancer Assembly and Hub
The crankshaft hub (45) can be installed by a differ-
ent procedure if the engine should accidentally be cranked
over after matchmarking the hub and engine front cover
assembly.
A. Set number 1 piston assembly to top dead cen-
ter.
B. Install crankshaft hub (45) with cast arrow on
hub in the 12 o'clock position.
!-t+I Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Crankshaft hub (45) using J 39046.
2. Crankshaft hub washer and bolt/screw.
3. Crankshaft balancer assembly (42) and bolts/screws
(46).
m Important
• If balancer assembly is replaced, new balance
weights of the same size must be installed on
the new balancer assembly in the same hole
locations as the old balancer assembly.
l~I Tighten
• Crankshaft balancer hub bolt/screw to 102
N•m (75 lb. ft.).
• Crankshaft balancer bolts/screws (4.6) to 81
N•m (60 l.b. ft.).
4. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
5. Lower vehicle.
DISTRIBUTOR ASSEMBLY
The distributor assembly is mounted to the engine
front cover assembly and driven by a splined shaft con-
nected to the camshaft sprocket. Refer to SECTION 6D4
for the distributor assembly service procedures.
 5.7 LITER VS ENGINE ON·VEHICLE SERVICE RPO LT1 - VIN P 6A3A·13
ENGINE FRONT COVER ASSEMBLY
Figure 13
Tool Required:
J 39087 Driven Gear Shaft Front Cover Seal
Protector
.l++I Remove or Disconnect
1. Throttle body air duct.
2. Serpentine drive belt. Refer to "Serpentine Drive
Beltand Tensioner Assembly" in this section.
3. Water pump assembly. Refer to SECTION 6B::.
4. Crankshaft balancer assembly and hub. Refer to
"Crankshaft Balancer Assembly and Hub" in this
section.
5. Distributor assembly. Refer to SECTION 604.
6. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
7. Engine front cover bolts/screws (52).
8. En~ine front cover assembly (50) and gasket (51).
1,;.tJ Cl~an
• Engine front cover and engine block gasket surfaces.
!L'l'I Inspect
• Engine front cover assembly (50) for damage to the
seals or gasket surface. Refer to SECTION 6A3B to
replace front cover seals if necessary.
!++I Install or Connect
· NOTICE: See "Notice" on page 6A3A-1 of this
section.
50
Figure 13 - Engine Front Cover Assembly
NOTICE: Be careful not to damage the seal when
installing the engine front cover assembly over the
water pump driveshaft assembly.
1. Gasket (51) and engine front cover assembly (50)
using J 39087 on water pump driveshaft assembly.
2. Engine front cover bolts/screws (52).
l~I Tighten
• Engine front cover bolts/screws (52) to 11
N•m (100 lb. in.).
3. · Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
4. Distributor assembly. Refer to SECTION 6D4.
5: Crankshaft balancer assembly and hub. Refer to
"Crankshaft Balancer Assembly and Hub" in this
section.
6. Water pump assembly. Refer to SECTION 6B.
7. Serpentine drive belt.. Refer to. "Serpentine Drive
Belt and Tensioner Assembly" in this section.
8. Throttle body air duct.
TIMING CHAIN ASSEMBLY, CRANKSHAFT
AND CAMSHAFT SPROCKETS, AND WATER
PUMP DRIVESHAFT ASSEMBLY
Figures 14 and 15
Tools Required:
J 5825-A Crankshaft Gear Remover
J 5590 Crankshaft Gear Installer
J 3924.3 Driven Gear Assembly Remover
J 39092 Driven Gear Assembly Installer
J 39087 Driven Gear Shaft Front Cover Seal
Protector
50 COVER ASSEMBLY, ENGINE FRONT
51 GASKET, ENGINE FRONT COVER
52 BOLT/SCREW, ENGINE FRONT COVER
74 PIN, ENGINE FRONT COVER LOCATING
PC0019-8A3B-F-RP
6A3A·14 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

A TIMING MARKS
B KEYWAY
56 BOLT/SCREW, CAMSHAFT SPROCKET
57 SPROCKET, CAMSHAFT
58 BOLT/SCREW, CAMSHAFT RETAINER
59 RETAINER, CAMSHAFT
60 CAMSHAFT ASSEMBLY
61 CHAIN ASSEMBLY, TIMING
62 SPROCKET, CRANKSHAFT
63 DRIVESHAFT ASSEMBLY, WATER PUMP
64 BOLT/SCREW, WATER PUMP DRIVESHAFT BEARING
RETAINER

PC0020-6A3B-F-RP

Figure 14 - Camshaft Assembly, Sprockets and Water Pump Driveshaft Assembly

J 39089 Driven Gear/Water Pump Shaft Seal • Remove and discard 0-ring from water pump
Installer driveshaft assembly (63).
6. Crankshaft sprocket (62) using J 5825-A.
!+-+I Remove or Disconnect 7. Key, if necessary.
1. Engine front cover assembly. Refer to "Engine
Front Cover Assembly" in this section.
2. Rotate crankshaft assembly until timing marks
!l'l'l lnspect
punched on crankshaft sprocket (62) and camshaft • Refer to SECTION 6A3B for component inspection.
sprocket (57) are aligned as shown in Figure 14.
3. Camshaft sprocket bolts/screws (56).
!++I Install or Connect
4. Camshaft sprocket (57) and timing chain assembly NOTICE: See "Notice" on page 6A3A-1 of this
(61). section.
NOTICE: Do not turn the crankshaft assembly after 1. Key, if previously removed.
the timing chain has been removed to prevent dam- 2. Crankshaft sprocket (62) using J 5590.
age to piston assemblies or valves.
3. Water pump driveshaft assembly (63) using J 39092.
5. Water pump bearing retainer bolts/screws (64) and
water pump driveshaft assembly (63) using J 39243. 4. Water pump bearing retainer bolts/screws (64).
 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·15

8. Engine front cover assembly. Refer to "Engine

Front Cover Assembly" in this section.
CAMSHAFT ASSEMBLY
Figures 14, 16 and 17

!++! Remove or Disconnect

60 CAMSHAFT ASSEMBLY
62 SPROCKET, CRANKSHAFT
PC0021-IIA3B·f.RP
Figure 15 - Crankshaft Sprocket Replacement
I~! Tighten
• Water pump bearing retainer bolts/screws (64)
to 12 N•m (105 lb. in.).
5. Camshaft sprocket (57) and timing chain assembly
(61).
• Camshaft sprocket and water pump driveshaft
gears must mesh, or damage to camshaft
retainer (59) could occur.
6. Camshaft sprocket bolts/screws (56).
• Make sure that camshaft and crankshaft timing
marks align as shown in Figure 14.
1. Intake manifold assembly. Refer to "Intake Man-
ifold Assembly" in this section.
2. Valve rocker anns and pushrod assemblies. Refer to
"Valve Rocker Anns and Pushrod Assemblies" in
this section.
3. Bolt/screw (66) and oil pump driveshaft assembly
(65).
4. Engine front cover assembly. Refer to "Engine
Front Cover Assembly" in this section.
5. Camshaft sprocket. Refer to "Timing Chain Assem-
bly, Crankshaft and Camshaft Sprockets, and Water
Pump Driveshaft Assembly" in this section.
6. Valve lifter assemblies. Refer to "Valve Lifter
Assemblies" in this section.
7. Discharge air conditioning system. Refer to SEC-
TION lB.
8. Air conditioning compressor and condenser hose
from condenser.
9. Air conditioning receiver and dehydrator hose from
condenser.
10. Radiator assembly with air conditioning condenser.
Refer to SECTION 6B.
11. Air conditioning condenser support assembly.
12. Camshaft retainer bolts/screws (58) and camshaft
retainer (59).
NOTICE: All camshaft journals are the same diam-
eter so care must be used in removing the camshaft
to avoid damage to the bearings.
13. Camshaft assembly (60).
A. Install three 5/16-18 x 4-inch bolts/screws in
camshaft bolt holes.
B. Carefully rotate and pull camshaft assembly
out of bearings.
[I] Important
• Refer to "Cleaning, Inspection and Repair" in SEC-
TION 6A3B for inspection and measurement proce-
dures for the camshaft assembly.
• Refer to "Valve Rocker Anns and Pushrod Assem-
blies" in SECTION 6A3B to measure camshaft lobe
lift.
!L'l'! Inspect
• Camshaft bearings for scratches, pits, or loose fit in

l~I Tighten
their bores. Replace the camshaft bearings, if neces-
sary. Refer to SECTION 6A3B.
• Camshaft sprocket bolts/screws (56) to 28
N•m (21 lb. ft.). !·H·! Install or Connect
7. New 0-ring to water pump driveshaft assembly NOTICE: See "Notice" on page 6A3A-1 of this
using J 39089. section.
6A3A·16 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
65 DRIVESHAFT ASSEMBLY, OIL PUMP
66 BOLT/SCREW, OIL PUMP DRIVESHAFT
PC0022·6A3B-F-RP
Figure 16 - Oil Pump Driveshaft Assembly
1. When installing a new camshaft assembly (60), coat
camshaft lobes with "Molykote" or its equivalent.
2. When installing a new camshaft assembly (60),
replace all valve lifter assemblies to ensure durabili-
ty of the camshaft lobes and lifter rollers.
3. Lubricate all camshaft journals with engine oil.
4. Camshaft assembly (60).
5. Camshaft retainer (59) and camshaft retainer bolts/
screws (58).
l~I Tighten
• Camshaft retainer bolts/screws (58) to 12 N•m
(105 lb. in.).
6. Air conditioning condenser support assembly.
7. Radiator assembly with air conditioning condenser.
Refer to SECTION 6B.
8. Air conditioning receiver and dehydrator hose to
condenser.
9. Air conditioning compressor and condenser hose to
condenser.
I 0. Charge air conditioning system. Refer to SECTION
IB.
11. Valve lifter assemblies. Refer to "Valve Lifter
Assemblies" in this section.
12. Camshaft sprocket. Refer to "Timing Chain Assem-
bly, Crankshaft and Camshaft Sprockets, and Water
Pump Driveshaft Assembly" in this section.
A 5/16-18x4"BOLTS
60 CAMSHAFT ASSEMBLY
PC0023-6A3B-F-RP
Figure 17 - Removing Camshaft Assembly
13. Engine front cover assembly. Refer to "Engine
Front Cover Assembly" in this section.
14. Oil pump driveshaft assembly (65) and bolt/screw
(66).
l~I Tighten
• Bolt/screw (66) to 18 N•m (13 lb. ft.).
15. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
16. Intake manifold assembly. Refer to "Intake Man-
ifold Assembly" in this section.
VALVE SPRING AND STEM SEAL
Figures 18, 19 and 20
Tools Required:
J 22794 Spark Plug Port Adapter
J 5892-C Valve Spring Compressor (Head-On)
l+-+I Remove or Disconnect
I. Valve rocker arms and pushrod assemblies at cylin-
der to be serviced. Refer to "Valve Rocker Arms and
Pushrod Assemblies" in this section.
2. Spark plug at cylinder to be serviced.
3. Install J 22794 to spark plug hole and apply com-
pressed air to hold valves in place.
4. Compress valve spring (69) using J 5892-C (Figure
18).
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-17

5. Valve stem keys (72).

6. Valve spring cap (70).
7. Valve spring (69).
8. Valve stem oil seal (73).

!++I Install or Connect

1. Valve stem oil seal (73) and seat seal against valve
spring shim (76).
2. Valve spring (69).
3. Valve spring cap (70).
4. Compress valve spring (69) using J 5892-C.
5. Valve stem keys (72).
A. Use grease to hold keys in place while discon-
necting J 5892-C.
B. Remove J 22794.
C. Make sure keys seat properly in upper groove
of valve stem.
D. Tap end of stem with plastic-faced hammer to
seat keys, if necessary.
6. Spark plug.

31 NUT, VALVE ROCKER ARM

69 SPRING, VALVE
l~I Tighten
• Spark plug to 15 N•m (11 lb. ft.).
PCOCMM-8A3A·F·RP 7. Valve rocker arms and pushrod assemblies. Refer to
Figure 18 - Compressing Valve Spring "Valve Rocker Arms and Pushrod Assemblies" in
this section.

CYLINDER HEAD ASSEMBLY AND GASKET

11 Figure 20
Left Cylinder Head Assembly

!++I Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Drain coolant. Refer to SECTION 6B.
3. Crossover pipe from exhaust manifold assembly.
Refer to SECTION 6F.
4. Lower vehicle.
5. Intake manifold assembly. Refer to "Intake Man-
ifold Assembly" in this section.
6. Secondary air injection hose from check valve
assembly.
7. Coolant air bleed pipe bolt/screw from left cylinder
head assembly using a backup wrench on pipe fit-
ting.
8. Ignition coil bolts/screws and coil assembly. Refer
69 SPRING, VALVE to SECTION 604.
70 CAP, VALVE SPRING 9. Left exhaust manifold assembly. Refer to"Exhaust
71 VALVE, INTAKE
72 KEY, VALVE STEM Manifold Assemblies" in this section.
73 SEAL, VALVE STEM OIL 10. Spark plug wire harness assembly from clips.
76 SHIM, VALVE SPRING
11. Spark plug wire harness assembly from spark plugs.
Figure 19 - Valve Assembly (Intake Shown, Exhaust Similar) 12. Spark plugs.
13. Coolant temperature sensor connector.
6A3A·18 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

B
34

16 12 8 7 11 15
82

A GASKET TAB (YELLOW SIDE UP)

B BOLT TIGHTENING SEQUENCE
34 HEAD ASSEMBLY, CYLINDER
67 BLOCK, ENGINE
81 BOLT/SCREW, CYLINDER HEAD
82 GASKET, CYLINDER HEAD
PC0024-6A3B-F·RP
Figure 20 - Cylinder Head Assembly

14. Rocker arm cover bolts/screws and cover assembly. 6. Right valve rocker arm cover assembly and bolts/
Refer to "Valve Rocker Arm Cover Assemblies" in screws.
this section.
15. Rocker arm nuts, rocker arms, and pushrod assem-
blies. Refer to "Valve Rocker Arms and Pushrod
l~I Tighten
• Valve rocker arm cover bolts/screws to 11 N•m
Assemblies" in this section. (100 lb. in.).
16. Cylinder head bolts/screws (81 ). 7. Coolant temperature sensor connector.
17. Cylinder head assembly (34) and cylinder head gas- 8. Spark plugs.
ket (82).
• Discard cylinder head gasket (82). l~I Tighten

m Important
• Refer to SECTION 6A3B for cylinder head assem-
bly cleaning, inspection and repair.
j++I Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
• Spark plugs to 15 N•m (11 lb. ft.).
9. Spark plug wire harness assembly to spark plugs.
10. Spark plug wire harness assembly to clips.
11. Left exhaust manifold assembly. Refer to"Exhaust
Manifold Assemblies" in this section.
12. Ignition coil bolts/screws and coil assembly.

I.
section.
New cylinder head gasket (82) with yellow tab fac-
l~I Tighten
• Ignition coil bolts/screws to 33 N •m (24 lb.
ing up. ft.).
2. Cylinder head assembly (34) over locator pins and 13. Engine coolant air bleed pipe and bolt/screw to left
cylinder head gasket (82). cylinder head assembly using a backup wrench on
3. Coat threads of cylinder head bolts/screws (81) with pipe fitting.
sealing compound, GM P/N 1052080 or equivalent.
4. Cylinder head bolts/screws (81) finger tight. l~I Tighten
• Engine coolant air bleed pipe bolt/screw to
l~I Tighten 41 N•m (30 lb. ft.).
14. Secondary air injection hose to check valve assem-
• Cylinder head bolts/screws (81) in sequence
and in three passes to 88 N•m (65 lb. ft.) (Fig- bly.
ure 20). 15. Intake manifold assembly. Refer to "Intake Man-
5. Pushrod assemblies and valve rocker arms. Refer to ifold Assembly" in this section.
"Valve Rocker Arms and Pushrod Assemblies" in 16. Raise and suitably support vehicle. Refer to SEC-
this section. TION OA.
 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·19

17. Crossover pipe to exhaust manifold assembly. Refer

to SECTION 6F.
18. Lower vehicle.
m Important
• Refer to SECTION 6A3B for cylinder head assem-
19. Refill with coolant. Refer to SECTION 6B. bly cleaning, inspection and repair.

Right Cylinder Head Assembly l++I Install or Connect

NOTICE: See "Notice" on page 6A3A-1 of this
l•+I Remove or Disconnect section.
1. Raise and suitably support vehicle. Refer to SEC- 1. Coolant air bleed pipe assembly and bolt/screw to
TION OA. cylinder head assembly using backup wrench.
2. Drain coolant. Refer to SECTION 6B. 2. New cylinder head gasket (82) with yellow tab fac-
ing up.
3. Serpentine drive belt and belt tensioner assembly.
Refer to "Serpentine Drive Belt and Tensioner 3. Cylinder head assembly (34) over dowel pins and
Assembly" in this section. gasket (82).
4. Transmission fluid level indicator tube assembly 4. Coat threads of cylinder head bolts/screws (81) with
bracket from transmission housing. sealing compound, GM P/N 1052080 or equivalent.
5. Cylinder head bolts/screws (81) finger tight.
5. Air conditioning compressor rear brace bolt/screw
from engine block.
6. Air conditioning compressor electrical connector.
l~I Tighten
• Cylinder head bolts/screws (81) in sequence
7. Air conditioning compressor front mounting bolts/ and in three passes to 88 N•m (65 lb. ft.) (Fig-
screws and lay air conditioning compressor aside. ure 20).
8. Right exhaust manifold assembly. Refer to "Exhaust • Engine coolant air bleed pipe bolt/screw to
Manifold Assemblies" in this section. 41 N•m (30 lb . ft.).
9. Lower vehicle. 6. Pushrod assemblies and valve rocker arms. Refer to
10. Generator assembly. Refer to SECTION 6D3. "Valve Rocker Arms and Pushrod Assemblies" in
this section.
11. Right valve rocker arm cover assembly. Refer to
"Valve Rocker Arm Cover Assemblies" in this sec- 7. Spark plugs.
tion.
12. Intake manifold assembly. Refer to "Intake Man-
l~I Tighten
ifold Assembly" in this section. • Spark plugs to 15 N•m (11 lb. ft.).
13. Coolant air bleed pipe bolt/screw from left cylinder 8. Spark plug wire harness assembly to spark plugs.
head assembly. 9. Generator and air conditioning compressor and
14. Lower radiator hose from water pump assembly and power steering pump bracket assembly and genera-
reposition. tor bracket bolts/screws.
15. Heater hose from water pump assembly and reposi-
tion. l~I Tighten

16. Coolant air bleed pipe assembly hose from radiator. • Generator bracket bolts/screws to 42 N•m
(31 lb. ft.).
17. Power steering pump assembly. Refer to SECTION
3B. 10. Right valve rocker arm cover assembly. Refer to
"Valve Rocker Arm Cover Assemblies" in this sec-
18. Generator bracket bolts/screws and generator and air tion.
conditioning compressor and power steering pump
11. Generator assembly. Refer to SECTION 6D3.
bracket assembly.
12. Power steering pump assembly. Refer to SECTION
19. Spark plug wire harness assembly from spark plugs. 3B.
20. Spark plugs. 13. Coolant air bleed pipe assembly hose to radiator.
21. Valve rocker arms and pushrod assemblies. Refer to 14. Heater hose to water pump assembly and reposition.
"Valve Rocker Arms and Pushrod Assemblies" in
this section. 15. Lower radiator hose to water pump assembly.
22. Cylinder head bolts/screws (81). 16. Coolant air bleed pipe bolt/screw to left cylinder
head assembly using backup wrench.
23. Cylinder head assembly (34) and gasket (82).
, Discard gasket (82). l~I Tighten
24. Coolant air bleed pipe bolt/screw and pipe assembly • Engine coolant air bleed pipe bolt/screw to
from cylinder head assembly. 41 N•m (30 lb. ft.).
6A3A·20 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

17. Intake manifold assembly. Refer to "Intake Man-

ifold Assembly" in this section.
18. Raise and suitably support vehicle. Refer to SEC-
1~1 Tighten
• Engine oil cooler bolt/screw to 33 N•m (24 lb.
TION OA. ft.).
19. Right exhaust manifold assembly. Refer to "Exhaust 4. Engine oil cooler hose bracket nut.
Manifold Assemblies" in this section.
20. Air conditioning compressor front mounting bolts/
screws.
l~I Tighten
• Engine oil cooler hose bracket nut to 17 N•m
21. Air conditioning compressor electrical connector. (13 lb. ft.).
22. Air conditioning compressor rear brace bolt/screw 5. Oil filter assembly (144).
to engine block. 6. Refill coolant. Refer to SECTION 6B.

l~I Tighten OIL PAN ASSEMBLY

• Air conditioning compressor rear brace bolt/ Figures 22 and 23
screw to 33 N•m (24 lb. ft.).
23. Transmission fluid level indicator tube assembly
bracket to transmission housing.
l++I Remove or Disconnect
CAUTION: See "Caution" on page
24. Serpentine drive belt and belt tensioner assembly. 6A3A-1 of this section.
Refer to "Serpentine Drive Belt and Tensioner 1. Battery negative cable assembly.
Assembly" in this section.
25. Lower vehicle.
26. Refill with coolant. Refer to SECTION 6B.

ENGINE OIL COOLER AND HOSE

ASSEMBLY

Figure 21

l+-+I Remove or Disconnect

1. Drain coolant.
2. Oil filter assembly (144).
3. Engine oil cooler bolt/screw (140) from engine oil
cooler hose assembly manifold fitting and oil cooler
assembly (141).
4. Nut from engine oil cooler hose bracket.
5. Engine oil cooler hose assembly clamps from radia-
w~
~y-143
tor and water pump assemblies.
6. Engine oil cooler hose assembly (129).
7. Engine oil cooler assembly (141) from oil filter ~141
adapter assembly (142).
~ 144
!++-I Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Engine oil cooler assembly (141) to oil filter adapter
assembly (142).
~~ 140

l~I Tighten
129
140
141
HOSE ASSEMBLY, ENGINE OIL COOLER
BOLT/SCREW, ENGINE OIL COOLER
COOLER ASSEMBLY, ENGINE OIL
• Engine oil cooler fitting to 23 N •m ( 17 lb. ft.). 142 ADAPTER ASSEMBLY, OIL FILTER
2. Engine oil cooler hose assembly ( 129) and clamps to 143 BOLT/SCREW, OIL FILTER ADAPTER
144 FILTER ASSEMBLY, OIL
radiator and water pump assemblies. PC0083.aA3A·f.RP

3. Engine oil cooler bolt/screw (140) to engine oil Figure 21 - Engine Oil Cooler and Hose Assembly
cooler assembly (141).
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·21

~ I

55
55

A SEALER
53 REINFORCEMENT, OIL PAN
54 PAN ASSEMBLY, OIL
55 GASKET, OIL PAN
PC0052-6A3B-f..RP
Figure 22 - Oil Pan Sealer

2. Air intake duct.
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. Drain engine oil.
5. Drain coolant. Refer to SECTION 6B.
6. Oil level sensor connector.
!,.+! Install or Connect
7. Oil level sensor assembly (178).
8. Exhaust crossover pipes from exhaust manifold
assemblies. Refer to SECTION 6F.
9. Exhaust pipe hanger bolt/screw and reposition pipe.
10. Engine oil cooler hose bracket nut from oil pan as-
sembly.
11. Engine oil cooler bolt/screw from engine oil cooler
assembly and reposition engine oil cooler hose
assembly.
12. Transmission fluid cooler lines from clip at oil pan
assembly (automatic transmission).
13. Starter motor assembly. Refer to SECTION 6D2.
14. Converter cover bolts/screws and cover (automatic
transmission).
15. Engine mount through-bolts/screws.
16. Raise engine with jacking fixture.
17. Oil pan bolts/screws (84), studs (83) and nuts (85).
18. Oil pan assembly (54), reinforcements (53) and gas-
ket (55).
• Rotate crankshaft assembly to reposition coun-
terweights if necessary.
IW:,I Clean
1. Oil pan and engine block gasket surfaces.
2. Apply a small amount of sealer, GM PIN 1052914 or
equivalent, to the front cover assembly and engine
block junction and to the rear oil seal housing and
engine block junction. Apply sealer 25 mm (1 inch)
in either direction of the radius cavity of these junc-
tions. See Figure 22.
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Oil pan gasket (55), oil pan assembly (54) and rein-
forcements (53).
2. Oil pan nuts (85), bolts/screws (84) and studs (83).
l~I Tighten
• Corner oil pan bolts/screws (84) or stud (83),
and nuts (85) to 20 N•m (15 lb. ft.).
• Remainder of oil pan bolts/screws (84) and
studs (83) to 11 N•m (100 lb. in.).
3. Lower engine.
4. Engine mount through-bolts/screws.
5. Oil level sensor assembly (178).
l~I Tighten
• Engine mount through-bolts/screws to 95 N•m
(70 lb. ft.).
• Engine oil level sensor assembly (178) to 22
N•m (16 lb. ft.).
6. Converter cover and bolts/screws (automatic trans-
mission).
7. Starter motor assembly. Refer to SECTION 602.
8. Transmission fluid cooler lines to clip at oil pan
assembly (automatic transmission).
9. Engine oil cooler bolt/screw to engine oil cooler
assembly.
6A3A·22 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

I~! Tighten
• Engine oil cooler bolt/screw to 33 N•m (24 lb.
ft.).
10. Engine oil cooler hose bracket nut to oil pan assem-
bly.
11. Exhaust pipe hanger bolt/screw.
12. Exhaust crossover pipes to exhaust manifold assem-
blies. Refer to SECTION 6F.
13. Oil level sensor connector.
14. Lower vehicle.
15. Air intake duct.
16. Battery negative cable assembly;
17. Refill engine with oil.
18. Refill with coolant. Refer to SECTION 6B.

OIL PUMP ASSEMBLY

Figure 24

l.,+I Remove or Disconnect

1. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
2. Oil pan baffle nuts.
3. Bolt/screw (120) attaching oil pump assembly (118) 53
to rear crankshaft bearing cap.
4. Oil pan baffle (119), oil pump assembly (118) and
driveshaft (89) and retainer (95).

( ] ] Important
• Refer to SECTION 6A3B for oil pump assembly
cleaning, inspection and repair.

l+.,I Install or Connect

NOTICE: See "Notice" on page 6A3A-l of this
section.
I. Oil pump assembly (118), and driveshaft (89) with
retainer (95).
• Align slot on end of driveshaft (89) with drive
tang on oil pump assembly (118).
2. Oil pan baffle ( 119).
53 REINFORCEMENT, OIL PAN
3. Bolt/screw (120) attaching oil pump assembly (118) 54 PAN ASSEMBLY, OIL
to rear crankshaft bearing cap. 55 GASKET, OIL PAN
83 STUD, OIL PAN
4. Oil pan baffle nuts. 84 BOLT/SCREW, OIL PAN
85 NUT, OIL PAN
l~I Tighten 178
190
SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH
BRACKET, ENGINE WIRING HARNESS
• Bolt/screw (120) to 88 N•m (65 lb. ft.).
• Oil pan baffle nuts to 34 N•m (25 lb. ft.).
PC0053..fA3B-F-RP
5. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section. Figure 23 - Oil Pan Assembly
 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·23

[I] Important
• Place matchmarks or numbers on connecting
rod assemblies (104) and connecting rod caps
(99). Connecting rod caps (99) must be as-
sembled to their original connecting rod as-
semblies (104 ).
3. Connecting rod nuts ( l 00).
4. Connecting rod cap (99) and bearings (101).
• Keep bearings (IO l) with their original con-
necting rod assembly (104) and connecting rod
cap (99) for reassembly.
• Wipe oil from bearings (101) and crankpins.

IL'l"! Inspect
• Bearings (101) for excessive wear or damage.

l:f¥1 ! Measure
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Crankpin for out-of-round and taper with a microm-
eter. Refer measurements to "Specifications" in this
section.
• If not within specifications, replace or recondi-
tion crankshaft assembly (98).
• If installing new bearings (101), determine
new bearing size from maximum crankpin di-
ameter.
89 DRIVESHAFT, OIL PUMP
95 RETAINER, OIL PUMP DRIVESHAFT 2. Bearing clearances, using gaging plastic.
118 PUMP ASSEMBLY, OIL A. Place piece of gaging plastic the full width of
119 BAFFLE, OIL PAN
120 BOLT/SCREW, OIL PUMP bearing (101), (parallel to crankshaft assem-
bly) onto crankpin.
• Plastic gage should be positioned in
PC0026-6A3B·F·RP middle of bearing (101). Bearing (101) is
Figure 24 - Oil Pump Assembly thickest in center and bearing clearance
must be measured at this location.
B. Install connecting rod cap (99) with bearing
(101) onto connecting rod assembly ( 104 ).
CONNECTING ROD BEARINGS
C. Install connecting rod nuts ( 100).
Figure 25
Connecting rod bearings are the precision insert type I~! Tighten
and do not use shims for adjustment. Do not file connect- • Connecting rod nuts ( 100), evenly, to
ing rods or rod caps. If clearances are found to be exces- 61 N•m (45 lb. ft.).
sive, a new bearing will be required. Service bearings are NOTICE: Do not turn the crankshaft assembly with
available in standard size and 0.00 l and 0.002-inch under- the gaging plastic installed or the accuracy of the
size for use with new and used standard size crankshafts,
measurement will be affected.
and in D.010 and 0.020-inch undersize for use with
reconditioned crankshafts. D. Remove connecting rod nuts ( 100) and con-
necting rod cap (99). The gaging plastic will be
When removing a connecting rod cap, you may find found adhering to either the connecting rod cap
a 0.0 l 0-inch undersize bearing. These are used in (99) or crankshaft journal. Leave the gaging
manufacturing for selective fitting. plastic in place to measure it.
E. Measure gaging plastic at its widest, using
l+,+I Remove or Disconnect
scale provided with gaging plastic. Refer mea-
I. Oil pan assembly. Refer to "Oil Pan Assembly" in surements to "Specifications" in this section.
this section. • If clearance is greater than specified,
2. Oil pump assembly. Refer to "Oil Pump Assembly" select an undersize bearing ( 101) and
in this section. re-measure clearance.
6A3A·24 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

• If clearance cannot be brought to specifi-

cations, regrind crankpin. If crankpin is
already at maximum undersize, replace
crankshaft assembly (98).
F. Remove gaging plastic.

!++I Install or Connect

NOTICE: See "Notice" on page 6A3A-l of this
section.
1. Coat inside surface of bearings (101) with engine
oil.
2. Connecting rod cap (99) and bearings (101).
3. Connecting rod nuts (100).

l©..I Tighten
• Connecting rod nuts (100), evenly, to 61 N•m
(45 lb. ft.).

l~I Measure
• Connecting rod side clearance.
A. When all connecting rod bearings (101)
have been installed, tap each connecting
rod assembly (104) lightly parallel to
crankpin to make sure they have clear-
ance.
B. Measure side clearance between connect-
ing rod caps (99) using a feeler gage, or
dial indicator.
C. Rod side clearance should be 0.16 to 0.35
98
mm (0.006 to 0.014 inch).
4. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
5. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.

PISTON AND CONNECTING ROD

ASSEMBLIES
Figure 25

!++I Remove or Disconnect jv1ewe I

Tools Required:
J 8037 Piston Ring Compressor
J 5239 Connecting Rod Bolt Guide Set A FLANGES OF CONNECTING RODS MUST FACE TO THE
FRONT IN THE LEFT BANK AND TO THE REAR IN THE
1. Oil pan assembly. Refer to "Oil Pan Assembly" in RIGHT BANK
this section. B ARROW TO BE ORIENTED TO FRONT OF ENGINE
98 CRANKSHAFT ASSEMBLY
2. Oil pump assembly. Refer to "Oil Pump Assembly" 99 CAP, CONNECTING ROD
in this section. 100 NUT, CONNECTING ROD
3. Cylinder head assembly. Refer to "Cylinder Head 101 BEARING, CONNECTING ROD
102 BOLT/SCREW, CONNECTING ROD
Assembly and Gasket" in this section. 103 PISTON ASSEMBLY
4. Ring ridge. 104 ROD ASSEMBLY, CONNECTING

A. Turn crankshaft assembly (98) until piston

assembly (103) is at bottom of its stroke.
B. Place a cloth on top of piston assembly (103). PC0027-8A3B·f·RP

C. Use a ridge reamer to remove ring ridge. Figure 25 - Piston and Connecting Rod Assemblies
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A·25
D. Turn crankshaft assembly (98) so piston
assembly (103) is at top of its stroke.
E. Remove cloth and cutting debris.
rn Important
• Place matchmarks or numbers on connecting
rod assemblies ( 104) and connecting rod caps
(99). Connecting rod caps (99) must be
assembled to their original connecting rod
assemblies (104).
5. Connecting rod nuts (100) and connecting rod cap
(99).
6. Connecting rod assembly (104) and piston assembly
( I 03) out of top of engine block using J 5239.
[I] Important
• Refer to SECTION 6A3B for cleaning, inspection
and repair of the piston and connecting rod assem-
bly.
!~I Clean
1. Cylinder bores with hot water and detergent or with
a light honing.
2. Swab bores with engine oil and a clean, dry cloth.
!++! Install or Connect
NOTICE: See "Notice" on page 6A3A-l of this
section.
I. Coat piston assembly (103), piston rings, cylinder
bore, and bearing surfaces with engine oil.
2. Piston assembly (103) into its original bore using
J 5239 and J 8037 and lightly tapping top of piston
assembly (103) with a wooden hammer handle.
A. When installing piston assembly (I 03) and
connecting rod assembly (104), stamped arrow
on piston assembly (103) must point to front of
engine while flange on connecting rod assem-
bly (104) must face toward front of piston on
left-hand assembly and face toward rear of pis-
ton on right-hand assembly. Refer to Figure 25.
B. Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
3. Connecting rod caps (99) onto their original con-
necting rod assemblies ( 104 ).
• Align matchmarks or numbers which were
placed on connecting rod assembly ( 104) and
connecting rod cap (99) during removal.
4. Connecting rod nuts ( 100).
l~I Tighten
• Connecting rod nuts (100), evenly, to 61 N•m
(45 lb. ft.).
5. Cylinder head assembly. Refer to "Cylinder Head
Assembly and Gasket" in this section.
6. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
7. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
CRANKSHAFT BEARINGS
Figures 26 and 27
Tool Required:
J 8080 Main Bearing Shell Remover and In-
staller
Crankshaft bearings are of the precision insert type.
If clearances are found to be excessive, a new bearing,
both upper and lower halves, will be required. Service
bearings are available in both standard size and undersize.
Selective fitting of both connecting rod and crank-
shaft bearing inserts is necessary in production in order to
obtain close tolerances. For example, on a rear crankshaft
bearing you may find one half of a standard insert with
one half of a 0.001 inch undersize insert which will de-
crease the clearance 0.0005 inch from using a full stan-
dard bearing.
rn Important
• If replacing the rear crankshaft bearing, check for
the correct part number. Some rear crankshaft bear-
ings are 0.20 mm (0.008 inch) wider than standard.
The crankshaft assembly will be identified by
"0.008" stamped on the rear counterweight.
!++! Remove or Disconnect
1. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
2. Oil pump assembly. Refer to "Oil Pump Assembly"
in this section.
3. Spark plugs.
4. Cap ( 107 or 109) and lower bearing of crankshaft
bearing ( 110 or 111) requiring replacement.
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft assembly (98) allowing J 8080 to
push against insert's straight (unnotched) side. This
will roll upper bearing out of block.
7. Remove J 8080 from crankshaft assembly (98).
!L•! 1nspect
• In general, the lower half of the crankshaft bearing
insert (except #1 bearing) shows a greater wear and
the most distress from fatigue. If upon inspection the
lower half is suitable for use, it can be assumed that
the upper half is also satisfactory. If the lower half
shows evidence of wear or damage, both upper and
lower halves should be replaced. Never replace one
half without replacing the other half.
rn Important
• To obtain the most accurate results when checking
crankshaft bearing clearances, use gaging plastic.
6A3A·26 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

115

67 BLOCK, ENGINE
98 CRANKSHAFT ASSEMBLY
107 CAP, CRANKSHAFT BEARING
108 BOLT/SCREW, CRANKSHAFT BEARING CAP
109 CAP, CRANKSHAFT BEARING 139
110 BEARING, CRANKSHAFT
111 BEARING, CRANKSHAFT
112 STUD, CRANKSHAFT REAR OIL SEAL RETAINER
113 GASKET, CRANKSHAFT REAR OIL SEAL HOUSING
114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
115 NUT, CRANKSHAFT REAR OIL SEAL HOUSING
116 BOLT/SCREW, CRANKSHAFT REAR OIL SEAL HOUSING
139 PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
PCOOZ8·6A3B-F-RP

Figure 26 - Crankshaft Assembly

• If the engine is out of the vehicle and upside down,

the crankshaft assembly will rest on the upper bear-
ings and the total clearance can be measured
between the lower bearing and journal. If the engine
is to remain in the vehicle, the crankshaft assembly
must be supported upward to remove any clearance
from the upper bearing. The total clearance can then
be measured between the lower bearing and journal.
• To assure the proper seating of the crankshaft assem-
bly, all bearing cap bolts/screws should be at their
specified torque. In addition, prior to checking fit of
bearings, the surface of the crankshaft journal and
bearing should be wiped clean of oil.

!@! Measure
1. With oil pan and oil pump assemblies removed, and
starting with rear crankshaft bearing, remove bear-
KC0047-6A3-F-RP
ing cap and wipe oil from journal and bearing cap.
Figure 27 - Removing Crankshaft Bearing Note location of stud bolts/screws.
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·27
2. Place a piece of gaging plastic the full width of bear-
ing (parallel to the crankshaft assembly) on journal.
rn Important
• Do not rotate the crankshaft assembly while
the gaging plastic is between the bearing and
journal.
3. Install bearing cap and evenly tighten retaining
bolts/screws to specifications. Bearing cap must be
tightened to specification in order to assure proper
reading. Variations in torque affect the compression
of the gaging plastic.
I~! Tighten
• Crankshaft bearing cap bolts/screws (108) and
studs to 105 N•m (77 lb. ft.).
4. Remove bearing caps. The flattened gaging plastic
wiJJ be found adhering to either the bearing shell or
journal.
5. Without removing gaging plastic, measure its com-
pressed width (at the widest point) with graduations
on gaging plastic envelope. Normally crankshaft
bearing journals wear evenly and are not out-of-
round. However, if a bearing is being fitted to an
out-of-round journal (0.001 inch maximum), be sure
to fit to maximum diameter of journal: If bearing is
fitted to minimum diameter, and journal is out-of-
round 0.001 inch, interference between bearing and
journal will result in rapid bearing failure. If flat-
tened gaging plastic tapers toward middle or ends,
there is a difference in clearance indicating taper,
low spot or other irregularity of bearing or journal.
Be sure to measure journal with a micrometer if flat-
tened gaging plastic indicates more than 0.001 inch
difference.
6. If bearing clearance is within specifications, bearing
insert is satisfactory. If clearance is not within speci-
fications, replace insert. Always replace both upper
and lower inserts as a unit. When bearing cap is
installed and clearance is Jess than 0.001 inch,
inspect for burrs or nicks.
7. A standard, 0.001 inch or 0.002 inch undersize bear-
ing may produce proper clearance. If not, it will be
necessary to regrind crankshaft journal for use with
next undersize bearing. After selecting new bearing,
recheck clearance.
8. Proceed to next bearing. When checking #1 crank-
shaft bearing, loosen accessory drive belt so as to
prevent tapered reading with gaging plastic. After all
bearings have been checked, rotate crankshaft
assembly to see that there is no excessive drag.
I++! Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
I. Crankshaft bearings ( 110 and 111) into engine block
(67) and crankshaft bearing caps (107) and rear
crankshaft bearing cap (109).
A. Coat crankshaft bearings (110 and 111) with
oil.
B. Insert plain (unnotched) end between crank-
shaft assembly and indented or notched side of
block. Rotate bearing into place using J 8080
as previously described, and remove J 8080
from oil hole in crankshaft journal.
2. Crankshaft bearing caps ( 107) and rear crankshaft
bearing cap (109) with assembled crankshaft bear-
ings ( 110 and 111) with arrows pointing toward front
of engine.
3. Crankshaft bearing cap bolts/screws (108) and
studs.
• With crankshaft assembly (98), crankshaft
bearings ( 110 and 111) and crankshaft bearing
caps ( 107) and rear crankshaft bearing cap
( 109) installed and bolts/screws ( 108) and
studs started, thrust crankshaft assembly (98)
rearward to set and align bearing caps (107 and
109). Then thrust crankshaft assembly forward
to align rear faces of rear crankshaft bearings
(111 ).
l~I Tighten
• Crankshaft bearing cap bolts/screws ( 108) and
studs to 105 N•m (77 lb. ft.).
I@! Measure
• Crankshaft end play, using a dial indicator or
feeler gage. Refer to "Specifications" in this
section.
• If using a feeler gage, measure between the
front of the rear crankshaft bearing cap ( 109)
and the crankshaft thrust surface.
FLYWHEEL ASSEMBLY
Figure 28
Flywheel Assembly Replacement
I+-+! Remove or Disconnect
I. Transmission assembly. Refer to SECTION 7A for
an automatic transmission or SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
2. Flywheel bolts/screws ( 136 or 138) and flywheel as-
sembly (135 or 137).
I-++! Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
1. Flywheel assembly (135 or 137) and flywheel bolts/
screws ( 136 or 138).
I~! Tighten
• Flywheel bolts/screws (136 or 138) to 100
N•m (74 lb. ft.).
6A3A-28 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

2. Transmission assembly. Refer to SECTION 7A for CRANKSHAFT REAR OIL SEAL ASSEMBLY
an automatic transmission or SECTION 7B for a
manual transmission and SECTION 7C for the Figures 26, 29 and 30
clutch.
Flywheel Assembly Balancing
l++I Remove or Disconnect
Tool Required:
Figure 28 J 3562 J Rear Main Seal Installer

!L'l'I Inspect I. Flywheel assembly. Refer to "Flywheel Assembly

• Flywheel assembly (135 or 137) for missing or loose
converter-to-flywheel bolts/screws. Tighten or
replace as necessary.
• Converter for damage or missing balance weights. If
converter is damaged or balance weights are mis-
sing, replace converter. Refer to SECTION 7 A.
• If flywheel assembly is replaced, new balance
weights ( 134) of same size must be installed on new
flywheel assembly in same hole locations as old fly-
wheel assembly.
Replacement" under "Flywheel Assembly" in this
section.
• Care should be taken not to nick crankshaft
sealing surface when removing seal.
2. Crankshaft rear oil seal assembly.
• Using notches provided in crankshaft rear oil
seal housing assembly (114), pry out seal
assembly with a screwdriver.
A

A SEAL REMOVAL NOTCHES

114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL

PC0029·&A3B-F-RP

Figure 29 - Removing Crankshaft Rear Oil Seal Assembly

A FOR MANUAL TRANSMISSION

B FOR AUTOMATIC TRANSMISSION
C LOCATOR HOLE
98 CRANKSHAFT ASSEMBLY
133 PIN, FLYWHEEL LOCATOR
134 WEIGHT, FLYWHEEL
135 FLYWHEEL ASSEMBLY
136 BOLT/SCREW, FLYWHEEL
137 FLYWHEEL ASSEMBLY
138 BOLT/SCREW, FLYWHEEL
PC0008-8A3B·F-RP LC0012·6A4-B·RP

Figure 28 - Flywheel Assembly Figure 30 - Installing Crankshaft Rear Oil Seal

 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·29
!-++! Install or Connect
I. Coat new seal assembly entirely with engine oil.
2. Seal assembly onto J 35621.
3. J 35621 onto rear of crankshaft assembly (98).
Tighten screws snugly to ensure seal assembly will
be installed squarely over crankshaft assembly (98).
4. Crankshaft rear oil seal assembly to crankshaft as-
sembly (98) and crankshaft rear oil seal housing
(114 ).
5. Tighten wing nut on J 35621 until it bottoms.
6. Remove J 35621 from crankshaft rear oil seal hous-
ing assembly (114).
7. Flywheel assembly. Refer to "Flywheel Assembly
Replacement" under "Flywheel Assembly" in this
section.
CRANKSHAFT REAR OIL SEAL HOUSING
ASSEMBLY AND GASKET
Figures 26 and 29
!+-+! Remove or Disconnect
I. Flywheel assembly. Refer to "Flywheel Assembly
Replacement" under "Flywheel Assembly" in this
section.
2. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
3. Crankshaft rear oil seal housing nuts ( 115) and bolts/
screws (116).
4. Crankshaft rear oil seal housing assembly (114) with
the assembled seal, and gasket (113).
5. Crankshaft rear oil seal assembly from crankshaft
rear oil seal housing assembly (114 ).
l~I Clean
• Gasket surfaces.
!-++! Install or Connect
NOTICE: See "Notice" on page 6A3A-1 of this
section.
rn Important
• Always use a new crankshaft rear oil seal
assembly and a new oil seal housing gasket
(113) during the installation of the crankshaft
rear oil seal housing assembly (114).
I. New oil seal housing gasket (113) and crankshaft
rear oil seal housing assembly (114) on studs (112).
• It is not necessary to use any type of sealant to
hold oil seal housing gasket (113) in place.
2. Crankshaft rear oil seal housing nuts ( 115) and bolts/
screws ( 116).
l~! Tighten
• Crankshaft rear oil seal housing nuts ( 115) and
bolts/screws (116) to 15 N•m (11 lb. ft.).
IL'l'! 1nspect
• Oil pan gasket for damage. Replace gasket if
necessary.
3. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
4. New crankshaft rear oil seal assembly. Refer to
"Crankshaft Rear Oil Seal Assembly" in this sec-
tion.
5. Flywheel assembly. Refer to "Flywheel Assembly
Replacement" under "Flywheel Assembly" in this
section.
ENGINE ASSEMBLY
CAUTION: See "Caution" on page
6A2A-1 of this section.
l+-+! Remove or Disconnect
I. Discharge air conditioning system. Refer to SEC-
TION IB.
2. Battery negative cable assembly.
3. Battery positive cable assembly.
4. Raise and suitably support vehicle. Refer to SEC-
TION OA.
5. Front wheels and tires. Refer to SECTION 3E.
6. Drain coolant. Refer to SECTION 6B.
7. Drain engine oil.
8. Exhaust crossover pipe assembly from intermediate
pipe. Refer to SECTION 6F.
9. Converter bolts/screws (automatic transmission).
Refer to SECTION 7 A.
10. Front fascia lower deflectors. Refer to SECTION
10-5.
11. Stabilizer bar bolts/screws. Refer to SECTION 3C.
12. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
13. Air conditioning hose assembly from condenser and
compressor. Refer to SECTION 1B.
14. Transmission fluid cooler lines from radiator assem-
bly (automatic transmission). R.efer to SECTION
6B.
15. Lower radiator hose from radiator assembly. Refer
to SECTION 6B.
16. Lower heater hose from water pump. Refer to SEC-
TION 6B.
17. Electrical ground straps from right side of engine
block.
18. Shift linkage from transmission assembly. Refer to
SECTION 7 A or SECTION 7B.
19. Propeller shaft assembly after matchmarking. Refer
to SECTION 4A.
20. Torque arm from transmission assembly. Refer to
SECTION 30.
6A3A·30 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO l-T1 - VIN P

21. Intermediate steering shaft from rack and pinion as- 51. Engine frame and transm1ss10n support bolts/
sembly. Refer to SECTION 3F4. screws. Refer to SECTION 10-3.
22. Electrical ground straps from left side of frame rail. 52. Raise vehicle from engine, transmission and engine
23. Electrical connectors from wheel speed sensor frame assemblies.
assemblies. 53. Secure strut assemblies to engine frame.
24. Lower vehicle. 54, Transmission assembly. Refer to SECTION 7A or
25. Air intake duct. SECTION 7B.
26. Fuel lines from fuel rail assembly. Refer to SEC- 55. Clutch housing and clutch assembly (manual trans-
TION 6C. mission). Refer to SECTION 7C.
27. Accelerator control/cruise control servo cable 56. Power steering lines from power steering pump as-
adjuster assembly, if equipped. Refer to SECTION sembly. Refer to SECTION 3B.
5E2. 57. Hose assemblies from air conditioning compressor.
28. Cruise and accelerator control cables from throttle Refer to SECTION lB.
body assembly. 58. Air conditioning compressor bolts/screws and com-
29. Upper radiator hose from water pump assembly. Re- pressor. Refer to SECTION lB.
fer to SECTION 6B. 59. Engine mount through-bolts/screws. Refer to
30. Lower radiator hose from water pump assembly. Re- "Engine Mount Assemblies and Brackets" in this
fer to SECTION 6B. section.
31. Brake booster vacuum hose. 60. Engine assembly from engine frame.
32. Upper heater hose from water pump assembly. Refer
to SECTION 6B. [I] Important
33. Coolant air bleed pipe hose from radiator assembly. • Refer to SECTION 6A3B for engine block cleaning,
Refer to SECTION 6B. inspection and repair.
34. Air conditioning receiver and dehydrator hose from
condenser. Refer to SECTION 1B. !++I Install or Connect
35. Air conditioning hose from expansion tube. Refer to NOTICE: See "Notice" on page 6A2A-l ofthis
SECTION lB. section.
36. Brake lines from antilock brake system (ABS) brake 1. Engine assembly to engine frame.
combination valve. Refer to SECTION 5. 2. Engine mount through-bolts/screws. Refer to
37. Power steering reservoir and reposition. Refer to "Engine Mount Assemblies and Brackets" in this
SECTION lB. section.
38. Brake lines and clips from ABS hydraulic modulator 3. Power steering lines to power steering pump. Refer
assembly. Refer to SECTION 5. to SECTION 3B.
39. Right-hand body hinge pillar trim panel assembly. 4. Air conditioning compressor and bolts/screws.
Refer to SECTION I 0-5. Refer to SECTION I B.
40. Three engine wiring harness connectors (blue, black 5. Hose assemblies to air conditioning compressor.
and white connectors) and evaporator temperature Refer to SECTION 1B.
sensor connector. 6. Clutch housing and clutch assembly. Refer to SEC-
41. Forward lamp wiring harness connectors. TION 7C.
42. Powertrain control module (PCM) and harness. 7. Transmission assembly. Refer to SECTION 7A or
• Place PCM and harness on top of engine. SECTION 7B.
43. Engine wire harness through front of dash. 8. Position engine lift table and install engine, trans~
mission and engine frame assemblies by lowering
• Place harness on top of engine.
vehicle to crossmember assembly.
44. Positive lead at generator.
9. Engine frame and transmission support bolts/
45. Positive lead atjunction block. screws. Refer to SECTION 10-3.
46. Negative lead at mounting stud (located next to the 10. Engine lift table.
junction block).
11. Lower vehicle.
47. Lower shock attachment bolts/screws and nuts from
12. Upper control arm ball stud assembly to steering
lower control arm.
knuckle assembly. Refer to SECTION 3C.
48. Upper control arm ball stud assembly from steering
knuckle assembly. Refer to SECTION 3C. 13. Lower shock attachment bolts/screws and nuts to
lower control arm.
49. Raise and suitably support vehicle. Refer to SEC-
14. Negative lead at mounting stud (located next to
TION OA.
junction block).
50. Position lift table under engine and engine frame as-
sembly. Use Kent-Moore tool number 204-BX-75G 15. Positive lead at generator.
or equivalent. 16. Engine wire harness though front of dash.
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·31

rn Important
• When reinstalling engine wiring harness back
44. Air conditioning hose assembly to condenser and
compressor. Refer to SECTION lB.
45. Stabilizer bar bolts/screws. Refer to SECTION 3C.
through front of dash, the rubber grommet 46. Front fascia lower deflectors. Refer to SECTION
MUST BE INSTALLED PROPERLY to en- 10-5.
sure correct sealing. If grommet is torn or dam- 47. Converter bolts/screws (automatic transmission).
aged for any reason, it must be replaced. Refer to SECTION 7A.
17. PCM and harness. 48. Exhaust crossover pipe assembly from intermediate
18. Forward lamp wiring harness connectors. pipe. Refer to SECTION 6F.
19. Wiring harness connectors. 49. Lower vehicle.
20. Right-hand body hinge pillar trim panel assembly. 50. Refill with engine oil. Refer to SECTION OA.
Refer to SECTION 10-5. 51. Refill with engine coolant. Refer to SECTION 6B.
21. Brake lines and clips to ABS hydraulic modulator 52. Front wheels and tires. Refer to SECTION 3E.
assembly. Refer to SECTION 5. 53. Battery positive cable assembly.
22. Brake lines to ABS brake combination valve. Refer 54. Battery negative cable assembly.
to SECTION 5. 55. Bleed brake system. Refer to SECTION 5El.
23. Air conditioning hose to expansion tube. Refer to 56. Bleed power steering system. Refer to SECTION
SECTION lB. 3B.
24. Air conditioning receiver and dehydrator hose to 57. Charge air conditioning system. Refer to SECTION IB.
condenser. Refer to SECTION 1B. 58. Air intake duct.
25. Coolant air bleed pipe hose to radiator assembly. 59. Align wheels. Refer to SECTION 3A.
Refer to SECTION 6B.
26. Brake booster vacuum hose. THREAD REPAIR
27. Lower radiator hose to water pump assembly. Refer Figure 31
to SECTION 6B.
Damaged threads may be reconditioned by drilling
28. Upper radiator hose to water pump assembly. Refer out, re-threading and installing a suitable thread insert.
to SECTION 6B. General purpose thread repair kits are available commer-
29. Accelerator control/cruise control servo cable cially.
adjuster assembly, if equipped. Refer to SECTION CAUTION: Wear safety glasses to avoid
5E2. eye damage.
30. Cruise and accelerator control cables to throttle 1. Determine size, pitch and depth of damaged thread.
body assembly If necessary, adjust stop collars on cutting tool and
31. Fuel lines to fuel rail assembly. Refer to SECTION 6B. tap to required depth.
32. Raise and suitably support vehicle. Refer to SEC-
TION OA. m Important
• Refer to kit manufacturer's instructions
33. Electrical connectors to wheel speed sensor assem-
blies. regarding size of drill and tap to be used.
34. Electrical ground straps to left side of frame rail. 2. Drill out damaged thread. Clean out chips.
35. Intermediate steering shaft to rack and pinion as- 3. Tap hole.
sembly. Refer to SECTION 3F4. A. Lubricate tap with light engine oil.
36. Torque arm to transmission assembly. Refer to SEC- B. Clean thread.

37.
38.
TION 30.
Propeller shaft assembly. Refer to SECTION 4A.
Shift linkage to transmission assembly. Refer to
rn Important
• Avoid build-up of chips. Back out tap every
SECTION 7 A or SECTION 7B. few turns and remove chips.
39. Electrical ground straps to right side of engine 4. Thread the thread insert onto mandrel of installer.
block. Engage tang of insert onto end of mandrel.
40. Lower heater hose to water pump. Refer to SEC- 5. Lubricate insert with light engine oil (except when
TION 6B. installing in aluminum) and install.
41.

42.
Lower radiator hose to radiator assembly. Refer to
SECTION 6B.
Transmission fluid cooler lines to radiator assembly
rn Important
• When correctly installed, insert should be flush
(automatic transmission). Refer to SECTION 6B. to one turn below surface.
43. Serpentine drive belt. Refer to "Serpentine Drive 6. If tang of insert does not break off when backing out
Belt and Tensioner Assembly" in the section. installer, break tang off with drift pin.
6A3A·32 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

STEP 2 STEP 3 STEP 4 STEP 5

KC0049·6A4·B-RP

Figure 31 - Repairing Threaded Holes

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ............................ 10 N•m (90 lb. in.)
Air Conditioning Compressor Rear Brace-to-Engine Block Bolt/Screw ......... 33 N•m (24 lb. ft.)
Camshaft Retainer Bolt/Screw ........................................ 12 N•m (105 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 28 N•m (21 lb. ft.)
Catalytic Converter-to-Exhaust Manifold Nut ............................. 21 N•m (15 lb. ft.)
Connecting Rod Nut ................................................. 61 N•m (45 lb. ft.)
Crankshaft Balancer Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N •m ( 60 lb. ft.)
Crankshaft Balancer Hub Bolt/Screw ................................... 102 N•m (75 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw .................................... 105 N•m (77 lb. ft.)
Crankshaft Rear Oil Seal Housing Nut and Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . 15 N •m ( 11 lb. ft.)
Cylinder Head Bolt/Screw ............................................ 88 N•m (65 lb. ft.)
Distributor Bolt/Screw .............................................. 11 N•m (100 lb. in.)
Drive Belt Idler Pulley Bolt/Screw ...................................... 50 N•m (37 lb. ft.)
Drive Belt Tensioner Bolt/Screw ....................................... 33 N•m (24 lb. ft.)
EGR Control Valve Relay Nut ......................................... 22 N•m (16 lb. ft.)
EGR Valve Nut ..................................................... 22 N•m (16 lb. ft.)
Engine Block Oil Gallery Plug ......................................... 24 N•m (18 lb. ft.)
Engine Bracket Bolt/Screw ............................................ 58 N•m ( 43 lb. ft.)
Engine Coolant Air Bleed Pipe Bolt/Screw ............................... 41 N•m (30 lb. ft.)
Engine Front Cover Bolt/Screw ....................................... 11 N•m (100 lb. in.)
Engine Mount Through-Bolt Nut ....................................... 80 N•m (59 lb. ft.)
Engine Mount Through-Bolt/Screw ..................................... 95 N•m (70 lb. ft.)
Engine Mount-to-Frame or Engine Bolt/Screw ............................ 58 N•m (43 lb. ft.)
Engine Oil Cooler Bolt/Screw ......................................... 33 N•m (24 lb. ft.)
Engine Oil Cooler Fitting ............................................. 23 N•m (17 lb. ft.)
Engine Oil Cooler Hose Bracket Nut .................................... 17 N•m (13 lb. ft.)
Engine Oil Level Sensor Assembly ..................................... 22 N•m (16 lb. ft.)
Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt/Screw ........ 6 N•m (53 lb. in.)
Exhaust Manifold Bolt/Screw and Stud .................................. 35 N•m (26 lb. ft.)
Flywheel Bolt/Screw ................................................ 100 N•m (74 lb. ft.)
Fuel Injection Fuel Rail Bolt/Screw ..................................... 20 N •m (15 lb. ft.)
Fuel Pump Switch and Engine Oil Pressure Gage Sensor Assembly ........... 12 N•m (105 lb. in.)
Generator Bracket Bolt/Screw ......................................... 42 N•m (31 lb. ft.)
Ignition Coil Bolt/Screw .............................................. 33 N•m (24 lb. ft.)
Intake Manifold Bolt/Screw and Stud
First Pass ........................................................ 8 N •m (71 lb. in.)
Final Pass ...................................................... 48 N•m (35 lb. ft.)
Knock Sensor Assembly .............................................. 19 N•m (14 lb. ft.)
Oil Filter Adapter Bolt/Screw .......................................... 25 N•m (18 lb. ft.)
Oil Level Indicator Tube Nut .......................................... 34 N•m (25 lb. ft.)
Oil Pan
Corner Bolt/Screw and Nut ......................................... 20 N•m (15 lb. ft.)
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-33

Side Rail Bolt/Screw ............................................. 11 N•m (100 lb. in.)

Oil Pan Baffle Nut ................................................... 34 N•m (25 lb. ft.)
Oil Pan Drain Plug .................................................. 22 N•m (16 lb. ft.)
Oil Pump Cover Bolt/Screw ............................................ 9 N•m (80 lb. in.)
Oil Pump Driveshaft Bolt/Screw ....................................... 18 N•m (13 lb. ft.)
Oil Pump-to-Rear Crankshaft Bearing Cap Bolt/Screw ...................... 88 N•m (65 lb. ft.)
Oil Temperature Sensor Assembly ..................................... 12 N•m (108 lb. in.)
Secondary Air Injection Pipe Bracket Bolt/Screw .......................... 34 N•m (25 lb. ft.)
Secondary Air Injection Pipe Fitting-to-Exhaust Manifold Assembly .......... 34 N•m (25 lb. ft.)
Secondary Air Injection Pipe Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (19 lb. ft.)
Secondary Air Injection Pipe Flange Stud ................................ 10 N•m (89 lb. in.)
Spark Plug Bracket Bolt/Screw ....................................... 12 N•m (105 lb. in.)
Starter Motor Bolt/Screw ............................................. 46 N•m (34 lb. ft.)
Throttle Body Bolt/Screw ............................................. 26 N•m (19 lb. ft.)
Valve Lifter Guide Retainer Bolt/Screw .................................. 20 N•m (15 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw ................................... 11 N•m (100 lb. in.)
Valve Rocker Arm Stud .............................................. 68 N•m (50 lb. ft.)
Water Pump Bearing Retainer Bolt/Screw ............................... 12 N•m (105 lb. in.)
Water Pump Bolt/Screw .............................................. 41 N•m (30 lb. ft.)

ENGINE ASSEMBLY SPECIFICATIONS 5.7L (LT1)

GENERAL
TypeV8
Displacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (350 CID)
Bore ............................................................ 101.60 mm (4.000")
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.39 mm (3.480")
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5: 1
Firing Order ......................................................... 1-8-4-3-6-5-7-2
Spark Plugs
Type .................................................................. AC41-906
Gap ............................................................. 1.27 mm (0.050")
Torque .......................................................... 15 N•m (11 lb. ft.)
Oil Pressure (Minimum) ............................. 41.4 kPa (6.0 psig) at 1,000 engine rpm
124.l kPa (18.0 psig) at 2,000 engine rpm
165.5 kPa (24.0 psig) at 4,000 engine rpm
Oil Filter Torque .................................................... 19 N•m (14 lb. ft.)
CYLINDER BORE
Out-of-Round
Production .................................................. 0.02 mm (0.001 ") MAX.
Service Limit ................................................ 0.05 mm (0.002 ") MAX.
Taper
Production
Thrust Side .............................................. 0.012 mm (0.0005") MAX.
Relief Side ............................................... 0.025 mm (0.0010") MAX.
Service Limit .............................................. 0.025 mm (0.0010") MAX.
PISTON ASSEMBLY
Piston Bore Clearance
Production ........................................ 0.025 - 0.068 mm (0.0010 - 0.0027")
Service Limit .............................................. 0.068 mm (0.0027") MAX.
PISTON RINGS
Piston Compression Ring
Groove Clearance
Production Top ................................... 0.030 - 0.081 mm (0.0012 - 0.0032")
Production 2nd ................................... 0.030 - 0.081 mm (0.0012 - 0.0032")
Service Limit ............................................. 0.107 mm (0.0042") MAX.
Gap
Production Upper ..................................... 0.25 - 0.50 mm (0.010 - 0.020")
Production Lower ............................... 0.46 - 0.66 mm (0.018 - 0.026") MAX.
Service Limit ............................................... 0.88 mm (0.035") MAX.
Piston Oil Ring
Groove Clearance
Production .......................................... 0.051 - 0.17 mm (0.002 - 0.007")
6A3A·34 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

Service Limit ............................................... 0.20 mm (0.008 ") MAX.

Gap
Production ........................................... 0.25 - 0.76 mm (0.010 - 0.030")
Service Limit ............................................... 1.65 mm (0.065") MAX.
PISTON PIN
Diameter ......................................... 23.546 - 23.548 mm (0.9270 - 0.9271 ")
Clearance in Piston Assembly
Production ...................................... 0.0127 - 0.0203 mm (0.0005 - 0.0008")
Service Limit ............................................... 0.025 mm (0.001 ") MAX.
Fit In Connecting Rod Assembly .............. 0.021 - 0.040 mm (0.0008 - 0.0016") Interference
CRANKSHAFT ASSEMBLY
Main Journal
Diameter #1 ..................................... 62.189 - 62.212 mm (2.4484 - 2.4493 ")
Diameter #2, #3, #4 ............................... 62.182 - 62.205 mm (2.4481 - 2.4490")
Diameter #5 ..................................... 62.177 - 62.120 mm (2.4481 - 2.4488 ")
Taper
Production ............................................... 0.005 mm (0.0002") MAX.
Service Limit ............................................. 0.025 mm (0.0010") MAX.
Out-of-Round
Production ................................................ 0.005 mm (0.0002") MAX.
Service Limit ............................................. 0.025 mm (0.0010") MAX.
Crankshaft Bearing Clearance.
Production #1 ...................................... 0.020 - 0.051 mm (0.0008 - 0.0020")
Production #2, #3, #4 ................................ 0.028 - 0.051 mm (0.0011 - 0.0020")
Production #5 ...................................... 0.043 - 0.081 mm (0.0017 - 0.0032")
Service Limit #1 .................................... 0.025 - 0.038 mm (0.0010 - 0.0015")
Service Limit #2, #3, #4 .............................. 0.025 - 0.064 mm (0.0010 - 0.0025")
Service Limit #5 .................................... 0.064 - 0.089 mm (0.0025 - 0.0035")
Crankshaft Assembly End Play ............................. 0.03 - 0.17 mm (0.001 - 0.007")
CONNECTING ROD ASSEMBLY
Connecting Rod Journal
Diameter ............ , ........................... 53.068 - 53.334 mm (2.0893 - 2.0998 ")
Taper
Production ............................................... 0.013 mm (0.0005") MAX.
Service Limit ............................................. 0.025 mm (0.0010") MAX.
Out-of-Round
Production ............................................... 0.013 mm (0.0005") MAX.
Service Limit ............................................. 0.025 mm (0.0010") MAX.
Rod Bearing Clearance
Production ........................................ 0.033 - 0.088 mm (0.0013 - 0.0035")
Service Limit .............................................. 0.076 mm (0.0030") MAX.
Rod Side Clearance ....................................... 0.16 - 0.35 mm (0.006 - 0.014")
CAMSHAFT ASSEMBLY
Journal Diameter ................................... 47.452 - 47.477 mm (1.8682 - 1.8692")
End Play ............................................... 0.11-0.30 mm (0.004- 0.012")
Lobe Lift ± 0.050 mm (0.002 ")
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62 mm (0.300")
Exhaust .......................................................... 7.62 mm (0.300")
VALVE SYSTEM
Lifter Assembly ........................................................... Hydraulic
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Valve Lash ............................................. 1 ± 1/4 tum down from zero lash
Face Angle .................................................................... 45 °
Seat Angle ..................................................................... 46°
Seat Runout ................................................... 0.05 mm (0.002") MAX.
Seat Width
Intake ................................................ 0.76 - 1.27 mm (0.030 - 0.050")
Exhaust ............................................... 1.52 - 2.03 mm (0.060 - 0.080")
Stem Clearance
Production
Intake ........................................... 0.027 - 0.069 mm (0.0011 - 0.0027")
Exhaust ......................................... 0.027 - 0.069 mm (0.0011 - 0.0027")
 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A~35

Service
Intake ................................................... 0.093 mm (0.0037") MAX.
Exhaust ................................................. 0.119 mm (0.0047") MAX.
Valve Spring
Free Length ....................................................... 51.1 mm (2.01 ")
Pressure
Closed .................................... 360 - 395 N at 45.2 mm (81 - 89 lb. at 1. 78 ")
Open ................................ 1121 - 1208 Nat 33.1 mm (252 - 272 lb. at 1.305")
Installed Height
Intake ................................................... : ....... 45.2 mm (1.78")
Exhaust ......................................................... 45.2 mm (1.78")
Valve Lift
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43 n1m (0.450")
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68 mm (0.460")
6A3A-36 5.7LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

SPECIAL TOOLS

J5590 J 6098-01

J 39087 J 39088

0
~ J 5825-A 0 Ii} J8037

~
J 9666 or

0~ J 5892-C 0 J8056

J8062

J 39089

Q CRANKSHAFT GEAR INSTALLER

0 DRIVEN GEAR SHAFT FRONT COVER SEAL PROTECTOR

0 CRANKSHAFT GEAR REMOVER

0 VALVE SPRING COMPRESSOR (HEAD-ON)

0 DRIVEN GEAR/WATER PUMP SHAFT SEAL INSTALLER

0 CAMSHAFT BEARING REMOVER AND INSTALLER

G DRIVEN GEAR SHAFT FRONT COVER SEAL INST ALLER

0 PISTON RING COMPRESOR

0 VALVE SPRING TESTER

~ VALVE SPRING COMPRESSOR (HEAD-OFF)

NC1031-8A1A·Y·RP
 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A·37

~=U J8358 J 23738-A

@] ~~
...
J 8520

Q(N
iii:
p
@]
\liw:.~
J 24086-8

@] 2:::, J 21882

~ ODg
@@
e ,\ ~

J 39046
~e J 35468

~ ' /,-<# t )6 J 22794

~ @ J 35621

~ CARBON REMOVING BRUSH ~

~ CAM LOBE LIFT INDICATOR

G OIL SUCTION PIPE INSTALLER

G CRANKSHAFT HUB REMOVER AND INSTALLER

GJ SPARK PLUG PORT ADAPTOR

(14 mm TAPERED SEAT)
~ J 39092

~ VALVE STEM SEAL TESTER (MITY-VAC)

G PISTON PIN REMOVER AND INST ALLER SET

~ FRONT COVER OIL SEAL INSTALLER

~ REAR MAIN SEAL INSTALLER

~ @ ~ J39090

~ VALVE GUIDE CLEANER

~ DRIVEN GEAR ASSEMBLY INSTALLER

~ DISTRIBUTOR DRIVESHAFT FRONT COVER SEAL INSTALLER

NC1038-6A 1A-B-RP
6A3A-38 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P

J3049
e?] ~~"====} J 8080

J7872

;; J5239

J8001

~~ J9290-01

J39243
J 34730-1

~ HYDRAULIC VALVE
LIFTER REMOVER (PLIER TYPE)

~ MAGNETIC BASE INDICATOR

SET

~ DIAL INDICATOR SET

~ FUEL PRESSURE GAGE

ez1 MAIN BEARING SHELL

REMOVER & INSTALLER

~ CONNECTING ROD BOLT GUIDE SET

~ HYDRAULIC VALVE
LIFTER REMOVER
(SLIDE HAMMER TYPE)

~ DRIVEN GEAR ASSEMBLY REMOVER

NC1037·8A1A·Y·RP
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·1

SECTION 6A38

5.7 LITER VS ENGINE

UNIT REPAIR
RPO LT1 - VIN P

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

CONTENTS
General Description ...................... 6A3B-6 Engine Front Cover Oil Seals ........... 6A3B-30
Construction .......................... 6A3B-6 Oil Pan Assembly .................... 6A3B-30
Lubrication ........................... 6A3B-6 Water Pump Assembly ................. 6A3B-30
Disassembly ............................ 6A3B-6 Valve Lifter Assemblies ................ 6A3B-30
Flywheel Assembly ................... 6A3B-10 Valve Rocker Arms and Pushrod
Draining Engine Assembly ............. 6A3B-10 Assemblies ........................ 6A3B-31
Intake Manifold Assembly .............. 6A3B- l O Valve Rocker Arm Cover Assemblies ..... 6A3B-31
Exhaust Manifold Assemblies ........... 6A3B-10 Intake Manifold Assembly .............. 6A3B-31
Valve Rocker Arm Cover Assemblies ..... 6A3B-l 1 Assembly ............................. 6A3B-31
Valve Rocker Arms and Pushrod Engine Block ........................ 6A3B-31
Assemblies ........................ 6A3B- l 1 Camshaft Bearings .................... 6A3B-31
Valve Lifter Assemblies ................ 6A3B-11 Crankshaft Assembly .................. 6A3B-32
Water Pump Assembly ................. 6A3B-11 Crankshaft Rear Oil Seal Housing ........ 6A3B-32
Crankshaft Balancer Assembly and Hub ... 6A3B-1 l Crankshaft Rear Oil Seal ............... 6A3B-33
Distributor Assembly .................. 6A3B-12 Piston and Connecting Rod Assembly ..... 6A3B-33
Oil Pan Assembly .................... 6A3B-12 Connecting Rod Bearings .............. 6A3B-33
Engine Front Cover Assembly ........... 6A3B-12 Oil Pump Assembly ................... 6A3B-34
Timing Chain Assembly, Crankshaft Cylinder Head Assembly ............... 6A3B-34
and Camshaft Sprockets, and Water Pump Camshaft Assembly ................... 6A3B-34
Driveshaft Assembly .............. 6A3B-12 Timing Chain Assembly, Crankshaft
Camshaft Assembly ................... 6A3B-14 and Camshaft Sprockets, and Water
Cylinder Head Assembly ............... 6A3B-14 Pump Driveshaft Assembly ......... 6A3B-34
Oil Pump Assembly ................... 6A3B-15 Engine Front Cover Assembly ........... 6A3B-35
Piston and Connecting Rod Assembly ..... 6A3B- l 5 Distributor Assembly .................. 6A3B-35
Crankshaft Rear Oil Seal Housing Oil Pan Assembly .................... 6A3B-35
and Crankshaft Assembly ............ 6A3B-19 Crankshaft Balancer Assembly and Hub ... 6A3B-35
Camshaft Bearings .................... 6A3B-20 Water Pump Assembly ................. 6A3B-36
Cleaning, Inspection and Repair ........... 6A3B-21 Valve Lifter Assemblies ................ 6A3B-37
Engine Block ........................ 6A3B-21 Valve Rocker Arm Ball Studs ........... 6A3B-37
Crankshaft Bearing Fitting .............. 6A3B-22 Valve Rocker Arms and Pushrod
Crankshaft Assembly .................. 6A3B-23 Assemblies ........................ 6A3B-37
Piston and Connecting Rod Assembly ..... 6A3B-23 Valve Rocker Arm Cover Assemblies ..... 6A3B-38
Connecting Rod Bearings .............. 6A3B-25 Intake Manifold Assembly .............. 6A3B-38
Oil Pump Assembly ................... 6A3B-26 Exhaust Manifold Assemblies ........... 6A3B-39
Cylinder Head Assembly ............... 6A3B-27 Flywheel Assembly ................... 6A3B-40
Camshaft Assembly ................... 6A3B-29 Specifications .......................... 6A3B-40
Timing Chain Assembly, Crankshaft Fastener Tightening Specifications ....... 6A3B-40
and Camshaft Sprockets, and Water Engine Assembly
Pump Driveshaft Assembly ......... 6A3B-29 Specifications 5.7L (LTl) ............ 6A3B-41
Engine Front Cover Assembly ........... 6A3B-30 Special Tools .......................... 6A3B-44
6A3B·2 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P

1ss-=-19- 6

210

18

82 16

82

17

RC0001-6A3B-F-RP

Figure 1 - Upper Engine Assembly

 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·3

2 RAIL ASSEMBLY, MULTIPORT FUEL INJECTION FUEL 79 VALVE, EXHAUST

3 BODY ASSEMBLY, THROTTLE 81 BOLT/SCREW, CYLINDER HEAD
5 GASKET, THROTTLE BODY 82 GASKET, CYLINDER HEAD
6 MANIFOLD ASSEMBLY, INTAKE 193 SOLENOID ASSEMBLY, EGR CONTROL VALVE RELAY
8 BOLT/SCREW, INTAKE MANIFOLD 194 NUT, EGR CONTROL VALVE RELAY
9 STUD, INTAKE MANIFOLD 195 FITTING, INTAKE MANIFOLD VACUUM
10 GASKET, INTAKE MANIFOLD 196 VALVE ASSEMBLY, EVAPORATIVE EMISSION CANISTER
11 VALVE ASSEMBLY, SECONDARY AIR INJECTION CHECK PURGE SOLENOID
12 PIPE ASSEMBLY, SECONDARY AIR INJECTION 197 HOSE, EVAPORATIVE EMISSION CANISTER PURGE
15 PIPE ASSEMBLY, SECONDARY AIR INJECTION SOLENOID VALVE
16 MANIFOLD ASSEMBLY, EXHAUST 199 PIPE ASSEMBLY, EVAPORATIVE EMISSION CANISTER
17 GASKET, EXHAUST MANIFOLD PURGE SOLENOID VALVE
18 GASKET, EXHAUST MANIFOLD 200 HOSE, CRANKCASE VENT VALVE
19 MANIFOLD ASSEMBLY, EXHAUST 201 GROMMET, CRANKCASE VENT HOSE CONNECTOR
21 BOLT/SCREW, EXHAUST MANIFOLD 202 FITTING, POWER BRAKE BOOSTER VACUUM TUBE
23 COVER ASSEMBLY, VALVE ROCKER ARM 203 GASKET, EGR VALVE
24 BOLT/SCREW, VALVE ROCKER ARM COVER 204 VALVE ASSEMBLY, EGR
25 GASKET, VALVE ROCKER ARM COVER 205 BOLT/SCREW, EGR VALVE
27 PUSHROD ASSEMBLY, VALVE 206 GROMMET, CRANKCASE VENT VALVE
28 STUD, VALVE ROCKER ARM BALL 207 VALVE ASSEMBLY, CRANKCASE VENT
29 ARM, VALVE ROCKER 209 HOSE, CRANKCASE VENT VALVE
30 BALL, VALVE ROCKER ARM 210 PIPE, ENGINE COOLANT AIR BLEED
31 NUT, VALVE ROCKER ARM 211 HARNESS ASSEMBLY, EGR VALVE VACUUM
33 RETAINER, VALVE LIFTER GUIDE 21'2 BOLT/SCREW, ACCELERATOR CONTROL CABLE BRACKET
34 HEAD ASSEMBLY, CYLINDER 213 BRACKET, ACCELERATOR CONTROL CABLE
35 GUIDE, VALVE LIFTER 217 SHIELD, EXHAUST MANIFOLD HEAT OUTER
36 LIFTER ASSEMBLY, VALVE 218 SHIELD, EXHAUST MANIFOLD HEAT INNER
69 SPRING, VALVE 222 COIL ASSEMBLY, IGNITION
70 CAP, VALVE SPRING 226 SPARK PLUG
71 VALVE, INTAKE 227 SUPPORT, SPARK PLUG WIRE
72 KEV, VALVE STEM 235 HARNESS ASSEMBLY, IGNITION DISTRIBUTOR WIRING
73 SEAL, VALVE STEM OIL

RC0002-6A3B-F-RP

Figure 2 - Upper Engine Assembly - Legend

6A3B·4 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P

154
177

58 59

184 44

~~%~~ 45 138

,.!! 187
" _1
121

137

54

189

~ -,so
PC0003-6A3B-F-RP

Figure 3 - Lower Engine Assembly

 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B-5

A FOR MANUAL TRANSMISSION 114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
B FOR AUTOMATIC TRANSMISSION 115 NUT, CRANKSHAFT REAR OIL SEAL HOUSING
37 PUMP ASSEMBLY, WATER . 116 BOLT/SCREW, CRANKSHAFT REAR OIL SEAL HOUSING
38 GASKET, WATER PUMP 117 STUD, CRANKSHAFT BEARING CAP
39 COUPLING, WATER PUMP DRIVESHAFT 118 PUMP ASSEMBLY, OIL
40 BOLT/SCREW, WATER PUMP 119 BAFFLE, OIL PAN
41 BOLT/SCREW, WATER PUMP 120 BOLT/SCREW, OIL PUMP
42 BALANCER ASSEMBLY, CRANKSHAFT 121 BRACKET ASSEMBLY, GENERATOR AND AIR
43 BOLT/SCREW, CRANKSHAFT BALANCER HUB CONDITIONING COMPRESSOR AND POWER STEERING
44 WASHER, CRANKSHAFT BALANCER HUB PUMP
45 HUB, CRANKSHAFT BALANCER 135 FLYWHEEL ASSEMBLY
46 BOLT/SCREW, CRANKSHAFT BALANCER 136 BOLT/SCREW, FLYWHEEL
49 DISTRIBUTOR ASSEMBLY 137 FLYWHEEL ASSEMBLY
50 COVER ASSEMBLY, ENGINE FRONT 138 BOLT/SCREW, FLYWHEEL
51 GASKET, ENGINE FRONT COVER 139 PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
52 BOLT/SCREW, ENGINE FRONT COVER 141 COOLER ASSEMBLY, ENGINE OIL
53 REINFORCEMENT, OIL PAN 142 ADAPTER ASSEMBLY, OIL.FILTER
54 PAN ASSEMBLY, OIL 143 BOLT/SCREW, OIL FILTER ADAPTER
55 GASKET, OIL PAN 144 FILTEA ASSEMBLY, OIL
56 BOLT/SCREW, CAMSHAFT SPROCKET 145 TENSIONER ASSEMBLY, DRIVE BELT
57 SPROCKET, CAMSHAFT 154 HARNESS ASSEMBLY, SPARK PLUG WIRE
58 BOLT/SCREW, CAMSHAFT RETAINER 155 SENSOR ASSEMBLY, ENGINE COOLANT
59 RETAINER, CAMSHAFT TEMPERATURE
60 CAMSHAFT ASSEMBLY 156 SEAL, WATER PUMP DRIVESHAFT
61 CHAIN ASSEMBLY, TIMING 157 SEAL ASSEMBLY, WATER PUMP BEARING
62 SPROCKET, CRANKSHAFT 158 SEAL, DISTRIBUTOR
63 DRIVESHAFT ASSEMBLY, WATER PUMP 159 SEAL ASSEMBLY, CRANKSHAFT FRONT OIL
64 BOLT/SCREW, WATER PUMP DRIVESHAFT BEARING 160 INDICATOR ASSEMBLY, OIL LEVEL
RETAINER 161 TUBE ASSEMBLY, OIL LEVEL INDICATOR
65 DRIVESHAFT ASSEMBLY, OIL PUMP 162 NUT, OIL LEVEL INDICATOR TUBE
66 BOLT/SCREW, OIL PUMP DRIVESHAFT 165 SENSOR ASSEMBLY, FUEL PUMP AND ENGINE OIL
67 BLOCK, ENGINE PRESSURE INDICATOR SWITCH
68 PLUG, CAMSHAFT REAR BEARING HOLE 167 PLUG, ENGINE BLOCK OIL GALLERY
74 PIN, ENGINE FRONT COVER LOCATING 168 PIN, TRANSMISSION
77 WEIGHT, CRANKSHAFT BALANCER 170 PLUG, ENGINE BLOCK CORE HOLE
84 BOLT/SCREW, OIL PAN 171 SENSOR ASSEMBLY, KNOCK
89 DRIVESHAFT, OIL PUMP 172 PLUG, OIL FILTER ADAPTER HOLE
95 RETAINER, OIL PUMP DRIVESHAFT 174 BEARING, CAMSHAFT
98 CRANKSHAFT ASSEMBLY 175 BEARING, CLUTCH PILOT
99 CAP, CONNECTING ROD 176 STUD, CRANKSHAFT REAR OIL SEAL RETAINER
100 NUT, CONNECTING ROD 177 SEAL ASSEMBLY, CRANKSHAFT REAR OIL
101 BEARING, CONNECTING ROD 178 SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH
102 BOLT/SCREW, CONNECTING ROD 179 PIN, OIL PUMP LOCATOR
103 PISTON ASSEMBLY 180 KEY, CRANKSHAFT BALANCER
104 ROD ASSEMBLY, CONNECTING 181 CLIP, TRANSMISSION OIL COOLER PIPE
105 PIN, PISTON 183 NUT, CRANKSHAFT OIL DEFLECTOR
106 RING, PISTON 184 SHIM, STARTER MOTOR
107 CAP, CRANKSHAFT BEARING 185 MOTOR ASSEMBLY, STARTER
108 BOLT/SCREW, CRANKSHAFT BEARING CAP 186 BOLT/SCREW, STARTER MOTOR
109 CAP, CRANKSHAFT BEARING 187 STUD, STARTER MOTOR
110 BEARING, CRANKSHAFT 188 GASKET, OIL PAN DRAIN PLUG
111 BEARING, CRANKSHAFT 189 PLUG, OIL PAN DRAIN
112 STUD, CRANKSHAFT REAR OIL SEAL RETAINER 190 BRACKET, ENGINE WIRING HARNESS
113 GASKET, CRANKSHAFT REAR OIL SEAL HOUSING 191 PLUG, ENGINE BLOCK OIL GALLERY
223 HARNESS ASSEMBLY, IGNITION COIL WIRE

Figure 4 - Lower Engine Assembly - Legend

6A3.B-6 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P
GENERAL DESCRIPTION
CONSTRUCTION
Figures 1 through 4
Engine Block
The engine block is made of cast iron and has eight
cylinders arranged in a "V" shape with four cylinders in
each bank. It is a one-piece casting with the cylinders
encircled by coolant jackets.
Cylinder Head Assemblies
The cylinder head assemblies are cast aluminum and
have powdered metal valve guides and valve seats pressed
into the intake and exhaust ports. The spark plugs are
located between the intake and exhaust ports.
Crankshaft Assembly
The crankshaft assembly is made of cast nodular
iron. It is supported by five crankshaft bearings that are
retained by bearing caps which are machined with the
block for proper alignment and clearances. The bearing
caps are retained by two bolts/screws each. The number
five bearing at the rear of the engine assembly is the end
thrust bearing. Four connecting rod journals (two rods per
journal) are spaced 90 degrees apart.
Piston and Connecting Rod Assemblies
The pistons are cast aluminum that use two com-
pression rings and one oil control ring assembly. The pis-
ton is a low-friction, lightweight design with a flat top and
barrel-shaped skirt. The piston pins are chromium steel.
They have a floating fit in the piston and are retained by a
press fit in the connecting rod assembly.
The connecting rod assemblies are made of forged
steel. They are machined with the rod cap installed for
proper clearances and alignment.
Camshaft Assembly
A steel camshaft assembly is supported by five bear-
ings pressed into the engine block. The timing sprocket
mounted to the front of the camshaft assembly is driven
by the crankshaft sprocket through a timing chain assem-
bly.
The camshaft sprocket also has spur gear teeth
which drive a geared shaft assembly to operate the water
pump assembly.
A spiral gear machined into the camshaft assembly
near the rear journal drives a shaft assembly which oper-
ates the oil pump assembly.
The center of the camshaft sprocket has a splined
opening with a keyway (missing tooth) that mates with the
distributor driveshaft. This provides net build timing,
meaning that the ignition timing does not have to be
adjusted.
Valve Train
The valve train is a ball pivot type. Motion is trans-
mitted from the camshaft assembly through hydraulic
roller lifter and tubular pushrod assemblies to the rocker
arms. The rocker arm pivots on a ball to open the valve.
Th~ ~ydraulic lifter assemblies keep all parts of the valve
tram m constant contact.
The rocker arm ball is retained on the rocker arm
stud with a locking nut. The rocker arm stud is threaded
into the cylinder head assembly.
Intake Manifold Assembly
The intake manifold assembly is a one-piece cast
aluminum unit. The intake manifold assembly has exhaust
gas recirculation and crankcase vent passages cast into it
but coolant crossover passages have been eliminated.
Exhaust Manifold Assemblies
The two cast-iron exhaust manifold assemblies
direct exhaust gases from the combustion chambers to the
exhaust system. The exhaust manifold assemblies each
have a port for air injection system pipe fittings.
LUBRICATION
Figures 5 through 7
~ngine assembly lubrication is supplied by a gear-
type 011 pump assembly. The oil pump assembly is driven
by an intermediate shaft which is connected to a shaft
assembly driven by the camshaft assembly. The pump
gears rotate and draw oil from the oil pan sump through a
pick-up screen and pipe. The oil is pressurized as it passes
through the pump and sent through engine block oil gal-
leries.
Contained within the oil pump assembly is a pres-
sure relief valve that maintains oil pressure within a speci-
fied range.
Pressurized oil is directed to the oil filter where
harmful contaminants are removed. A bypass valve is also
incorporated into the oil filter. The bypass allows oil to
bypass the filter and flow to the engine assembly if the
filter becomes clogged.
The oil is then pumped to the main oil gallery which
is drilled through the length of the engine block just above
the camshaft assembly. At the rear of the engine block, oil
also flows into the right and left lifter oil galleries. From
the main oil gallery, oil is pumped downward to the cam-
shaft bearings, then to the crankshaft bearings. The crank-
shaft bearing upper inserts are grooved to align with oil
passages drilled from the crankshaft bearing journal to the
connecting rod journal. After lubricating the connecting
rod bearings, the cylinder walls, rings and piston pins are
lubricated by oil which is "slung" front the connecting
rod bearing journals due to the rotation of the crankshaft
assembly. This oil then returns to the oil pan sump. Oil
that has entered the left and right lifter oil galleries pres-
surizes the hydraulic lifter assemblies and is then pumped
up through the pushrod assemblies to lubricate the rocker
arms and valve stems.
Oil returning to the oil pan assembly from the cylin-
der head assemblies and the front camshaft bearing, lubri-
cates the timing chain assembly and crankshaft and
camshaft sprockets.
DISASSEMBLY
When beginning the engine assembly unit repair, the
belt tensioner, power steering pump, air injection pump,
generator, A/C compressor, and generator and A/C com-
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·7

NC1042-8A111-Y-RP

Figure 5 - Engine Assembly Lubrication (Left Side View)

6A3B·8 5.7 LITER va ENGINE UNIT REPAIR RPO LT1·VIN P

.
I

: \
J~
SECTIONA·A

NC1043-U1B-Y·RP

Figure 6 - Engine Assembly Lubrication (Front View)

 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·9

SECTION B-B

SECTION C·C

c c
NC1044-6A1B·Y·RP

Figure 7 - Engine Assembly Lubrication (Rear Views)

6A38-10 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P

pressor braces should already be removed. For removal INTAKE MANIFOLD ASSEMBLY
procedures, refer to the specific section in the service
manual for each component. Figures 9 through 11

FLYWHEEL ASSEMBLY l+-•I Remove or Disconnect

Figure 8 1. Fuel pressure regulator vacuum tube assembly (7).
2. Fuel rail bolts/screws ( 1).
!+-•I Remove or Disconnect 3. Canister purge valve vacuum hose.
1. Flywheel bolts/screws (136 or 138). 4. Fuel injectors and fuel rail assembly (2) from intake
manifold assembly (6).
2. Flywheel assembly ( 135 or 137).
5. Exhaust gas recirculation (EGR) vacuum harness
DRAINING ENGINE ASSEMBLY assembly and crankcase vent hoses.
6. EGR solenoid assembly and bracket.
!+-•I Remove or Disconnect 7. Canister purge valve assembly and bracket.
8. Move wiring harness assemblies out of area.
1. Oil pan plug and drain engine oil.
9. Disconnect distributor wiring harness assembly, if
2. Oil filter assembly. necessary.
3. Knock sensor assemblies and drain plug and allow 10. EGR valve nuts, valve assembly and gasket.
coolant to drain.
11. EGR valve pipe bolt/screw (229), nut (14), pipe
assembly (12) and gasket (22).
12. Accelerator cable bracket bolt/screw and bracket.
13. Engine coolant air bleed pipe bolts/screws and pipe.
133
• Use a backup wrench on pipe fitting when
removing bolts/screws.
14. Manifold absolute pressure (MAP) sensor bolts/
screws and MAP sensor.
15. Throttle body bolts/screws (4), throttle body assem-
bly (3) and gasket (5).
16. Intake manifold bolts/screws (8) and studs (9).
17. Intake manifold assembly (6) and gaskets (10).
EXHAUST MANIFOLD ASSEMBLIES
Figures 11 and 12
Right Exhaust Manifold Assembly

l+•I Remove or Disconnect

1. Right cylinder bank spark plug wire harness assem-
bly from spark plugs and supports.
2. Oil level indicator tube nut.
3. Oil level indicator and tube.
4. Right exhaust manifold air injection pipe assembly
(15) and check valve (11).
5. Right exhaust manifold studs (20) and bolts/screws
(21) and spacers (245).
B 6. Right heat shields, exhaust manifold assembly (19)
and gasket (18).
A FOR MANUAL TRANSMISSION
B FOR AUTOMATIC TRANSMISSION Left Exhaust Manifold Assembly
C LOCATOR HOLE
98
133
134
CRANKSHAFT ASSEMBLY
PIN, FLYWHEEL LOCATOR
WEIGHT, FLYWHEEL
l+•I Remove or Disconnect
135 FLYWHEEL ASSEMBLY 1. Left exhaust manifold air injection pipe assembly
136 BOLT/SCREW, FLYWHEEL (15) and check valve (11).
137 FLYWHEEL ASSEMBLY 2. Left cylinder bank spark plug wire harness assembly
138 BOLT/SCREW, FLYWHEEL
from spark plugs and supports.
PC0008-8A3B-F-RP
3. Left exhaust manifold bolts/screws (21) and spacers
Figure 8 - Flywheel Assembly (245).
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·11

RC0009-6A3B-F-RP

Figure 9 - Fuel Rail and Throttle Body Assemblies

4. Left heat shields, exhaust manifold assembly (16) VALVE LIFTER ASSEMBLIES
and gasket ( 17).
Figure 15
VALVE ROCKER ARM COVER ASSEMBLIES
!++! Remove or Disconnect
Figure 13 1. Valve lifter guide retainer bolts/screws (32) and
retainer (33).
Right Valve Rocker Arm Cover Assembly
2. Valve lifter guides (35) and valve lifter assemblies
j++! Remove or Disconnect (36).
• Some valve lifter assemblies (36) may be stuck
I. Crankcase vent hose. in their bores because of gum or varnish depos-
2. Right valve rocker arm cover bolts/screws (24). its. These lifter assemblies (36) can be
3. Right valve rocker arm cover assembly (23) and gas- removed using J 3049 or J 9290-01.
ket (25).
WATER PUMP ASSEMBLY
Left Valve Rocker Arm Cover Assembly Figure 16
j++! Remove or Disconnect j++l Remove or Disconnect
I. Left valve rocker arm cover bolts/screws (24). 1. Air injection pump bracket bolts/screws and
2. Left valve rocker arm cover assembly (23) and gas- bracket.
ket (25). 2. Water pump bolts/screws (40 and 41).

VALVE ROCKER ARMS AND PUSHROD

ASSEMBLIES
rn Important
A. Keep ignition wires connected to distributor
Figure 14 assembly until water pump is removed.
B. Make sure coolant is drained.
j++! Remove or Disconnect 3. Water pump assembly (37), coupling (39) and gas-
I. Rocker arm nuts (31) and balls (30). kets (38).
2. Rocker arms (29) and pushrod assemblies (27). CRANKSHAFT BALANCER ASSEMBLY AND
• Place rocker arms (29), rocker arm balls (30) HUB
and pushrod assemblies (27) in a rack so that
they can be reinstalled in same locations from Figure 17
which they were removed. Tool Required:
3. Rocker arm ball stud (28). J 39046 Crankshaft Hub Remover/Installer
6A38·12 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P

!+-+I Remove or Disconnect

I. Crankshaft balancer bolts/screws (46) and balancer
assembly (42).
2. Crankshaft balancer hub bolt/screw and washer.
3. Crankshaft balancer hub (45) using J 39046.

DISTRIBUTOR ASSEMBLY
Figure 18

!+-+I Remove or Disconnect

1. Ignition harness assembly from coil assembly.
• Do not remove wires from distributor assem-
bly unless necessary.
2. Distributor bolts/screws (47) and distributor assem-
bly (49).
3. Distributor driveshaft (48).

9 OIL PAN ASSEMBLY

!+-+I Remove or Disconnect

1. Oil level sensor assembly.
• Oil level sensor assembly must be removed to
prevent it from being damaged as oil pan
assembly is removed.
2. Oil pan bolts/screws, nuts and studs.
3. Oil pan assembly, reinforcements and gasket.

ENGINE FRONT COVER ASSEMBLY

Figure 19

!+-+I Remove or Disconnect

1. Front cover bolts/screws (52).
2. Front cover assembly (50) and gasket (51).

TIMING CHAIN ASSEMBLY, CRANKSHAFT

AND CAMSHAFT SPROCKETS, AND WATER
PUMP DRIVESHAFT ASSEMBLY
Figures 20 and 21
Tools Required:
J 39243 Driven Gear Assembly Remover
J 5825-A Crankshaft Gear Remover

!+-+I Remove or Disconnect

1. Camshaft sprocket bolts/screws (56).
NOTICE: To prevent damage to piston or valve
A SEALER assemblies, do not turn the crankshaft assembly after
6 MANIFOLD ASSEMBLY, INTAKE the timing chain assembly has been removed.
8 BOLT/SCREW, INTAKE MANIFOLD
9 STUD, INTAKE MANIFOLD 2. Camshaft sprocket (57) and timing chain assembly
10 GASKET, INTAKE MANIFOLD (61 ).
3. Water pump driveshaft bolts/screws (64) and drive-
shaft assembly (63) using J 39243.
PC001CMA3B-f.RP 4. Crankshaft sprocket (62) using J 5825-A.
Figure 1O - Intake Manifold Assembly 5. Key, if necessary.
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·13

15
11

~/

_]]--~,~ 229
jv1EWA I

'
11 VALVE ASSEMBLY, SECONDARY AIR INJECTION 14 NUT, EGR VALVE PIPE
CHECK 15 PIPE ASSEMBLY, SECONDARY AIR INJECTION
12 PIPE ASSEMBLY, EGR VALVE 22 GASKET, EGR VALVE PIPE
13 STUD, EGR VALVE PIPE 229 BOLT/SCREW, EGR VALVE PIPE
RC0011-6A4A·B·RP

Figure 11 - Secondary Air Injection and EGR Valve Pipe Assemblies

16

245 20
16 MANIFOLD ASSEMBLY, EXHAUST
17 GASKET, EXHAUST MANIFOLD
18 GASKET, EXHAUST MANIFOLD
19 MANIFOLD ASSEMBLY, EXHAUST 21
20 STUD, EXHAUST MANIFOLD
21 BO~T/SCREW, EXHAUST MANIFOLD
245 SPACER, EXHAUST MANIFOLD
RC0005·6A4A·B·RP

Figure 12 - Exhaust Manifold Assemblies

6A38·14 5.7 LITER V8 ENGINE UNIT REPAI.R RPO LT1·VIN P

27 PUSHROD ASSEMBLY, VALVE

32 BOLT/SCREW, VALVE LIFTER GUIDE RETAINER
33 RETAINER, VALVE LIFTER GUIDE
23 COVER ASSEMBLY, VALVE ROCKER ARM 34 HEAD ASSEMBLY, CYLINDER
24 BOLT/SCREW, VALVE ROCKER ARM COVER 35 GUIDE, VALVE LIFTER
25 GASKET, VALVE ROCKER ARM COVER 36 LIFTER ASSEMBLY, VALVE

PC0013·8A3B-F-RP PC0015-6A3B·F·RP

Figure 13 - Valve Rocker Arm Cover Assemblies Figure 15 - Valve Lifter Assemblies

27 PUSHROD ASSEMBLY, VALVE

2. Camshaft retainer bolts/screws (58) and retainer
28 STUD, VALVE ROCKER ARM BALL (59).
29 ARM, VALVE ROCKER NOTICE: All camshaft journals are the same diam-
30 BALL, VALVE ROCKER ARM
31 NUT, VALVE ROCKER ARM
eter so care must be used in removing the camshaft
assembly to avoid damage to the bearings.
3. Camshaft assembly (60).
A. Install three 5/16-18 x 4-inch bolts/screws in
camshaft bolt holes.
B. Carefully rotate and pull camshaft assembly
(60) out of bearings.

CYLINDER HEAD ASSEMBLY

Figures 24 and 25

l++I Remove or Disconnect

1. Engine coolant air bleed pipe bolts/screws and pipe.
• Use a backup wrench on pipe fitting when
removing bolts/screws.
PC001"'8A3B-F·RP
2. Generator bracket bolts/screws (122 and 123) spark
Figure 14 - Valve Rocker Arms and Pushrod Assemblies
plug wire support (173) and bracket assembly (121)
from right cylinder head assembly (34).
CAMSHAFT ASSEMBLY
3. Cylinder head bolts/screws (81 ).
Figures 20, 22 and 23 NOTICE: After removal, place the cylinder head
assembly on two wood blocks to prevent damage.
!++I Remove or Disconnect 4. Cylinder head assembly (34) and gasket (82).
1. Bolt/screw (66) and oil pump driveshaft assembly 5. Ignition coil studs, coil and bracket assembly from
(65). left cylinder head assembly (34).
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·15

!VIEWA I

63

37

40
41
PC001MA3B-f.RP

Figure 16 - Water Pump Assembly

42 BALANCER ASSEMBLY, CRANKSHAFT

45 HUB, CRANKSHAFT BALANCER
46 BOLT/SCREW, CRANKSHAFT BALANCER
77 WEIGHT, CRANKSHAFT BALANCER PC00, 7-6A3B-F-RP

Figure 17 - Crankshaft Balancer Assembly and Hub 47 BOLT/SCREW, DISTRIBUTOR

48 DRIVESHAFT, DISTRIBUTOR
49 DISTRIBUTOR ASSEMBLY
PC0018-6A3B-f.RP
OIL PUMP ASSEMBLY
Figure 18 - Distributor Assembly
Figure26

!++I Remove or Disconnect PISTON AND CONNECTING ROD

I. Oil pan baffle nuts. ASSEMBLY
2. Bolt/screw ( 120) attaching oil pump assembly ( 118)
to rear crankshaft bearing cap. Figure 27
3. Oil pan baffle (119), oil pump assembly (118), dri- Tool Required:
veshaft (89) and retainer (95). J 5239 Connecting Rod Bolt Guide Set
6A38~16 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P

50

50 COVER ASSEMBLY, ENGINE FRONT

51 GASKET, ENGINE FRONT COVER
52 BOLT/SCREW, ENGINE FRONT COVER
74 PIN, ENGINE FRONT COVER LOCATING

PC0019-IA3B·f·RP

Figure 19 - Engine Front Cover Assembly

A TIMING MARKS
B KEYWAY
56 BOLT/SCREW, CAMSHAFT SPROCKET
57 SPROCKET, CAMSHAFT
58 BOLT/SCREW, CAMSHAFT RETAINER
59 RETAINER, CAMSHAFT
60 CAMSHAFT ASSEMBLY
61 CHAIN ASSEMBLY, TIMING
62 SPROCKET, CRANKSHAFT
63 DRIVESHAFT ASSEMBLY, WATER PUMP
64 BOLT/SCREW, WATER PUMP DRIVESHAFT BEARING
RETAINER

PC002G-6A3B·f.RP

Figure 20 - Camshaft Assembly, Sprockets and Water Pump Driveshaft Assembly

 5.7 LITER va ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·17

65 DRIVESHAFT ASSEMBLY, OIL PUMP

66 BOLT/SCREW, OIL PUMP DRIVESHAFT

PC0022-6A311-F-RP

Figure 22 - Oil Pump Driveshaft Assembly

60 CAMSHAFT ASSEMBLY
62 SPROCKET, CRANKSHAFT

PC0021-6A311-F-RP

Figure 21 - Crankshaft Sprocket Replacement

!++I Remove or Disconnect

1. Ring ridge.
A. Turn crankshaft assembly (98) until piston
assembly (103) is at bottom of its stroke.
B. Place a cloth on top of piston assembly (103).
C. Use a ridge reamer to remove ring ridge.
D. Turn crankshaft assembly (98) so piston
assembly (103) is at top of its stroke.
E. Remove cloth and cutting debris.

[I] Important
• Place matchmarks or numbers on connecting
rod assemblies (104) and connecting rod caps
(99). Connecting rod caps (99) must be A 5/16-18 x 4" BOLTS
60 CAMSHAFT ASSEMBLY
assembled to their original connecting rod PC0023-6A3B·F·RP
assemblies (104).
Figure 23 - Removing Camshaft Assembly
2. Connecting rod nuts ( 100).
3. Connecting rod cap (99) and bearings ( 101).
6A38·18 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P

B
34

16 12 8 4 3 7 11 15

A GASKET TAB (YELLOW SIDE UP)

B BOLT TIGHTENING SEQUENCE
34 HEAD ASSEMBLY, CYLINDER
67 BLOCK, ENGINE
81 BOLT//SCREW, CYLINDER HEAD
82 GASKET, CYLINDER HEAD
RC0010-6A4A-B-RP

Figure 24 - Cylinder Head Assembly

121

123

121 BRACKET ASSEMBLY, GENERATOR AND AIR

CONDITIONING COMPRESSOR AND POWER STEERING
PUMP
122 BOLT/SCREW GENERATOR BRACKET
123 BOLT/SCREW GENERATOR BRACKET
173 SUPPORT, SPARK PLUG WIRE

Figure 25 - Generator and Air Conditioning Compressor and Power Steering Pump Bracket Assembly

• Keep bearings (101) with their original con- • Wipe oil from bearings (101) and crankpins.
necting rod assembly (104) and connecting rod 4. Connecting rod assembly (104) and piston assembly
cap (99) for reassembly if they are being ( l 03) out of top of engine block using J 5239.
reused.
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1·VIN P 6A38·19

89 DRIVESHAFT, OIL PUMP

95 RETAINER, OIL PUMP DRIVESHAFT
118 PUMP ASSEMBLY, OIL 98
119 BAFFLE, OIL PAN
120 BOLT/SCREW, OIL PUMP

PC00211-6A3B-F-RP

Figure 26 - Oil Pump Assembly

CRANKSHAFT REAR OIL SEAL HOUSING

AND CRANKSHAFT ASSEMBLY ~FRT

Figures 28 and 29 !VIEWB I

!++! Remove or Disconnect
1. Crankshaft rear oil seal housing nuts ( 115) and bolts/ A FLANGES OF CONNECTING RODS MUST FACE TO THE
screws ( 116). FRONT IN THE LEFT BANK AND TO THE REAR IN THE
RIGHT BANK
2. Crankshaft rear oil seal housing assembly (114) with B ARROW TO BE ORIENTED TO FRONT OF ENGINE
assembled seal, and gasket ( 113). 98 CRANKSHAFT ASSEMBLY
3. Crankshaft rear oil seal from crankshaft rear oil seal 99 CAP, CONNECTING ROD
100 NUT, CONNECTING ROD
housing assembly (114). 101 BEARING, CONNECTING ROD
4. Crankshaft bearing cap bolts/screws ( 108) and 102 BOLT/SCREW, CONNECTING ROD
studs. · 103 PISTON ASSEMBLY
104 ROD ASSEMBLY, CONNECTING
5. Crankshaft bearing caps (107) and rear crankshaft
bearing cap ( 109).
6. Crankshaft assembly (98).
PC0027-8A38-F-RP
7. Crankshaft bearings ( 110 and 111) from engine
block (67). Figure 27 - Piston and Connecting Rod Assemblies
6A3B·20 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P

117

67 BLOCK, ENGINE 112 STUD, CRANKSHAFT REAR OIL SEAL RETAINER

98 CRANKSHAFT ASSEMBLY 113 GASKET, CRANKSHAFT REAR OIL SEAL HOUSING
107 CAP, CRANKSHAFT BEARING 114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
108 BOLT/SCREW, CRANKSHAFT BEARING CAP 115 NUT, CRANKSHAFT REAR OIL SEAL HOUSING
109 CAP, CRANKSHAFT BEARING 116 BOLT/SCREW, CRANKSHAFT REAR OIL SEAL HOUSING
110 BEARING, CRANKSHAFT 117 STUD, CRANKSHAFT BEARING CAP
111 BEARING, CRANJ<SHAFT 139 PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
RC0015-6A4A-B·RP

Figure 28 - Crankshaft Assembly

r-~~~~~~~~~~~~~~~~~~---,

8. Crankshaft bearings (110 and 111) from crankshaft

bearing caps ( 107) and rear crankshaft bearing cap
(109).
A

CAMSHAFT BEARINGS
Figures 30 and 31
Tool Required:
J 6098-01 Camshaft Bearing Remover/In-
staller

l++I Remove or Disconnect

1. Camshaft rear bearing hole plug.
2. Inner camshaft bearings using J 6098-01.
A 114
A. With nut and thrust washer installed to end of
puller screw threads, index pilot in camshaft
A SEAL REMOVAL NOTCHES front bearing and install puller screw through
114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL pilot and bearing to be removed.
B. Install bearing tool with shoulder toward bear-
PCQ029.6A3B·f·RP
ing. Make sure that enough threads are
Figure 29 - Removing Crankshaft Rear Oil Seal engaged.
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·21

C. Using two wrenches, hold puller screw while CLEANING, INSPECTION AND
turning nut to draw bearing out of bore.
REPAIR
• When bearing has been pulled from bore,
remove bearing tool and bearing from ENGINE BLOCK
puller screw.
Figure 32
D. Repeat above steps for remaining inner cam-
shaft bearings.
· • Index pilot in rear camshaft bearing to
!++! Remove or Disconnect
remove rear inner bearing. 1. Engine oil cooler assembly (141).
2. Oil filter adapter bolts/screws (143).
3. Front and rear camshaft bearings using J 6098-01.
3. Oil filter adapter assembly (142).
A. Assemble bearing tool to driver handle.
4. Front and rear oil gallery plugs.
B. Drive front and rear bearings out, toward cen- 5. Fuel pump and oil pressure sensor assembly.
ter of engine block (67).
6. Starter motor assembly. Refer to SECTION 6D2.
7. Engine block core plugs.

!.,! Clean
• Engine block in solvent.
• Gasket surfaces.
• Coolant passages.
• Oil passages.

!l'l'! rnspect
• For cracks in cylinder walls, coolant jacket, valve
lifter bores and crankshaft bearing webs.

!~! Measure
• Cylinder bores for taper, out-of-round, or excessive
ring ridge at top of ring travel. Use a dial indicator.
A BEARING TOOL Compare measurements to "Specifications" in this
B PILOT section.
C PULLER SCREW 67
D WASHER - Cylinders with less than 0.025 mm (0.0010
E NUT inch) of wear or taper may be reconditioned
67 BLOCK, ENGINE
PC0030-8A3B-F·RP
with a hone.
- Cylinders with more than 0.025 mm (0.0010
Figure 30 - Removing Camshaft Inner Bearing
inch) of wear or taper must be bored and honed
to smallest oversize piston assembly that will
permit complete resurfacing of all cylinders.

Boring
1. Draw a flat file across top of engine block several
times to remove any burrs or gasket material. If
engine block surface is not completely smooth and
flat, boring bar may be tilted which would result in
cylinder having an incorrect angle to crankshaft
assembly.
2. Measure piston assembly to be installed 11.5 mm
(0.45 inch) from bottom of piston skirt and at right
angles to piston pin.
3. Bore cylinder to same diameter as piston assembly.
4. Hone cylinder as outlined below to provide speci-
fied clearance.
• Follow instructions provided by manufacturer
of boring equipment being used.
NC0022-6A1·Y·RP NOTICE: Handle piston assemblies with care. Do
Figure 31 - Replacing Camshaft Front Bearing not attempt to force them into the cylinder. The pis-
ton assemblies may be easily distorted.
6A3B·22 5.7 LITER VS . ENGI.NE UNIT REPAIR RPO LT1·VIN P

- Any abrasive material left in cylinder bores

will cause rapid wear of piston rings, bearings,
and other engine assembly parts.
- Do not use kerosene or gasoline for cleaning.
- After cleaning, swab cylinder bores with light
engine oil and a clean cloth. Then wipe them
out with a clean dry cloth.

CRANKSHAFT BEARING FITTING

Figure 28
If replacing rear crankshaft bearing, check for cor-
rect part number. Some rear crankshaft bearings are 0.20
mm (0.008-inch) wider than standard. Crankshaft assem-
bly will be identified by "0.008" stamped on rear coun-
terweight.
It is necessary to measure clearance of each crank-
shaft bearing to determine proper sizes. Factory installed
crankshaft bearings may not be same size for each journal.

!L'i'I Inspect
• Lower half of crankshaft bearing (110 or 111).
- If lower half is worn or damaged, both upper
and lower half should be replaced.
- If lower half is suitable for use, upper half will
also be suitable for use.

1@1 Measure
• Crankshaft bearing clearance using gaging plastic.
67 BLOCK, ENGINE A. Place a piece of gaging plastic full width of
141 COOLER ASSEMBLY, ENGINE OIL crankshaft bearing ( 110 or 111) onto journal.
142 ADAPTER ASSEMBLY, OIL FILTER
143 BOLT/SCREW, OIL FILTER ADAPTER B. Measure all five bearing clearances at same
144 FILTER ASSEMBLY, OIL time.

PC0032-6A3B-F-RP

Figure 32 - Oil Cooler and Filter Adapter Assemblies

Honing
1. Follow instructions provided by manufacturer of
honing equipment being used.
2. Occasionally during honing operation:
A. Clean cylinder bore.
B. Measure cyiinder bore for proper piston fit.
3. Finish operation with a 45 to 65 degree crosshatch
m Important
• Do not rotate crankshaft assembly (98)
while gaging plastic is between journal
and crankshaft bearing ( 110 or 111 ).
C. Install crankshaft bearing caps (107) and rear
crankshaft bearing cap ( 109) with arrows
pointing toward front of engine block assem-
bly.
D. Install bearing cap bolts/screws (108) and
studs.
l~I Tighten

pattern on cylinder walls. • Crankshaft bearing cap · bolts/screws

• Finish marks should be clean but not sharp,
free from imbedded particles and torn or faded
metal.
4. Place a permanent mark on each piston assembly to
match it to its proper cylinder.
(108) and studs to 106 N•m (78 lb. ft.).
E. Remove crankshaft bearing cap bolts/screws
(108), studs, crankshaft bearing caps (107) and
rear crankshaft bearing cap ( 109).
F. Measure gaging plastic at its widest using scale
provided with gaging plastic. Refer measure-

l~I Clean
ments to "Specifications" in this section.
• If gaging plastic shows an irregularity in
• Cylinder bores and block with hot water and deter- journal exceeding 0.025 mm (0.0010
gent using a stiff bristle brush. Rinse thoroughly and inch), measure journal with a microme-
dry with a clean cloth. ter.
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B-23

• If clearance is greater than specified,

select an undersize bearing and re-mea-
sure clearance. Always replace both
upper and lower crankshaft bearings (II O
and I 11) as a unit.
• If clearance cannot be brought to specifi-
cations using a standard undersize bear-
ing, regrind crankshaft assembly (98) for
use with next undersize bearing.

CRANKSHAFT ASSEMBLY
J 24086-8
Figure28

lt:11 Clean
• Crankshaft assembly (98) in solvent and dry it with
compressed air.

!~I Measure
• Crankpins for out-of-round, taper, or undersize with
a micrometer. Refer to "Specifications" in this sec-
tion.
• Crankshaft run-out at front and rear intermediate
journals with a dial indicator. Support crankshaft A PRESS
front and rear journals on V-blocks. Refer to "Speci- 103 PISTON ASSEMBLY
104 ROD ASSEMBLY, CONNECTING
fications" in this section.
PC0033-8A3B-F·RP
• Replace or recondition crankshaft assembly (98) if
measurements are outside of specifications. Figure 33 - Removing Piston Pin

PISTON AND CONNECTING ROD - Cracked ring lands, skirts, or pin bosses.
ASSEMBLY - Grooves for nicks or burrs that may cause
binding.
Figures 27 and 33 through 37
- Warped or worn ring lands.
Tool Required:
- Scuffed or damaged skirts.
J 24086-B Piston Pin Remover and Installer
Set - Eroded areas at top of piston assembly (103).
- Worn piston bores and piston pins (105).
!+!+I Disassemble - Replace piston assemblies ( 103) that are dam-
1. Piston rings (106) from piston assembly (103). aged or show signs of excessive wear.
2. Piston pin (105) from piston assembly (103), using J
24086-B (Figure 33). !~I Measure
1. Piston pin bore-to-piston pin clearance.
!t:11 Clean A. Piston pin bores and piston pins (105) must be
1. Connecting rod assembly (104) in cleaning solvent. free of varnish or scuffing when being mea-
sured.
2. Dry connecting rod assembly (104) with com-
pressed air. Do not wire brush any part of piston B. Use a micrometer to measure piston pin (105)
and an inside micrometer to measure piston pin
assembly.
bore.
3. Varnish from piston skirts and pins with cleaning
C. If clearance is in excess of 0.025 mm (0.001 O
solvent.
inch), piston assembly (103) and piston pin
4. Piston ring grooves with a groove cleaner. (105) should be replaced. Piston assembly
5. Piston oil ring holes and slots. (103) and piston pin (105) are matched and are
not serviced separately.
!L'l'I Inspect 2. Piston compression ring end gap.
• Connecting rod assembly (104) for twisting, nicks
and cracks. Replace any damaged connecting rod
assemblies (104).
rn Important
• Fit each compression ring to cylinder in which
• Piston assemblies (103) for: it will be used.
6A38·24 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P
106
A FEELER GAGE
106 RING, PISTON
PC0034-8A3B·F·RP
Figure 34 - Measuring Piston Ring End Gap
A. Place compression ring into cylinder
bore.
B. Push compression ring into cylinder bore
to approximately 6.5 mm (1/4 inch)
above ring travel. Ring must be square to
cylinder wall.
C. Measure end gap with a feeler gage.
Refer to "Specifications" in this section
for acceptable end gaps.
D. If end gap exceeds specifications, select
!•!•! Assemble
another size ring set.
3. Piston ring side clearance.
A. Roll piston ring (106) entirely around its ring
groove on piston assembly (103).
B. If any binding is caused by ring groove, dress
groove with a fine cut file.
C. If any binding is caused by a distorted piston
ring ( 106), replace piston ring ( 106).
D. Measure side clearance of piston ring (106)
and groove with a feeler gage. For acceptable
side clearances, refer to "Specifications" in
this section.
E. If side clearance is too small, try another piston
ring (106).
4. Piston-to-cylinder bore clearance to determine suit-
ability of a used piston assembly ( 103 ). Measure pis-
ton-to-cylinder bore clearance as follows:
A. Measure cylinder bore diameter at a point 64
mm (2 1/2 inches) from top of cylinder bore
using a bore gage.
B. Measure piston assembly (103) 11.5 mm (0.45
inch) from bottom of skirt at right angles to
piston pin ( 105) using a caliper or micrometer.
C. Subtract piston diameter from cylinder bore
diameter. This wi11 indicate piston-to-bore
clearance.
D. Compare measurements to "Specifications" in
this section.
A FEELER GAGE
103 PISTON ASSEMBLY
106 RING, PISTON
Figure 35 - Measuring Piston Ring Side Clearance
E. If clearance exceeds specifications, subtract
size of new piston assembly from cylinder bore
diameter previously measured.
F. If clearance with new piston assembly is
within specifications, mark that piston assem-
. bly to cylinder to which it is to be installed.
G. If clearance is within specifications, used pis-
ton assembly (103) may be reinstalled.
Tool Required:
J 24086-B Piston Pin Remover and Installer
Set
m Important
• When assembling piston assembly (103) and
connecting rod assembly (104), stamped arrow
on piston assembly (103) must point to front of
engine block assembly while flange on con-
necting rod assembly must face toward front of
piston assembly on left hand assembly and
face toward rear of piston assembly on right
hand assembly. Refer to Figure 27.
NOTICE: After J 24086-B installer bottoms on sup-
port assembly, do not exceed 34 475 kPa (5000 psi)
or the tool may be damaged.
1. Piston assembly (103) and connecting rod assembly
(104).
A. Lubricate piston pin holes in both piston
assembly (103) and connecting rod assembly
(104).
B. Press piston pin (105) into piston assembly
(103) and connecting rod assembly (104) using
J 24086-B (Figure 36).
IL"'! Inspect
• For freedom of movement of piston
assembly (103) on piston pin (105).
2. Piston rings (106) onto piston assembly (103).
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P 6A38·25

Q
ENGINE LEFT
0
ENGINE FRONT
~
ENGINE RIGHT

s----
J 24086-B
c-- --A D

B---

A OIL RING SPACER GAP

IT ANG IN HOLE OR SLOT WITHIN ARC)
B OIL RING RAIL GAPS

C 2ND COMPRESSION RING GAP

D TOP COMPRESSION RING GAP

LC0011-6A4-B·RP

Figure 37 - Piston Ring Gap Locations

A PRESS
103
104
PISTON ASSEMBLY
ROD ASSEMBLY, CONNECTING
!l'l'I Inspect
105 PIN, PISTON • Bearings (101) for excessive wear or damage.
PC0036-6A3B-F-RP

Figure 36 - Installing Piston Pin

!~I
• Marked side of piston rings ( 106) must face
toward top of piston assembly (103). Locate
piston ring gaps as shown in Figure 37.
A. Install oil ring spacer in groove.
B. Hold spacer en.ds together and install
lower oil ring rail with gap properly
located.
C. Install upper oil ring rail with gap prop-
erly located.
D. Flex oil ring assembly to make sure rings
are free.
E. Install lower compression ring with gap
properly located.
F. Install upper compression ring with gap
properly located.
CONNECTING ROD BEARINGS
Figure 27
Connecting rod bearings are the precision insert type
and do not use shims for adjustment. Do not file connect-
ing rod assemblies or rod caps. If clearances are found to
be excessive, a new bearing will be required. Service
bearings are available in standard size and 0.001 and
0.002-inch undersize for use with new and used standard
size crankshaft assemblies, and in 0.010 and 0.020-inch
undersize for use with reconditioned crankshaft assem-
blies.
When removing a connecting rod cap, you may find
a 0.010-inch undersize bearing. These are used in
manufacturing for selective fitting.
Measure
1. Crankpin for out-of-round and taper with a microm-
eter. Refer measurements to "Specifications" in this
section.
• If not within specifications, replace or recondi-
tion crankshaft assembly.
• If installing new bearings ( 101 ), determine
new bearing size from maximum crankpin
diameter.
2. Bearing clearances using gaging plastic.
A. Place a piece of gaging plastic full width of
bearing ( 101 ), (parallel to crankshaft assem-
bly) onto crankpin.
• Plastic gage should be positioned in
middle of bearing ( 101 ). Bearing (101) is
thickest in center and bearing clearance
must be measured at this location.
B. Install connecting rod cap (99) with bearing
(101) onto connecting rod assembly (104).
C. Install connecting rod nuts ( 100).
l~I Tighten
• Connecting rod nuts ( 100), evenly, to 64
N•m (47 lb. ft.).
m Important
• Do not turn crankshaft assembly with
gaging plastic installed or accuracy of
measurement will be affected.
D. Remove connecting rod nuts (100) and cap.
 6A38·26 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P

E. Measure gaging plastic at its widest using scale

provided with gaging plastic. Refer measure-
ments to "Specifications" in this section.
F. If clearance is greater than specified, select an 87
undersize bearing (101) and re-measure clear-
ance.
G. If clearance cannot be brought to specifica-
tions, regrind crankpin. If crankpin is already
at maximum undersize, replace crankshaft
assembly'. (98).

OIL PUMP ASSEMBLY

Figure 38

l+!+I Disassemble
1. Oil pump cover bolts/screws (97) and pump cover
(96).
• Matchmark gear teeth for reassembly.
2. Driven gear (86), drive gear (94), driveshaft (89) and
retainer (95) from housing assembly (87). 88
3. Oil pressure relief valve pin (90), relief valve (92),
spring (91) and plug (93). 86 GEAR, OIL PUMP DRIVEN
87 HOUSING ASSEMBLY, OIL PUMP
4. Screen assembly (88) from housing assembly (87), 88 SCREEN ASSEMBLY, OIL PUMP
if replacement is necessary. 89 DRIVESHAFT, OIL PUMP
90 PIN, OIL PRESSURE RELIEF VALVE SPRING SEAT
• Mount housing assembly (87) in a soft-jaw 91 SPRING, OIL PRESSURE RELIEF VALVE
vise and extract screen assembly (88). 92 VALVE, OIL PRESSURE RELIEF
93 PLUG, OIL PRESSURE RELIEF VALVE BORE
• Screen assembly (88) is serviced as a unit. Do 94 GEAR, OIL PUMP DRIVE
not disturb pipe on screen. 95 RETAINER, OIL PUMP DRIVESHAFT
96 COVER, OIL PUMP
!r:.-1 Clean 97 BOLT/SCREW, OIL PUMP COVER

1. All parts in cleaning solvent.

PC0038-6A3B-F-RP
2. Dry parts with compressed air.
Figure 38 - Oil Pump Components

ll'i'I Inspect
• Housing assembly (87) and cover (96) for cracks,
scoring, casting imperfections, and damaged
threads.
• Drive gear shaft. If loose in housing assembly (87),
replace oil pump.
• Pressure relief valve (92) for scoring and sticking.
- Burrs may be removed with a fine oil stone.
• Relief valve spring (91) for loss of tension.
• Screen assembly (88) for broken .wire mesh or
screen, or looseness.
- If pipe is loose or has been removed from
screen, screen assembly (88) must be replaced.
• Gears for chipping, galling, and wear.
• Drive gear (94) and driveshaft (89) for looseness and
wear.
[I) Important
• If wear is noted, replace entire pump assembly.
l+!+l Assemble
Tool Required:
J 21882 Oil Suction Pipe Installer
NOTICE: See "Notice" on page 6A3B-1 of this
section.
[I) Important
• Be careful not to twist, shear, or collapse
screen assembly while installing it to oil pump
assembly.
1. A new screen assembly (88), if previously disas-
sembled, to housing assembly (87).
A. Mount housing assembly (87) in a soft-jaw
vise.
B. Apply sealer to end of pipe.
C. Tap pipe into place using J 21882 and a plastic-
faced hammer.
2. Relief valve (92), spring (91 ), plug (93) and pin (90).
 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P 6A38-27

3. Drive gear (94), driveshaft (89) and retainer (95) to 8. Shim (76).
housing assembly (87).
4. Driven gear (86) to housing assembly (87) with
smooth side of gear toward pump cover (96).
!r:tl Clean
1. Carbon from combustion chambers and valve parts
5. Pump cover (96). using J 8358.
6. Oil pump cover bolts/screws (97). 2. Valve guides using J 8101 (Figure 41).

l~J Tighten 3. Carbon and sludge from pushrod assemblies and

rocker arms.
• Oil pump cover bolts/screws (97) to 9 N•m (80 4. Valve stems and heads on a buffing wheel.
lb. in.). 5. Cylinder head assembly and engine block gasket
surfaces.
!L•l 1nspect 6. Bolt/screw hole threads in cylinder head assembly
• For smoothness of operation by turning pump drive- (34) and engine block (67).
shaft (89) by hand.

CYLINDER HEAD ASSEMBLY

Figures 24 and 39 through 45
Tools Required:
J 8001 Dial Indicator Set
J 9666 Valve Spring Tester
J 8062 Valve Spring Compressor
J 8358 Carbon Removing Brush
J 8101 Valve Guide Cleaner

!+f+I Disassemble
1. Spark plugs from cylinder head assembly.
2. Compress valve springs (69) using J 8062.
3. Valve stem keys (72).
4. Cap (70) from valve.
5. Valve spring (69).
34 HEAD ASSEMBLY, CYLINDER
6. Valve seal (73).
7. Valve. PC0040-6A3B-f.RP

• Place valves in a rack in proper sequence so Figure 40 - Cleaning Combustion Chamber

they can be assembled in their original order.
J 8101

34

34 HEAD ASSEMBLY, CYLINDER

PC0039-6A3B-f.RP PC0041 ·6A3B-F·RP

Figure 39 - Compressing Valve Spring Figure 41 - Cleaning Valve Guide

6A38·28 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P

A. Excessive valve stem-to-bore clearance will

cause excessive oil consumption and may
cause a valve to break. Insufficient clearance
will result in noisy and sticky functioning of
valve and disturb engine assembly smooth-
ness.
B. Clamp J 8001 on exhaust port side of cylinder
head assembly.
69 C. Locate indicator so movement of valve stem
from side to side (crosswise to cylinder head
assembly) will cause a direct movement of
indicator stem. Indicator stem must contact
side of valve stem just above valve guide.
D. Drop valve head about 1.6 mm (1/16 inch) off
valve seat.
A TORQUE WRENCH E. Move stem of valve from side to side using
69 SPRING, VALVE
PC0042·6A3B·F·RP light pressure to obtain a clearance reading. If
clearance exceeds specifications, it will be
Figure 42 - Checking Valve Spring Tension necessary to ream valve guides for oversize
valves. Refer to "Specifications" in this sec-
tion.
A F. Service valves are available in standard, 0.003,
0.015, 0.030 inch oversize.

Recondition
1. Valves with oversize stems are available as outlined
2. Reconditioning valve seats is very important. Valve
A STEM, VALVE
B GUIDE, VALVE
NC0032-6A1·Y·RP
Figure 43 - Measuring Valve Stem Clearance
fL"l'l tnspect
l. Cylinder head assembly (34) for cracks in exhaust
ports, combustion chambers, or external cracks to
water chamber.
3. Valves that are pitted can be refaced to proper angle,
2. Valves for burned heads, cracked faces, or damaged
stems.
3. Valve springs (69) for squareness.
l@I Measure
1. Valve spring tension using J 9666 (Figure 42).
• If spring tension is less than 360 N (81 lb.) at
45.2 mm (1.78 inch), replace spring.
2. Valve stem-to-bore clearance.
above. Ream valve guide bores for oversize valves
as necessary.
seat reconditioning must be done after reaming
valve guide bores or installing new valve guides.
• Seating of valves must be perfect for engine
assembly to deliver optimum power and per-
formance.
• Another important factor is cooling of valve
heads. Good contact between each valve and
its seat in cylinder head assembly is necessary
to insure that heat in valve head will be prop-
erly carried away.
• Several different types of equipment are avail-
able for reconditioning valve seats. Recom-
mendations of manufacturer of equipment
being used should be carefully followed to
attain proper results.
• Regardless of what type of equipment is used,
it is essential that valve guide bores be free
from carbon or dirt to ensure proper centering
of pilot in guide. Valve seats should be concen-
tric to within 0.05 mm (0.002 inch) total indi-
cator reading.
insuring correct relation between head and stem, on
a valve refacing mechanism. Valve stems which
show excessive wear, or valves that are warped
excessively should be replaced. If edge of valve
head is less than 0. 79 mm ( 1/32 inch) thick after
grinding, replace valve.
• Several different types of equipment are avail-
able for refacing valves. Recommendation of
manufacturer of equipment being used should
be carefully followed to attain proper results.
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P 6A38-29

6. Compress valve spring (69) using J 8062 (Figure

71
39).
7. Valve stem keys (72).
A. Use grease to hold keys (72) in place while dis-
connecting J 8062.
B. Make sure keys (72) seat properly in upper
groove of valve stem.

70
c. Tap end of stem with a plastic-faced hammer to
seat keys (72), if necessary.
8. Remaining valves.

!@I Measure
• Valve spring installed height from valve spring seat
to top of cap (Figure 45).
- If installed height exceeds 45.2 mm (1.78
inch), install a valve spring seat shim approxi-
mately 1.6 mm (1/16 inch) thick.
- Do not shim a valve spring to obtain a less than
specified installed height.
69 SPRING, VALVE
70 CAP, VALVE SPRING
71 VALVE, INTAKE CAMSHAFT ASSEMBLY
72 KEY, VALVE STEM
73 SEAL, VALVE STEM OIL
76 SHIM, VALVE SPRING Figures 46 and 47
Tool Required:
Figure 44 - Valve Assembly
(Intake Shown, Exhaust Similar) J 7872 Magnetic Base Indicator Set

l@I Measure
1. Camshaft journals with a micrometer.
• If journals are more than 0.025 mm (0.0010
inch) out-of-round, replace with a new cam-
shaft assembly.
2. Camshaft runout using J 7872.
• Mount camshaft assembly in V-blocks or
between centers. Using J 7872, check inter-
mediate camshaft journal. If runout exceeds
0.038 mm (0.0015 inch) camshaft assembly is
excessively bent and should be replaced.

TIMING CHAIN ASSEMBLY, CRANKSHAFT

A SCALE ln
69 SPRING, VALVE
PC0045-8A3B-F·RP
AND CAMSHAFT SPROCKETS, AND WATER
PUMP DRIVESHAFT ASSEMBLY

Figure 45 - Measuring Valve Spring Installation Height Figures 20 and 21

ll"'I Inspect
• Camshaft and crankshaft sprockets (57 and 62) and
l+!+I Assemble water pump driveshaft assembly (63) for wear.
1. Shim (76) to cylinder head assembly. • One edge of teeth worn or teeth no longer concen-
2. Valve into proper port. tric.
3. Valve seal (73) and seat seal (73) against shim (76). • Valley between teeth worn.
4. Valve spring (69). • Key and crankshaft keyway for wear.
5. Cap (70) on valve stem. • Timing chain assembly for binding.
6A38·30 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1-VIN P

ENGINE FRONT COVER OIL SEALS

A CAMSHAFT JOURNALS l++I Remove or Disconnect
• Front cover oil seals for crankshaft assembly, dis-
tributor shaft and water pump driveshaft assembly.

l++l tnstall or Connect

1. Crankshaft seal using J 35468.
2. Distributor driveshaft seal using J 39090.
3. Water pump driveshaft seal using J 39088.

OIL PAN ASSEMBLY

IS:.-1 Clean
NC1014-6A1B-Y-RP
• Oil pan assembly in solvent. Remove all sludge and
Figure 46 - Measuring Camshaft Journals varnish.
• Gasket surfaces.

IL'l'I Inspect
• Gasket flanges for bending or damage.
• Oil pan assembly for rock damage or cracks.
• Oil pan baffle for lack of fit.
• Drain plug threads for stripping.

WATER PUMP ASSEMBLY

Figure 16
Tool Required:
KC0024-6A3-F-RP
J 39089 Driven Gear/Water Pump Shaft Seal
Installer
Figure 47 - Measuring Camshaft Runout

l~I Clean
• Water pump assembly (37) and engine block gasket
surfaces.
ENGINE FRONT COVER ASSEMBLY
IL'l'I Inspect
Figure 19 • 0-ring seals (156) on water pump driveshaft assem-
Tools Required: bly (63) and water pump shaft. Replace seals (156),
if necessary, using J 39089.
J 35468 Front Cover Aligner and Oil Seal
Installer
VALVE LIFTER ASSEMBLIES
J 39090 Distributor Driveshaft Front Cover
Seal Installer Figure 15
J 39088 Driven Gear Shaft Front Cover Seal
Installer ll"'I Inspect
• Lifter body for wear and scuffing. Also inspect bor~
l~I Clean in engine block for scuffing. ·
• Front cover assembly and engine block gasket sur- • Lifter roller for:
faces. - Binding or roughness.

ll'l'I Inspect - Excessive looseness in roller bearings.

- Flat spots.
• Front cover assembly (50) for damage to seals or
gasket surface. - Pitting.
 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·31

• Lifter pushrod seat and pushrod end for wear or • For cracked or broken bypass valve.
scoring. - Oil filter adapter and bypass valve assem-
bly must be replaced as a unit.
VALVE ROCKER ARMS AND PUSHROD 3. Oil filter adapter assembly (142).
ASSEMBLIES
4. Oil filter adapter bolts/screws (143).
Figures 14 and 15
!~I Tighten
!L'l'I Inspect • Oil filter adapter bolts/screws (143) to 23 N•m
• Rocker arms (29) and balls (30) at their mating sur- (17 lb. ft.).
faces. These surfaces should be smooth and free of 5. Engine oil cooler assembly (141).
scoring or other damage. 6. Oil filter assembly (144).
• Rocker arm pushrod sockets and valve stem mating 7. Fuel pump and oil pressure sensor assembly.
surfaces. These surfaces should be smooth with no 8. Knock sensor assemblies.
scoring or exceptional wear.
9. Starter motor assembly and bolts/screws.
• Pushrod assemblies (27) for scored ends or bends.

VALVE ROCKER ARM COVER ASSEMBLIES l~I Tighten

• Knock sensor assemblies to 19 N•m (14 lb. ft.).
Figure 13 • Starter motor bolts/screws to 46 N•m (34 lb.
ft.).
li,I Clean • Fuel pump switch and oil pressure gage sensor
• Valve rocker arm cover and cylinder head gasket assembly to 12 N•m (108 lb. in.).
surfaces.
CAMSHAFT BEARINGS
IL'l'l tnspect Figures 30, 31 and 48
• Gasket flanges for damage. Tool Required:
• Rubber grommets for deterioration. J 6098-01 Camshaft Bearing Remover/In-
staller
INTAKE MANIFOLD ASSEMBLY Outer front and rear camshaft bearings must be
installed first. These bearings serve as guides for tool
Figure 10 pilot, and help center inner bearings during installation
ji,I Clean process.

• Intake manifold bolts/screws (8) and studs (9). l++l tnstall or Connect
• Cylinder head assembly, engine block and intake
manifold sealing surfaces. [I] Important
• Align camshaft bearing oil holes properly dur-
ASSEMBLY ing installation.
- Number one (front) camshaft bearing oil
ENGINE BLOCK holes must be positioned so that they are
at 1 o'clock and 5 o'clock positions.
Figure 32
- Number two through number four inner
1++1 tnstall or Connect camshaft bearing oil holes must be posi-
tioned at 5 o'clock toward left side of
NOTICE: See "Notice" on page 6A3B-1 of this engine block and even with bottom of
section. cylinder bore.
1. Engine block core plugs. - Number five (rear) camshaft bearing oil
2. Front and rear oil gallery plugs. hole must be positioned at 12 o'clock.
1. Front and rear camshaft bearings using J 6098-01.
l~I Tighten A. Assemble bearing tool to driver handle.
• Rear engine block oil gallery plugs to 24 N •m B. Align oil holes as outlined above.
(18 lb. ft.). C. Drive front and rear bearings in, toward center
of engine block.
IL'l'I Inspect 2. Inner camshaft bearings using J 6098-01.
• Oil filter adapter bypass valve and spring for A. With nut and thrust washer assembled to end of
operation. puller screw threads, index pilot in camshaft
6A3B-32 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P
front bearing and install puller screw through
pilot.
B. Index camshaft bearing in bore, aligning oil
hole as outlined above.
C. Install puller screw through bearing bore and
bearing to be installed and assemble bearing
tool to puller screw with shoulder toward bear-
ing. Make sure that enough threads are
engaged.
D. Using two wrenches, hold puller screw while
turning nut to draw bearing into bore.
• When bearing has been pulled into bore,
remove bearing tool and puller screw and
check alignment of bearing oil hole to
bore oil hole.
E. Repeat above steps for remaining inner cam-
shaft bearings.
• Index pilot in rear camshaft bearing to
install rear inner bearing.
3. New camshaft rear bearing hole plug (68).
A. Coat plug outside diameter with GM PIN
1052080 sealant, or equivalent.
B. Install camshaft rear bearing hole plug (68) as
shown in Figure 48.
SECTION A-A
67 BLOCK, ENGINE
68 PLUG, CAMSHAFT REAR BEARING HOLE
PC0048-8A3B·F·RP
Figure 48 - Camshaft Rear Bearing Hole Plug
CRANKSHAFT ASSEMBLY
Figure 28
l++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
section.
1. Crankshaft bearings ( 110 and 111) into engine block
(67) and crankshaft bearing caps (107) and rear
crankshaft bearing cap ( 109).
• Coat crankshaft bearings ( 110 and 111) with
oil.
2. Crankshaft assembly (98).
3. Crankshaft bearing caps (107) and rear crankshaft
bearing cap (109) with assembled crankshaft bear-
ings ( 110 and 111) with arrows pointing toward front
of engine block.
4. Crankshaft bearing cap bolts/screws (108) and
studs.
• With crankshaft assembly (98), crankshaft
bearings ( 110 and 111) and crankshaft bearing
caps (107) and rear crankshaft bearing cap
(109) installed and bolts/screws (108) and
studs started, thrust crankshaft assembly (98)
rearward to set and align bearing caps (107 and
109). Then thrust crankshaft assembly forward
to align rear faces of rear crankshaft bearings
(111).
l~I Tighten
• Crankshaft bearing cap bolts/screws (108) and
studs to 106 N•m (78 lb. ft.).
l~I Measure
• Crankshaft end play using a dial indicator or
feeler gage. Refer to "Specifications" in this
section.
- If using a feeler gage, measure between
front of rear crankshaft bearing cap (109)
and crankshaft thrust surface.
CRANKSHAFT REAR OIL SEAL HOUSING
Figure 28
~ Clean
• Gasket surfaces.
l++l lnstall or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
section.
m Important
• Always use new crankshaft rear oil seal and
new housing gasket (113) during installation of
crankshaft rear oil seal housing assembly
(114).
1. New gasket (113) and crankshaft rear oil seal hous-
ing assembly (114) on studs (112).
 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B·33

• It is not necessary to use any type of sealant to

hold gasket (113) in place.
2. Crankshaft rear oil seal housing nuts ( 115) and bolts/
screws (116).

l©J Tighten
• Crankshaft rear oil seal housing nuts ( 115) and
bolts/screws (116) to 15 N•m (11 lb. ft.).

CRANKSHAFT REAR OIL SEAL

Figures 28 and 49
NC1028-6A1B-Y-RP
Tool Required:
Figure 50 - Installing Piston Assembly
J 35621 Rear Main Seal Installer

!++I Install or Connect
1. Coat new seal entirely with engine oil.
2. Seal onto J 35621.
3. J 35621 onto rear of crankshaft assembly (98).
Tighten screws snugly to ensure seal will be
installed squarely over crankshaft assembly (98).
4. Crankshaft rear oil seal to crankshaft assembly (98)
and crankshaft rear oil seal housing (114).
• Tighten wing nut on J 35621 until it bottoms.
5. Remove J 35621 from crankshaft rear oil seal hous-
ing (114).
PISTON AND CONNECTING ROD
ASSEMBLY
Figures 27 and 50
!++I Install or Connect
Tool Required:
J 8037 Piston Ring Compressor
J 5239 Connecting Rod Bolt Guide Set
1. Coat piston assembly (103), piston rings, cylinder
bore, and bearing surfaces with engine oil.
2. Piston assembly (103) with stamped arrow facing
forward into its matched bore using J 8037 and J
5239 and lightly tapping top of piston assembly
(103) with wooden hammer handle.
• Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
• Guide connecting rod using J 5239.
• Remove J 5239.
CONNECTING ROD BEARINGS
Figure 27
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-l of this
section.
1. Coat inside surface of bearings (101) with engine
oil.
[I] Important
• When assembled, flanges on connecting rod
assembly and cap should face to front in left
bank and to rear in right bank.
2. Connecting rod cap (99) and bearings ( 101 ).
3. Connecting rod nuts (100).

l©J Tighten
• Connecting rod nuts (100), evenly, to 64 N•m
(47 lb. ft.).

!~I Measure
1. When all connecting rod bearings (101) have been
installed, tap each connecting rod assembly lightly
parallel to crankpin to make sure they have clear-
ance.
2. Side clearance between connecting rod caps (99)
LC0012-6A4·B-RP using a feeler gage or dial indicator.
Figure 49 - Installing Crankshaft Rear Oil Seal • Rod side clearance should be 0.16 to 0.35 mm
(0.006 to 0.014 inch).
6A38·34 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1-VIN P

Oil PUMP ASSEMBLY

Figure26

!++I Install or Connect 17

·o
13
0 9
0
5
0 1
0
2
0 6
0
10
0
0
14

NOTICE: See "Notice" on page 6A3B-1 of this

section.
1. Oil pump assembly (118) and driveshaft (89).
16 12 8 4 3 7 11 15
• Align slot on end of driveshaft (89) with drive
tang on oil pump shaft. ~FRT NC1022-8A1B·Y-RP
2. Oil pan baffle (119).
Figure 51 - Cylinder Head Tightening Sequence
3. Bolt/screw (120) attaching oil pump assembly (118)
to rear crankshaft bearing cap.
CAMSHAFT ASSEMBLY
4. Oil pan baffle nuts.
Figures 20, 22 and 23
l~I Tighten When installing new camshaft assembly, coat cam-
shaft lobes and journals with engine oil. Also, inspect all
• Oil pump bolt/screw (120) to 88 N•m (65 lb.
ft.). valve lifter assemblies and replace as necessary to ensure
durability of camshaft lobes and lifter rollers.
• Oil pan baffle nuts to 34 N•m (25 lb. ft.).
l++I Install or Connect

CYLINDER HEAD ASSEMBLY NOTICE: See "Notice" on page 6A3B-1 of this

section.
1. Camshaft assembly (60).
Figures 24 and 51
2. Camshaft retainer (59) and camshaft retainer bolts/
!++I Install or Connect
screws (58).

NOTICE: See "Notice" on page 6A3B-1 of this

section.
l~I Tighten
• Camshaft retainer bolts/screws (58) to 12 N•m
I. New cylinder head gasket (82). (108 lb. in.).
2. Gasket (82) over locating pins, with yellow side of 3. Oil pump driveshaft assembly (65) and bolt/screw
tab on outboard side facing up. (66).
3. Cylinder head assembly (34) over locating pins and • Bolt/screw hole "ear" must be seated on boss
gasket (82). before tightening bolt/screw (66).

• Coat threads of cylinder head bolts/screws (81)

with sealing compound, GM PIN 1052080 or
l~I Tighten

equivalent. • Bolt/screw (66) to 18 N•m ( 13 lb. ft.).

4. Cylinder head bolts/screws (81) finger tight.
l~I Tighten
• Cylinder head bolts/screws (81) in sequence
and in three passes to 88 N•m (65 lb. ft.) (Fig-
ure 51).
5. Spark plugs.
6. Engine coolant air bleed pipe and bolts/screws.
• Use a backup wrench on pipe fittings when
installing bolts/screws.
TIMING CHAIN ASSEMBLY, CRANKSHAFT
AND CAMSHAFT SPROCKETS, AND WATER
PUMP DRIVESHAFT ASSEMBLY
Figures 20 and 21
Tools Required:
J 5590 Crankshaft Gear Installer
J 39089 Driven Gear/Water Pump Shaft Seal
Installer
J 39092 Driven Gear Assembly Installer

l~I Tighten
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
• Engine coolant air bleed pipe bolts/screws to section.
41 N•m (30 lb. ft.). 1. Key, if previously removed.
• Spark plugs to 15 N•m (11 lb. ft.). 2. Crankshaft sprocket (62) using J 5590.

3. Water pump driveshaft assembly (63) using J 39092.
4. Water pump driveshaft bearing retainer bolts/screws
(64).
l~I Tighten
• Water pump driveshaft bearing retainer bolts/
screws (64) to 12 N•m (108 lb. in.).
5. Camshaft sprocket (57) and timing chain assembly
(61).
• Gears must mesh, or damage to camshaft
retainer could occur.
6. Camshaft sprocket bolts/screws (56).
• Make sure that camshaft and crankshaft timing
marks align as shown in Figure 20.
l~I Tighten
• Camshaft sprocket bolts/screws (56) to 28
N•m (21 lb. ft.).
7. New 0-ring seal to water pump driveshaft assembly
(63) using J 39089.
ENGINE FRONT COVER ASSEMBLY
Figure 19
Tool Required:
J 39087 Driven Gear Shaft Front Cover Seal
Protector
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
section.
NOTICE: Be careful not to damage seal when
installing front cover assembly over water pump dri-
veshaft assembly.
I. Gasket (51) and front cover assembly (50) using J
39087 on water pump driveshaft assembly.
2. Front cover bolts/screws (52).
l~I Tighten
• Front cover bolts/screws (52) to 11 N•m (100
lb. in.).
DISTRIBUTOR ASSEMBLY
Figure 18
m Important
• Distributor driveshaft (48) has a keyway (missing
spline) on both ends that positively locates distribu-
tor assembly (49) to camshaft sprocket.
• Install distributor driveshaft (48) to camshaft
sprocket. Rotate crankshaft assembly until keyway
on driveshaft distributor end is near 12 o'clock posi-
tion. Remove distributor driveshaft (48), install in
distributor assembly (49) and turn until keyway on
camshaft sprocket end is in same position ( 12
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·35
o'clock) when crankshaft assembly was turned. This
will help make installation of distributor assembly
(49) easier.
l++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
section.
1. Distributor assembly (49) and distributor driveshaft
(48).
2. Before torquing bolts/screws, make sure distributor
assembly is properly seated. If it is difficult to seat,
check shaft alignment.
3. Distributor bolts/screws (4 7).
!~I Tighten
• Distributor bolts/screws (47) to 12 N•m (106
lb. in.).
4. Ignition coil and bracket assembly and studs.
!~I Tighten
• Ignition coil studs to 34 N•m (25 lb. ft.).
5. Spark plug and ignition harness assemblies to dis-
tributor assembly (49) if removed.
OIL PAN ASSEMBLY
Figures 52 and 53
!++I Install or Connect
1. Apply a small amount of sealer, GM P/N 1052914 or
equivalent, to front cover assembly and engine block
junction and to rear seal housing and engine block
junction. Apply sealer 25 mm (1 inch) in either
direction of radius cavity of junctions. See Figure
52.
2. Oil pan gasket (55), oil pan assembly (54) and rein-
forcements (53).
3. Oil pan nuts (85), bolts/screws (84) and studs (83).
l~I Tighten
• Corner bolts/screws (84) or stud (83), and nuts
(85) to 20 N•m (15 lb. ft.).
• Remainder of bolts/screws (84) and studs (83)
to 11 N•m (100 lb. in.).
4. Oil level sensor assembly (178).
!~I Tighten
• Oil level sensor assembly (178) to 35 N•m (26
lb. ft.).
CRANKSHAFT BALANCER ASSEMBLY AND
HUB
Figure 17
Tool Required:
J 39046 Crankshaft Hub Remover/Installer
6A3B-36 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P

~·

55 55

A SEALER
53 REINFORCEMENT, OIL PAN
54 PAN ASSEMBLY, OIL
55 GASKET, OIL PAN PC0052-6A3B-F-RP

Figure 52 - Oil Pan Seal

!++I Install or Connect l~I Tighten

NOTICE: See "Notice" on page 6A3B-1 of this • Crankshaft balancer hub bolt/screw to 102
section. N•m (75 lb. ft.).
1. Crankshaft balancer hub (45) must be installed by • Crankshaft balancer bolts/screws (46) to 81
following procedure: N•m (60 lb. ft.).

A. Set number 1 piston assembly to top dead cen- WATER PUMP ASSEMBLY
ter.
B. Install crankshaft balancer hub with cast arrow Figure 16
on hub in 12 o'clock position.
2. Crankshaft balancer hub ( 45) using J 39046.
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
3. Crankshaft balancer hub washer and bolt/screw. section.
4. Crankshaft balancer assembly (42) and bolts/screws 1. Coupling (39) to water pump shaft with groove on
(46). coupling toward engine block.

m Important
• If crankshaft balancer assembly is replaced,
new balancer weights of same size must be
installed on new balancer assembly in same
location as old balancer assembly.
A. Measure depth of empty balancer weight
hole. Record measurement.
B. Drive weights in old balancer to bottom
of hole then measure depth of hole.
Record measurement.
C. Subtract measurement of hole with
weight from measurement of empty hole.
Difference will be the length of the
balancer weight that must be installed in
the new balancer assembly in the same
location.
• Apply a light coat of grease to 0-ring seals and
grease to coupling.
2. Position water pump assembly (37) and gaskets
(38), with tabs straight up, to engine block and rotate
coupling (39), if necessary, to align it to water pump
driveshaft splines and then seat water pump assem-
bly (37).
3. Water pump bolts/screws (40 and 41).
l~I Tighten
• Water pump bolts/screws ( 40 and 41) to 41
N•m (30 lb. ft.).
4. Air injection pump bracket and bolts/screws.
l~I Tighten
• Air injection pump bracket bolts/screws to 25
N•m (18 lb. ft.).
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·37

VALVE LIFTER ASSEMBLIES

Figure 15

l++I Install or Connect

NOTICE: See "Notice" on page 6A3B-1 of this
section.
1. Coat valve lifter rollers with prelube, GM P/N
1052365 or equivalent.
2. Valve lifter assemblies (36) in same location from
which they were removed.
3. Valve lifter guides (35), retainer (33) and valve lifter
guide retainer bolts/screws (32).

l~I Tighten
• Valve lifter guide retainer bolts/screws (32) to
20 N•m (15 lb. ft.).
VALVE ROCKER ARM BALL STUDS
Figure 14

l++I Install or Connect

NOTICE: See "Notice" on page 6A3B-l of this
section.
1. Apply sealer, GM P/N 1052080 or equivalent, to
threads of new rocker arm ball stud.
2. Rocker arm ball stud (28).

53
l~I Tighten
• Valve rocker arm ball stud (28) to 68 N•m (50
lb. ft.).
VALVE ROCKER ARMS AND PUSHROD
ASSEMBLIES
Figures 14 and 54
Tool Required:
J 8520 Cam Lobe Lift Indicator

l++I Install or Connect

I. Coat rocker arm and rocker arm ball bearing sur-
faces with prelube, GM P/N 1052365 or equivalent,
when installing. Install these components and push-
rod assemblies (27) in locations from which they
were removed.
2. Pushrod assemblies (27). Make sure pushrod assem-
blies (27) seat in lifter sockets.
53
54
55
REINFORCEMENT, OIL PAN
PAN ASSEMBLY, OIL
GASKET, OIL PAN
!@! Measure

83 STUD, OIL PAN

• Camshaft lobe lift.
84 BOLT/SCREW, OIL PAN A. Position J 8520 with ball socket adapter
85 NUT, OIL PAN on pushrod assembly. Make sure pushrod
178 SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH assembly is in lifter socket.
190 BRACKET, ENGINE WIRING HARNESS
B. Rotate crankshaft assembly slowly in
direction of rotation until lifter roller is
on heel of cam lobe. At this point, push-
PC0063-6A3B-F-RP
rod assembly will be in its lowest posi-
Figure 53 - Oil Pan Assembly tion.
6A38·385.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P
(\n O NOTICE: See "Notice" on page 6A3B-1 of this
PC0054-6A3B·F·RP
Figure 54 - Measuring Camshaft Lobe Lift
C. Set J 8520 on zero.
D. Rotate crankshaft assembly slowly until
pushrod assembly is in fully raised posi-
tion.
E. Compare total lift shown on J 8520 with
specifications. Refer to "Specifications"
in this section.
F. Remove J-8520.
3. Rocker arms (29).
4. Rocker arm balls (30) and nuts (31 ).
~ Adjust
• Rocker arm nuts until all lash is eliminated.
A. Turn crankshaft assembly until cast arrow on
crankshaft balancer hub is in 12 o'clock posi-
tion and number 1 cylinder is in firing position
(top dead center).
• Watch number 1 cylinder valves as
crankshaft balancer hub arrow
approaches 12 o'clock position. If a valve
moves as arrow moves to position,
engine assembly is in number 6 cylinder
firing position. Crankshaft assembly
must then be turned one more time to
reach number 1 cylinder firing position.
B. With engine assembly in number 1 cylinder fir-
ing position, following valves can be adjusted:
- Exhaust I, 3, 4, 8
- Intake 1, 2, 5, 7
C. Back off rocker arm nut (31) until lash is felt in
pushrod assembly (27). Then tighten rocker
arm nut (31) until all lash is removed. Zero lash
can be felt by moving pushrod assembly (27)
up and down using thumb and forefinger until
there is no more movement.
D. When all free play has been removed, tighten
rocker arm nut (31) one additional turn (360
degrees).
E. Turn crankshaft assembly one revolution until
hub arrow is again at 12 o'clock position. This
is number 6 cylinder firing position. Following
valves can now be adjusted:
- Exhaust 2, 5, 6, 7
Intake 3, 4, 6, 8
VALVE ROCKER ARM COVER ASSEMBLIES
Figure 13
Right Valve Rocker Arm Cover Assembly
!++I Install or Connect
section.
1. Gasket (25) and valve rocker arm cover assembly
(23).
2. Valve rocker arm cover bolts/screws (24).
l~I Tighten
• Valve rocker arm cover bolts/screws (24) to 11
N•m (100 lb. in.).
3. Crankcase vent hose.
Left Valve Rocker Arm Cover Assembly
!++! Install or Connect
1. Gasket (25) and valve rocker arm cover assembly
(23).
2. Valve rocker arm cover bolts/screws (24).
!~I Tighten
• Valve rocker arm cover bolts/screws (24) to 11
N•m (100 lb. in.).
INTAKE MANIFOLD ASSEMBLY
Figures 9, 10 and 55
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-l of this
section.
1. Apply a 5 mm (3/16-inch) bead of RTV sealer, GM
P/N 1052366 or equivalent, to front and rear of
engine block. Extend bead 13 mm ( 1/2 inch) up each
cylinder head assembly to seal and retain gaskets.
2. Intake manifold assembly (6) with new gaskets (10).
3. Intake manifold bolts/screws (8) and studs (9).
l~I Tighten
• Intake manifold bolts/screws (8) and studs (9)
in a first pass to 8 N•m (71 lb. in.) in sequence
as shown in Figure 55. Tighten in sequence in
a second pass to final specifications of 48 N•m
(35 lb. ft.).
4. Throttle body assembly (3), gasket (5) and bolts/
screws (4).
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·39

6 l~I Tighten
• Fuel injection fuel rail bolts/screws (1) to 10
6 N•m (89 lb. in.).
16. Wiring harness assemblies if moved or discon-
nected.
17. MAP sensor and bolts/screws.

0
3 2 7
l~I Tighten
0 0 • Map sensor bolts/screws to 6 N•m (53 lb. in.).
6 MANIFOLD ASSEMBLY, INTAKE PC0055-8A311-F-RP
EXHAUST MANIFOLD ASSEMBLIES
Figure 55 - Intake Manifold Tightening Sequence
Figures 11 and 12

l~I Tighten
Right Exhaust Manifold Assembly
• Throttle body bolts/screws (4) to 26 N•m (19
lb. ft.).
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
5. Accelerator cable bracket. section.
6. Engine coolant air bleed pipe and bolts/screws. 1. Exhaust manifold gasket (18), manifold assembly

l~I Tighten
(19) and heat shields.
2. Exhaust manifold studs (20) and bolts/screws (21)
• Accelerator control cable bracket bolts/screws and spacers (245).
to 10 N•m (90 lb. in.).
• Engine coolant air bleed pipe bolts/screws to
41 N•m (30 lb. ft.).
l~I Tighten
• Exhaust manifold studs (20) and bolts/screws
- Use a backup wrench when tightening (21) to 47 N•m (35 lb. ft.).
engine coolant air bleed pipe bolts/ 3. Air injection pipe assembly (15) and check valve
screws. (11 ).
7. EGR valve assembly and nuts.
8. EGR solenoid assembly and nut. !~I Tighten

l~I Tighten
• Secondary air injection pipe fitting-to-exhaust
manifold assembly to 34 N•m (25 lb. ft.).
• EGR valve nuts and EGR control valve relay 4. Apply sealer, GM P/N 1052080 or equivalent,
nut to 22 N•m (16 lb. ft.). around oil level indicator tube 13 mm (1/2 inch)
below bead.
9. Canister purge valve assembly bracket and bolt/
screw. 5. Oil level indicator, tube and bolt/screw to engine
block.
l~I Tighten
!~I Tighten
• Evaporative emission canister purge solenoid
valve bracket bolt/screw to 6 N•m (53 lb. in.). • Oil level indicator bolt/screw to 11 N•m (100
lb. in.).
10. EGR vacuum harness assembly and crankcase vent
hoses. 6. Spark plug wire harness assembly.
11. Generator bracket assembly, spark plug wire support 7. EGR valve pipe gasket (22), pipe assembly (12), nut
and bolts/screws. (14) and bolt/screw (229).

l~I Tighten !~I Tighten

• Generator bracket bolts/screws to 42 N •m (31 • EGR valve pipe nuts (14) and bolt/screw (229)
lb. ft.). to 25 N•m (18 lb. ft.).
12. Canister purger valve vacuum hose. Left Exhaust Manifold Assembly
13. Fuel injectors with fuel rail assembly (2) to intake

14.
manifold assembly (6).
Fuel pressure regulator vacuum tube assembly (7).
!++I Install or Connect
NOTICE: See "Notice" on page 6A3B-1 of this
15. Fuel rail bolts/screws (1 ). section.
6A3B-40 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1-VIN P

I. Exhaust manifold gasket (17), manifold assembly manifold assembly to 34 N•m (25 lb. ft.).
(16) and heat shields.
2. Exhaust manifold stud (20) and bolts/screws (21) FLYWHEEL ASSEMBLY
and spacers (245). Figure 8
l~I Tighten !++I Install or Connect
• Exhaust manifold stud (20) and bolts/screws 1. Flywheel assembly (135 or 137) to crankshaft
(21) to 47 N•m (35 lb. ft.). assembly (98).
3. Spark plug wire harness assembly. • Align locator hole to pin ( 133).
4. Secondary air injection pipe assembly ( 15), and 2. Flywheel bolts/screws (136 or 138).
check valve (11 ).

l~I Tighten
l~I Tighten
• Flywheel bolts/screws (136 or 138) to 100
• Secondary air injection pipe fitting-to-exhaust N•m (74 lb. ft.).

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ............................ 10 N•m (90 lb. in.)
Camshaft Retainer Bolt/Screw ........................................ 12 N•m (108 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 28 N•m (21 lb. ft.)
Connecting Rod Nut ................................................. 64 N•m (47 lb. ft.)
Coolant Air Bleed Pipe Bolt/Screw ..................................... 41 N•m (30 lb. ft.)
Crankshaft Balancer Bolt/Screw ........................................ 81 N•m (60 lb. ft.)
Crankshaft Balancer Hub Bolt/Screw ................................... 102 N•m (75 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw and Stud ............................ 106 N•m (78 lb. ft.)
Crankshaft Rear Oil Seal Housing Nut and Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . 15 N•m (11 lb. ft.)
Cylinder Head Bolt/Screw ............................................ 88 N•m (65 lb. ft.)
Distributor Bolt/Screw .............................................. 12 N•m (106 lb. in.)
Drain Plug ......................................................... 14 N•m (10 lb. ft.)
EGR Control Valve Relay Nut ......................................... 22 N•m (16 lb. ft.)
EGR Valve Nut ..................................................... 22 N•m (16 lb. ft.)
EGR Valve Pipe Bolt/Screw and Nut .................................... 25 N•m (18 lb. ft.)
Engine Block Oil Gallery Plug ......................................... 24 N•m (18 lb. ft.)
Engine Front Cover Bolt/Screw ....................................... 11 N •m (100 lb. in.)
Engine Oil Level Sensor Assembly ..................................... 35 N•m (26 lb. ft.)
Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt/Screw ........ 6 N•m (53 lb. in.)
Exhaust Manifold Stud and Bolt/Screw .................................. 47 N•m (35 lb. ft.)
Flywheel Bolt/Screw ................................................ 100 N•m (74 lb. ft.)
Fuel Injection Fuel Rail Bolt/Screw ..................................... 10 N•m (89 lb. in.)
Fuel Pump Switch and Oil Pressure Gage Sensor Assembly ................. 12 N•m (108 lb. in.)
Generator Bracket Bolt/Screw ......................................... 42 N•m (31 lb. ft.)
Ignition Coil Stud ................................................... 34 N•m (25 lb. ft.)
Intake Manifold Bolt/Screw and Stud
First Pass ........................................................ 8 N•m (71 lb. in.)
Final Pass ....................................................... 48 N•m (35 lb. ft.)
Knock Sensor Assembly .............................................. 19 N•m (14 lb. ft.)
MAP Sensor Bolt/Screw ............................................... 6 N•m (53 lb. in.)
Oil Filter Adapter Bolt/Screw .......................................... 23 N•m (17 lb. ft.)
Oil Level Indicator Tube Bolt/Screw ................................... 11 N•m (100 lb. in.)
Oil Pan Assembly
Corner Bolt/Screw and Nut ......................................... 20 N•m (15 lb. ft.)
Side Rail Bolt/Screw ............................................. 11 N•m (100 lb. in.)
Oil Pan Baffle Nut ................................................... 34 N•m (25 lb. ft.)
Oil Pan Drain Plug .................................................. 22 N•m (16 lb. ft.)
Oil Pump Bolt/Screw-to-Rear Crankshaft Bearing Cap ...................... 88 N•m (65 lb. ft.)
Oil Pump Cover Bolt/Screw ............................................ 9 N•m (80 lb. in.)
Oil Pump Driveshaft Bolt/Screw ....................................... 18 N•m (13 lb. ft.)
Secondary Air Injection Pipe Fitting-to-Exhaust Manifold Assembly ........... 34 N•m (25 lb. ft.)
Secondary Air Injection Pump Bracket Bolt/Screw ......................... 25 N•m (18 lb. ft.)
 5.7LITER V8 ENGINE UNIT REPAIR RPO LT1·VIN P 6A3B·41

Starter Motor Bolt/Screw ............................................. 46 N•m (34 lb. ft.)

Throttle Body Bolt/Screw ............................................. 26 N•m (19 lb. ft.)
Valve Lifter Guide Retainer Bolt/Screw .................................. 20 N•m (15 lb. ft.)
Valve Rocker Arm Ball Stud ... : ....................................... 68 N•m (50 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw ................................... 11 N•m (100 lb. in.)
Water Pump Bolt/Screw and Stud ....................................... 41 N•rrt (30 lb. ft.)
Water Pump Driveshaft Bearing Retainer Bolt/Screw ...................... 12 N•m (108 lb. in.)

ENGINE ASSEMBLY SPECIFICATIONS 5.7L (LT1)

GENERAL
Type .......................................................................... V8
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (350 CID)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.60 mm (4.000")
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.39 mm (3.480")
Compression Ratio ............................................................ 10.5:1
Firing Order .......................................................... 1-8-4-3-6-5-7-2
Spark Plugs
Type ................ , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC41-906
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27 mm (0.050")
Torque .......................................................... 15 N•m (11 lb. ft.)
Oil Pressure (Minimum) ............................. 41.4 kPa (6.0 psig) at 1,000 engine rpm
124.1 kPa (18.0 psig) at 2,000 engine rpm
165.5 kPa (24.0 psig) at 4,000 engine rpm
Oil Filter Torque .................................................... 19 N•m (14 lb. ft.)
CYLINDER BORE
Diameter ...................................... 101.618-101.643 mm (4.0007-4.0017")
Out-of-Round
Production .................................................. 0.02 mm (0.001 ") MAX.
Service Limit ................................................ 0.05 mm (0.002") MAX.
Taper
Production
Thrust Side ............................................. 0.012 mm (0.0005") MAX.
Relief Side .............................................. 0.025 mm (0.0010") MAX.
Service Limit .............................................. 0.025 mm (0.0010") MAX.
PISTON ASSEMBLY
Piston Bore Clearance
Production ....................................... 0.025 - 0.068 mm (0.0010- 0.0027")
Service Limit .............................................. 0.068 mm (0.0027") MAX.
PISTON RINGS
Piston Compression Ring
Groove Clearance
Production Top ................................. 0.030 - 0.068 mm (0.0012- 0.0027")
11
Production 2nd ................................. 0.038 - 0.078 mm (0.0015- 0.0031 )
Service Limit ............................................ 0.107 mm (0.0042") MAX.
Gap
Production Upper ................................... 0.25-0.50 mm (0.010- 0.020")
Production Lower .............................. 0.46-0.66 mm (0.018 - 0.026") MAX.
Service Limit .............................................. 0.88 mm (0.035") MAX.
Piston Oil Ring
Groove Clearance
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 - 0.17 mm (0.002 - 0.007 ")
Service Limit .............................................. 0.20 mm (0.008 ") MAX.
Gap
Production ......................................... 0.25 - 0.76 mm (0.010- 0.030")
Service Limit .............................................. 1.65 mm (0.065") MAX.
PISTON PIN
Diameter ........................................ 23.546 - 23.548 mm (0.9270- 0.9271 ")
6A3B·42 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1·VIN P

Clearance in Piston Assembly

Production ..................................... 0.0127 -0.0203 mm (0.0005 -0.0008 11 )
11
Service Limit .............................................. 0.025 mm (0.0010 ) MAX.
11
Fit In Connecting Rod Assembly ............. 0.013 -0.050 mm (0.0005- 0.0020 ) Interference
CRANKSHAFT ASSEMBLY
Main Journal
Diameter #162 ..................................... 189- 62.212 mm (2.4484-2.4493 11 )
Diameter #2, #3, #462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 - 62.205 mm (2.4481 - 2.4490 11 )
Diameter #562 ..................................... 177 - 62.120 mm (2.4479- 2.4488 11 )
Taper
Production .............................................. 0.005 mm (0.0002 11 ) MAX.
Service Limit ............................................ 0.025 mm (0.0010 11 ) MAX.
Out-of-Round
Production .............................................. 0.005 mm (0.0002") MAX.
Service Limit ............................................ 0.025 mm (0.0010") MAX.
Crankshaft Bearing Clearance
Production #10 ..................................... 020- 0.051 mm (0.0008 - 0.0020")
Production #2, #3, #40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .028 - 0.051 mm (0.0011 - 0.0020")
Production #50 ..................................... 043 - 0.081 mm (0.0017 - 0.0032")
Service Limit #10 ................................... 025 - 0.038 mm (0.0010- 0.0015")
Service Limit #2, #3, #40 ............................. 025 - 0.064 mm (0.0010- 0.0025")
Service Limit #50 ................................... 064-0.089 mm (0.0025 -0.0035")
Crankshaft Assembly End Play ............................ 0.03-0.17 mm (0.001-0.007")
Crankshaft Assembly Runout (at rear flange) ........................... 0.038 mm (0.0015")
CONNECTING ROD ASSEMBLY
Connecting Rod Journal
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.284 - 53.334 mm (2.0978 - 2.0998 ")
Taper
Production .............................................. 0.007 mm (0.0003") MAX.
Service Limit ............................................ 0.025 mm (0.0010") MAX.
Out-of-Round
Production .............................................. 0.007 mm (0.0003") MAX.
Service Limit ............................................ 0.025 mm (0.0010") MAX.
Rod Bearing Clearance
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.033 - 0.088 mm (0.0013 - 0.0035 ")
Service Limit .............................................. 0.076 mm (0.0030") MAX.
Rod Side Clearance ...................................... 0.16 - 0.35 mm (0.006 - 0.014")
CAMSHAFT ASSEMBLY
Journal Diameter .................................. 47.440 - 47.490 mm (1.8677 - 1.8697")
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11 - 0.30 mm (0.004 - 0.012 ")
Lobe Lift ....................................................... ± 0.050 mm (0.002")
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62 mm (0.300")
Exhaust ......................................................... 7.80 mm (0.307")
VALVE SYSTEM
Lifter Assembly ........................................................... Hydraulic
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Valve Lash ............................................. 1 ± 1/4 turn down from zero lash
Face Angle .................................................................... 45 °
Seat Angle ..................................................................... 46 °
Seat Runout ................................................... 0.05 mm (0.002") MAX.
Seat Width
Intake ............................................... 0.76- 1.27 mm (0.030-0.050")
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52 - 2.03 mm (0.060 - 0.080")
Stem Clearance
Production
Intake ......................................... 0.023 - 0.069 mm (0.0009 - 0.0027")
Exhaust ....................................... 0.023 - 0.069 mm (0.0009 - 0.0027")
Service
Intake .................................................. 0.093 mm (0.0037") MAX.
Exhaust ................................................ 0.119 mm (0.0047") MAX.
Valve Spring
Free Length ....................................................... 51.1 mm (2.01 ")
 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1-VIN P 6A3B-43

Pressure
Closed .................................. 360 - 395 Nat 45.2 mm (81 - 89 lb. at 1. 78 ")
Open .............................. 1121 - 1208 Nat 33.1 mm (252 - 272 lb. at 1.305")
Installed Height
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.2 mm ( 1. 78 ")
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.2 mm (1. 78 ")
Valve Lift
Intake .......................................................... 11.43 mm (0.450")
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68 mm (0.460")
6A3B·44 5.7 LITERV8 ENGINE UNIT REPAIR RPO LT1-VIN P

SPECIAL TOOLS

1. J 5590 6.
J 6098-01

2. J 39087 7. J 39088

J 5825-A 8. J 8037

4 . ~ J 3049 9.

10.
J 8062

5. J 39089

1. CRANKSHAFT GEAR INSTALLER

11.
a-, i J 5239

2. DRIVEN GEAR SHAFT FRONT COVER SEAL PROTECTOR

3. CRANKSHAFT GEAR REMOVER
4. HYDRAULIC VALVE LIFTER REMOVER (PLIER TYPE)
5. DRIVE GEAR/WATER PUMP SHAFT SEAL INSTALLER
6. CAMSHAFT BEARING REMOVER AND INSTALLER
7. DRIVEN GEAR SHAFT FRONT COVER SEAL INSTALLER
8. PISTON RING COMPRESSOR
9. VALVE SPRING TESTER J 9290-01
10. VALVE SPRING COMPRESSOR (HEAD-OFF) 12.
11. CONNECTING ROD BOLT GUIDE SET
12. HYDRAULIC VALVE LIFTER REMOVER (SLIDE HAMMER
TYPE)
13. DRIVEN GEAR ASSEMBLY REMOVER

13.
c~ '
J 39243

RC0016-6A3B·F-RP
 5.7 LITER va ENGINE UNIT REPAIR RPO LT1-VIN P 6A38-45

19.~ J 7872

15. ~~
F - J 8520 20.
Q~
\li~t<::1:.>
J 24086-B

16.
:::::, J 21882
21.
Q J 35468

17.

ODg
@(§)
~
,\ ~

J 39046
22.

8 .
J 35621

J 22794 23.
18. ' --- be

J 39092
24.

25. @CE==:3D J 39090

14. CARBON REMOVING BRUSH
15. CAM LOBE LIFT INDICATOR
16. OIL SUCTION PIPE INSTALLER
17. CRANKSHAFT HUB REMOVER AND INSTALLER
18. SPARK PLUG POAT ADAPTOR (14 mm TAPERED SEAT)
19. MAGNETIC BASE INDICATOR SET
20. PISTON PIN REMOVER AND INSTALLER SET
21. FRONT COVER ALIGNER AND OIL SEAL INSTALLER
22. REAR MAIN SEAL INSTALLER
23. VALVE GUIDE CLEANER
24. DRIVEN GEAR ASSEMBLY INSTALLER
25. DISTRIBUTOR DRIVESHAFT FRONT COVER SEAL
INSTALLER
26. DIAL INDICATOR SET

PC0057-8A3B-F·RP

SECTION 68
COOLING AND RADIATOR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B-1
Radiator Assembly ....................... 6B-2
Cross-Flow Radiator Core and
Outlet and Inlet Tanks . . . . . . . . . . . . . . . . 6B-2
Transmission Oil Cooler Assembly ........ 6B-2
Engine Oil Cooler Assembly . . . . . . . . . . . . . 6B-2
Radiator Drain Cock Assembly . . . . . . . . . . . 6B-2
Heater Core ................ Refer to Section lA
Radiator Filler Cap Assembly . . . . . . . . . . . . . . 6B-2
Electric Engine Coolant Fan Assembly . . . . . . . 6B-3
Engine Coolant Temperature Gage Sensor . . . . 6B-3
Engine Coolant Temperature (ECT) Sensor . . . 6B-3
Engine Coolant Thermostat Assembly . . . . . . . 6B-3
Coolant Recovery System . . . . . . . . . . . . . . . . . 6B-3
Radiator Air Baffle Assemblies and
Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3
Serpentine Drive Belt . . . . . . . . . . . . . . . . . . . . . 6B-3
Engine Block Coolant Drain Hole Plug . . . . . . . 6B-3
Maintenance Recommendations . . . . . . . . . . . . . . 6B-3
Checking Engine Coolant . . . . . . . . . . . . . . . . . 6B-3
Engine Coolant Concentration . . . . . . . . . . . . . . 6B-4
Hose Assemblies and Clamps Inspection . . . . . 6B-4
Water Pump Assembly Coolant Weepage . . . . . 6B-4
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
_Exteri.or Radiator Assembly Cleaning ........ 6B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
Cooling System Overheating . . . . . . . . . . . . . . . 6B-4
Engine Coolant Thermostat Assembly Test . . . . 6B-4
Radiator Filler Cap Assembly . . . . . . . . . . . . . . 6B-5
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Serpentine Drive Belt ..................... 6B-5
Cooling System Diagnosis Chart . . . . . . . . . . . . 6B-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 6B-7
Draining and Refilling Cooling System ....... 6B-7
Engine Coolant Flushing and Recycling . . . . . . 6B-7
Aluminum Radiator Service . . . . . . . . . . . . . . . 6B-9
GENERAL DESCRIPTION
The cooling system, which consists of a radiator
assembly and coolant recovery subsystem, electric engine
coolant fan assembly, engine coolant thermostat assembly
and water pump assembly and serpentine drive belt,
works to maintain engine temperature at an efficient level
during all engine operating conditions.
COOLING AND RADIATOR 68·1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Repairable Leaks . . . . . . . . . . . . . . . . . . . . . 6B-11
Repair Methods . . . . . . . . . . . . . . . . . . . . . . 6B-11
Cooling Fin Removal .................. 6B-ll
Tube Blocking . . . . . . . . . . . . . . . . . . . . . . . 6B-11
Header Repair . . . . . . . . . . . . . . . . . . . . . . . 6B-11
General Core Repair . . . . . . . . . . . . . . . . . . 6B-11
Radiator Side Tank Gasket Leak Repair . . . 6B-13
Transmission Oil Cooler Gasket . . . . . . . . . 6B-13
Transmission Oil Cooler . . . . . . . . . . . . . . . 6B-15
Recore ............................. 6B-15
Radiator Drain Cock Assembly .......... 6B-15
Engine Coolant Thermostat Assembly ...... 6B-15
Electric Engine Coolant Fan Assembly ...... 6B-15
Water Pump Assembly ................... 6B-16
Battery Tray and Coolant Recovery
Reservoir Assembly ................... 6B-19
Engine Oil Cooler Inlet and Outlet
Hose Assemblies ..................... 6B-20
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . 6B-20
Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . 6B-20
Radiator Air Baffle Assemblies
and Deflectors ....................... 6B-21
Radiator Upper Mounting Panel ......... 6B-21
Radiator Air Lower Baffle Assembly
and Deflector ...................... 6B-21
Radiator Air Upper Baffle Assembly ..... 6B-21
Engine Coolant Hose Assemblies .......... 6B-21
Coolant Air Bleed Pipe Assembly . . . . . . . . . . 6B-22
Testing the Coolant Concentration . . . . . . . . . . 6B-23
Specifications ....................... , . . . . 6B-24
General Specifications . . . . . . . . . . . . . . . . . . . 6B-24
Fastener Tightening Specifications . . . . . . . . . 6B-24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25
On the 3.4L L32 engine, coolant is drawn from the
radiator assembly by the water pump assembly and circu-
lated through coolant jackets in the engine block assembly,
intake manifold assembly, and cylinder head assemblies.
It is then directed back to the radiator assembly.
On the 5.7L LTl engine, coolant is drawn from the
radiator assembly by the water pump assembly and circu-
lated through coolant jackets in the cylinder heads, then
68-2 COOLING AND RADIATOR
through coolant jackets in the engine block. It is then
directed back to the radiator assembly.
The system directs some engine coolant through
hose assemblies to the heater core to provide defrost and
passenger compartment heat. A coolant recovery reser-
voir assembly is connected to the radiator assembly to
recover engine coolant displaced by expansion. As the
engine assembly cools, the engine coolant is drawn back
into the radiator assembly by vacuum.
RADIATOR ASSEMBLY
Cross-Flow Radiator Core and Outlet and
Inlet Tanks
A cross-flow radiator core is used on all models.
Outlet and inlet tanks are located to the right and left of
the cross-flow radiator core. All radiator assemblies used
with automatic transmissions have transmission oil cool-
ers and inlet and outlet fittings for transmission fluid
circulation. Vehicles with manual transmission assem-
blies use radiator assemblies without transmission oil
coolers.
An aluminum-plastic radiator assembly can be iden-
tified by a note on the. outlet tank 127 mm (5 inches)
below the filler neck which reads: "Important - for repair
see Harrison Service Manual." Service procedures for the
aluminum-plastic radiator assembly are described in that
manual and in this section.
Transmission Oil Cooler Assembly
If equipped, the transmission oil cooler assembly is
located in the outlet tank on the right side of the radiator
assembly. For information on servicing the transmission
oil cooler and pipe assemblies, refer to SECTION 7 A.
Engine Oil Cooler Assembly
The 5.7L LTI engines equipped with a GUS axle
require an engine oil cooler assembly which is located in
the left end of the radiator assembly. Engine oil cooler
pipe assemblies connect the radiator assembly to the
engine block assembly through an adapter assembly,
located between the oil filter assembly and engine block.
Radiator Drain Cock Assembly
The radiator drain cock assembly includes the radi-
ator drain cock and the radiator drain cock sealer; it is
located on the inner right side of the radiator assembly,
near the bottom.
RADIATOR FILLER CAP ASSEMBLY
Figure 1
A pressure-type radiator filler cap assembly is used
with the cross-flow radiator assembly to allow a buildup
of 124 kPa ( 18 psi) in the cooling system. This pressure
raises the boiling point of engine coolant to approximately
125°C (257°F) at sea level.
0 VACUUM RELIEF
0 PRESSURE RELIEF
KC0056-6B-B-RP
Figure 1 - Pressure-Type Radiator Filler Cap Assembly
(Typical)
CAUTION: Do not remove radiator filler
cap assembly to check engine cool-
ant level; check engine coolant at the
coolant recovery reservoir assembly.
Engine coolant should be added only
to the coolant recovery reservoir
assembly, when the system cools.
CAUTION: As long as there is pressure
in the cooling system, the temperature
can be considerably higher than the
boiling temperature of the solution.
Removal of the radiator filler cap
assembly while engine assembly is hot
and pressure is high will cause the
solution to boil instantaneously and
possibly with explosive force, spewing
the solution over engine assembly,
fenders and person removing cap. If
the solution contains flammable anti-
freeze, such as alcohol (not recom-
mended for use at any time), there is
also the possibility of causing a serious
fire.
The pressure-type radiator filler cap assembly
contains a blow-off (pressure) valve and a vacuum
(atmospheric) valve. The pressure valve is held against its
seat by a heavy spring. This spring protects the radiator
assembly by relieving pressure exceeding 124 kPa
(18 psi).
To prevent radiator assembly collapse caused by
vacuum as the engine assembly cools, the vacuum valve
prevents excessive pressure differences from occurring
between the cooling system and the atmosphere.
The radiator filler cap assembly has, been designed
without finger grips to discourage inadvertent removal.
To safely remove the radiator filler cap assembly, rotate
the cap assembly slowly counter-clockwise (do not press
down) to de.tent. Allow any pressure to be relieved. Next,
press down on the cap assembly and continue to rotate cap
assembly counterclockwise and lift off the cap assembly.
Embossed on the cap assembly is a caution against open-
ing it and arrows indicating the proper closed position.

ELECTRIC ENGINE COOLANT FAN
ASSEMBLY
An electric engine coolant fan assembly aids air
flow through the radiator assembly. There are five plastic
blades on each fan blade assembly. The fan blade assem-
bly is driven by a motor attached to the radiator support.
The 5.7L LT! engine assembly equipped with air condi-
tioning has two engine coolant fan assemblies attached to
the radiator support.
The fan motor is activated by an PCM controlled fan
relay. If the vehicle is equipped with air conditioning, the
fan motor also operates when the compressor assembly is
operating.
CAUTION: If a fan blade assembly is
bent or damaged in any way, no attempt
should be made to repair or reuse the
damaged part. A bent or damaged fan
blade assembly should always be
replaced. It is essential that fan blade
assemblies remain in proper balance
and proper balance cannot be assured
once a fan blade assembly has been
bent or damaged. A fan blade assembly
that is not in proper balance could
fail and fly apart during subsequent
use, creating an extremely dangerous
condition.
The fan blade assembly is designed to aid air flow
through the radiator and air conditioning condenser.
ENGINE COOLANT TEMPERATURE GAGE
SENSOR
This sensor controls a temperature gage in the
instrument cluster assembly. The temperature gage indi-
cates the operating temperature of the engine assembly.
Refer to SECTION 8A for engine coolant temperature
gage sensor diagnosis and location.
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
This sensor sends a signal to the powertrain control
module (PCM) which completes the ground for the
electric engine coolant fan relay, which operates the fan
assembly when the engine coolant temperature exceeds
I 10°C (230°F). Refer to SECTION 6E3 for engine cool-
ant temperature (ECT) sensor diagnosis and location.
ENGINE COOLANT THERMOSTAT
ASSEMBLY
A pellet-type engine coolant thermostat assembly is
used in the engine coolant outlet passage to control the
flow of engine coolant to provide fast engine warm-up
and to regulate engine temperatures. A wax pellet element
in the thermostat assembly expands when heated and
contracts when cooled. The pellet element is connected
through a piston to a valve. The valve remains closed
while the engine coolant is cold, preventing circulation
of engine coolant through the radiator assembly and
allowing the circulation of engine coolant only through
the engine assembly.
COOLING AND RADIATOR 68-3
As the engine assembly warms, the pellet element
expands and the thermostat valve opens, permitting
engine coolant to flow through the radiator assembly.
COOLANT RECOVERY SYSTEM
A plastic reservoir is connected to the radiator
assembly by a hose. As the vehicle is driven, the engine
coolant is heated and expands. The portion of the engine
coolant displaced by this expansion flows from the radia-
tor assembly into the reservoir assembly. When the engine
assembly is stopped and the engine coolant cools and con-
tracts, the displaced engine coolant is drawn back into the
radiator assembly by vacuum. Thus, the radiator assembly
is kept filled with engine coolant to the desired level at all
times, resulting in increased cooling efficiency.
RADIATOR AIR BAFFLE ASSEMBLIES AND
DEFLECTORS
Radiator air baffle assemblies and deflectors are
located at the top and bottom of the radiator assembly to
increase air flow through the radiator assembly.
SERPENTINE DRIVE BELT
The serpentine drive belt drives the water pump
assembly (V6 only) and engine accessories. To check the
condition of the serpentine drive belt and tensioner assem-
bly, refer to SECTION 6A2A or SECTION 6A3A.
ENGINE BLOCK COOLANT DRAIN HOLE
PLUG
The engine block coolant drain hole plug is on the
left side of the engine block assembly. It must be removed
during a complete drain and refill of the coolant system.
The knock sensor on the right side of the engine block
assembly must also be removed.
MAINTENANCE RECOMMENDATIONS
Regular maintenance of the cooling system will help
keep it operating properly. Use the following procedures
to check the cooling system at least once a year or 25 000
km (15,000 miles).
CHECKING ENGINE COOLANT
Check the engine coolant level in the reservoir
assembly by removing the reservoir cap and checking the
dipstick while the engine is cold. The level should be at or
above the "FULL COLD" mark on the dipstick when the
engine assembly is cold. At normal operating tempera-
tures the engine coolant level should be at or above the
"FULL HOT" mark on the dipstick.
Engine coolant should be added only to the reservoir
assembly to raise the level to the appropriate mark. Use a
50/50 mixture of high quality ethylene glycol and water
for engine coolant additions.
Every two years or 50 000 kilometers (30,000 miles),
whichever comes first, the cooling system should be
drained and refilled. Refer to "Draining and Refilling the
Cooling System" in this section.
68·4 COOLING AND RADIATOR
ENGINE COOLANT CONCENTRATION
The percentage of ethylene glycol in the engine
coolant should be checked periodically and when the
engine coolant level is adjusted or the system drained and
refilled.
This test is done by using a refractometer engine
coolant tester. Refractometers test for the amount of gly-
col in a coolant mixture by measuring the speed of light as
it passes through the fluid and are not affected by the spe-
cific gravity of the glycol. Refer to "Engine Coolant Test-
ing'' in this section for the test procedures.
HOSE ASSEMBLIES AND CLAMPS
INSPECTION
Inspect the condition of all hose assemblies and
clamps. Hose assemblies should be flexible and show no
signs of bulging, cracks, cuts, kinks or area of possible
leaks. Inspect the brackets, supports, ties and clamps.
Adjust and tighten as necessary.
WATER PUMP ASSEMBLY COOLANT
WE EPAGE
A very slight amount of weepage may occur at the
water pump vent hole during vehicle operation. Tracks of
residue may occur from the lower vent hole. The water
pump should be replaced only if coolant is dripping from
the vent hole while the engine is in operation or while the
cooling system is pressurized.
Minor water pump weepage and minor engine cool-
ing system leaks may be corrected by adding two sealant
pellets to the cooling system. The pellets are available
from GMSPO in packages of six under GM P/N 3634621.
Two engine coolant supplement pellets should be
added to the coolant system under the following condi-
tions:
• Vehicle encountering water pump weepage or minor
coolant leak/Joss that cannot be corrected through
normal service procedures.
• When cooling system is drained and coolant is
replaced with new coolant due to engine repair work
or at recommended coolant change intervals (two
years or 30,000 miles).
• Whenever engine water pump is replaced. The addi-
tion of pellets provides a mild lapping of the new
water pump seal that improves con formability of the
mating surfaces. Water pump seal weepage is mini-
mized by the addition of pellets.
CAUTION: To avoid the danger of being
burned, do not remove the cap while
the engine and radiator are still hot.
Scalding fluid and steam can be blown
out under pressure.
NOTICE: Do not add pellets into non-pressurized
coolant recovery bottles.
The two pellets should be installed into the radiator.
Care should be exercised to avoid contamination of the
pressure/radiator cap and mating sealing surfaces with
pellet debris. The use of sealant pellets may cause a film
to appear around the sides of non-pressurized coolant
recovery bottles. The presence of this film is considered to
be normal.
Following installation of the pellets, run the engine
for approximately 15 minutes, then check for coolant
leaks and proper cooling system operation.
rn Important
If pellets have been installed to correct an excessive
water pump seal weepage condition, one to two weeks of
normal vehicle operation may be required to lap in the
mating seal surfaces. Some staining due to minor weepage
may continue to occur. This is considered normal.
PRESSURE TESTING
Test the radiator filler cap assembly for the proper
pressure holding capacity. Refer to "Pressure Test" in this
section.
EXTERIOR RADIATOR ASSEMBLY
CLEANING
Clearing away bugs, leaves and other debris from
the small air passageways of the radiator assembly will
improve the operation of the cooling system.
Use compressed air to blow through the radiator
assembly from the rear towards the front of the vehicle. If
compressed air is not available, water can be used by
directing the water hose from the rear of the radiator
assembly.
NOTICE: The radiator fins are necessary for good
heat transfer and should not be brushed. Brushing
may damage the fins, reducing heat transfer.
DIAGNOSIS
COOLING SYSTEM OVERHEATING
Figure2
1. If overheating occurs due to prolonged idling in
gear, instruct operator on driving techniques which
would reduce possibility of engine assembly over-
heating:
• Idle in "NEUTRAL" as much as possible and
raise engine rpm using accelerator pedal
assembly.
• Turn air conditioning "OFF" during extended
idling.
2. If above does not apply, refer to diagnosis chart.
ENGINE COOLANT THERMOSTAT
ASSEMBLY TEST
Figure 2
Tools Required:
J 24731-188 Tempi! Stick
J 24731-206 Tempi! Stick
!L•f 1nspect
• Thermostat assembly opening temperature (Figure 2).
 COOLING AND RADIATOR 68·5

ENGINE OVERHEAT - BOILING - POOR ENGINE COOLING

1. RELIEVE PRESSURE AND CAREFULLY REMOVE RADIATOR
FILLER CAP ASSEMBLY.
2. RUB 206'F TEMPERATURE STICK* ONTO ENGINE COOLANT
THERMOSTAT WATER OUTLET ASSEMBLY.
3. WARM UP ENGINE AT FAST IDLE.
WATCH FOR ENGINE COOLANT FLOW BEFORE MARK BEGINS
..._ _ _ _ NO ENGINE COOLANT FLOW ---....i INSTALL NEW ENGINE
COOLANT THERMOSTAT
ASSEMBLY (WITH GASKET)
TO MELT.
•
ENGINE COOLANT FLOW
I
PROBLEM IS CAUSED BY OTHER
THAN BAD ENGINE COOLANT
THERMOSTAT ASSEMBLY (WITH
GASKET)

COLD ENGINE - SLOW WARMUP - NOT ENOUGH HEAT

1. RELIEVE PRESSURE AND CAREFULLY REMOVE RADIATOR
FILLER CAP ASSEMBLY.
2. RUB 188'F TEMPERATURE STICK* ONTO ENGINE COOLANT
THERMQSTATWATER OUTLET ASSEMBLY.
3. WARM UP ENGINE AT FAST IDLE.
WATCH FOR ENGINE COOLANT FLOW BEFORE MARK BEGINS
TO MELT.
....,_ _ _ _ ENGINE COOLANT FLOW ----....i INSTALL NEW ENGINE
COOLANT THERMOSTAT
ASSEMBLY (WITH GASKET)

•
NO ENGINE COOLANT FLOW

PROBLEM IS CAUSED BY OTHER

THAN BAD ENGINE COOLANT
THERMOSTAT ASSEMBLY (WITH
GASKET)
*NOTE: THE TEMPERATURE STICK IS A PENCIL LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING CERTAIN CHEMICALS WHICH MELT AT A GIVEN
TEMPERATURE. TEMPERATURE STICKS CAN BE USED TO DETERMINE THERMOSTAT OPERATING TEMPERATURE BY RUBBING 108'F AND 206°F STICKS
ON THE ENGINE COOLANT THERMOSTAT WATER OUTLET ASSEMBLY. THE MARKS MADE BY THE STICKS SHOULD MELT WHEN ENGINE COOLANT
TEMPERATURES OF 188'FAND 206'FARE REACHED, RESPECTIVELY. THESE TEMPERATURES ARE THE NORMAL OPERATING RANGE OF THE ENGINE
COOLANT THERMOSTAT ASSEMBLY (WITH GASKET), THEREFORE IF THE ENGINE COOLANT FLOWS AS INDICATED ON THE DIAGNOSIS CHART, THE
ENGINE COOLANT THERMOSTAT ASSEMBLY (WITH GASKET) MAY BE DEFECTIVE. PC0001-6B-F-RP

Figure 2 - Thermostat Assembly Diagnosis

RADIATOR FILLER CAP ASSEMBLY l. Clean cap assembly.

ll"'I Inspect
• Cap assembly for weak spring washer or damage
to gasket. If spring washer is weak, replace cap
assembly.
• Relief valve gasket in cap assembly and inner seal-
ing surface of neck assembly for damage or debris.
• Hose fitting on neck assembly for cracks. If fitting is
loose or cracked, replace radiator end tank.
Pressure Test
Tool Required:
J 24460-01 Cooling System Tester
2. Install cap assembly on J 24460-01.
3. Pump pressure tester slowly to obtain minimum
holding pressure.
A. If cap assembly fails to hold 83 kPa (12 psi),
replace cap assembly.
B. If installing new cap assembly, coat both
gaskets with engine coolant.
SERPENTINE DRIVE BELT
Routine inspection of the serpentine drive belt may
reveal cracks in the belt ribs. These cracks will not impair
belt performance and are not a basis for belt replacement.
For belt tensioning and replacement procedures, refer to
SECTION 6A2A or SECTION 6A3A.
68-6 COOLING AND RADIATOR
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE
Engine overheats. a. Loss of engine coolant.
b. Loss of system pressure.
c. Weak engine coolant solution.
d. Loose serpentine drive belt.
e. Advanced/Retarded ignition timing.
f. Obstructed radiator fins.
g. Cooling system passages blocked
by rust or scale.
h. Kinked reservoir hose assembly.
I. Inoperative engine coolant tern-
perature fan assembly.
J. Loose, damaged, and/or missing
radiator upper and lower shrouds,
air deflectors or baffle assemblies.
k. Thermostat assembly.
1. Faulty water pump assembly.
m. Incorrect radiator assembly.
n. Incorrect or damaged fan blade
assembly.
0. Faulty emission system components. o.
- PCV valve.
- Catalytic converter plugged.
p. Engine oil overfill.
Loss of engine coolant. a. Leaking radiator assembly.
b. Radiator filler cap assembly faulty.
c. Distorted neck assembly.
d. Leaking reservoir or hose assembly.
e. Loose or damaged radiator or heater e.
hose assemblies or connections.
CORRECTION
a. Refer to next condition - "Loss of
engine coolant."
b. Perform radiator filler cap
assembly pressure test.
c. Test engine coolant for proper
50-50 mixture.
d. Check serpentine drive belt
tension. Refer to SECTION 6A2A
or SECTION 6A3A.
e. Refer to SECTION 6E.
f. Remove or relocate added-on parts
that block air to radiator assembly.
Clean away bugs, leaves, and other
debris.
g. Flush cooling system or flow
check radiator assembly. Remove
cylinder head assembly and
inspect, if required.
h. Re-route reservoir hose assembly.
I. Refer to SECTION 8A.
J. Repair or replace as required.
k. Replace thermostat assembly stuck
in closed position.
1. Replace water pump assembly.
m. Determine proper radiator assembly
for vehicle and replace radiator
assembly if necessary.
n. Check for correct part number.
Replace fan blade assembly if
required.
Refer to SECTION 6E or 6F.
p. Check engine oil level.
a. Inspect radiator assembly. Repair
as necessary.
b. Perform cap assembly pressure
test.
c. If radiator neck assembly upper
sealing area is distorted, use wood
block and mallet to reform neck
assembly to fit cap assembly.
d. Replace reservoir or hose assem-
bly.
Reseat hose assemblies. Replace
hose assemblies or clamps.
 COOLING AND RADIATOR 68-7

CONDITION POSSIBLE CAUSE CORRECTION

f. Water pump assembly seal leaking. f. Replace water pump assembly.
g. Water pump gasket leaking. g. Replace water pump gasket.
h. Improper cylinder head assembly h. Re-tighten cylinder head bolts/
torque. screws to specifications. Replace
cylinder head gasket if required.
I. Leaking 1. Make repairs or replace compo-
- intake manifold assembly nents as necessary to correct leak.
(3.4L L32 engine).
- cylinder head assembly gasket.
- engine block coolant drain
hole plug or knock sensor.
- heater core.
- heater water valve, if equipped.

Engine fails to reach normal
operating temperature. Cool
air from the heater.
a. Thermostat assembly stuck open or a. Install new thermostat assembly of
wrong type of thermostat assembly. correct type and heat range.
b. Engine coolant is below the "FULL b. Add engine coolant.
COLD" mark.

ON-VEHICLE SERVICE However, the thermostat should be removed before flush-

DRAINING AND REFILLING COOLING
SYSTEM
CAUTION: To avoid the danger of being
burned, do not remove the radiator
filler cap assembly while the engine
and radiator assembly are still hot.
Scalding fluid and steam may be blown
out under pressure.
NOTICE: See "Notice" on page 6B-1 of this
section.
ing the system.
Engine Coolant Recycling
Tool Required:
GM approved Recycling System such as Pro
Clean (Available in the GM Dealer Equipment
program)
As the need arises to conduct cooling system main-
tenance or repairs, all of the used coolant must be
removed and replaced with qualified new or recycled

m Important
• Dispose of used coolant in a proper fashion, i.e., in a
used coolant holding tank. Never pour used coolant
down the drain. Ethylene glycol antifreeze is a very
toxic chemical; disposing of it into the sewer system
or ground water is both illegal and ecologically
unsound.
ENGINE COOLANT FLUSHING AND
RECYCLING
Engine Coolant Flushing
Tool Required:
Non-Aqueous Coolant Exchanger such as Pro-
Fill J 75010-KM (Available in the GM Dealer
Equipment program)
If your state/local environmental enforcement group
does not allow the discharge of coolant or if you do not
desire to put used coolant into the environment there are
various methods and equipment that can be used to flush
the coolant system. If using special equipment such as
back flusher, follow the manufacturer's instructions.
coolant. If only th.e radiator is drained, up to 50 percent of
the used, contaminated coolant can remain in the cooling
system. Removing used coolant (from the vehicle) can be
accomplished by several methods:
• Utilize waterless coolant evacuation system avail-
able in the GM Dealer Equipment program (or
equivalent) which removes the used coolant and
replaces it with approved new or recycled coolant.
• Utilize a GM approved coolant recycling system
available in the GM Dealer Equipment program (or
equivalent) which recycles the coolant on the
vehicle thereby eliminating the need for evacuation.
• Recover used coolant and store in a used coolant
holding tank and submit the used coolant for recycl-
ing on a regular basis.
3.4L L32 Engine
1. Park vehicle on a level surface.
2. Remove, clean and reinstall reservoir assembly.
Refer to "Battery Tray and Coolant Recovery
Reservoir Assembly" in this section.
3. Remove pressure cap assembly.
68·8 COOLING AND RADIATOR
A. Turn pressure cap assembly slowly counter-
clockwise until it reaches the "stop." Do
not press down while turning pressure cap
assembly.
B. Wait until any remaining pressure (indicated
by hissing sound) is relieved.
C. After all hissing ceases, press down on
pressure cap assembly and continue to rotate
pressure cap assembly counterclockwise.
4. Open drain cock assembly.
5. Remove drain hole plug and knock sensor, located
on either side of engine block.
6. Allow system to drain completely.
7. Close drain cock assembly.
8. Install drain hole plug and knock sensor.
!~! Tighten
• Drain hole plug to 21 N•m (15 lb. ft.).
• Knock sensor to 19 N•m (14 lb. ft.).
• Drain cock assembly to 1.5 N•m (13 lb. in.).
9. Add enough water to fill cooling system.
10. Run engine assembly until thermostat assembly
opens.
11. Stop engine assembly. Repeat steps 2 through 10,
until drained fluid is nearly colorless.
12. Remove, empty and reinstall reservoir assembly.
Refer to "Battery Tray and Coolant Recovery
Reservoir Assembly" in this section.
NOTICE: Use new ethylene glycol antifreeze,
meeting GM specification 1825M, to provide the
required freezing and corrosion protection - at least
50 percent solution, at temperature of - 37°C
(-34°F).
13. Add enough water and new ethylene glycol anti-
freeze (meeting GM specification 1825M) to pro-
vide a solution that is at least 50 percent antifreeze,
but no more than 70 percent antifreeze.
A. Fill radiator assembly to below neck assembly.
B. Fill reservoir assembly to "FULL COLD"
mark.
C. Add two cooling system sealer pellets.
D. Install reservoir assembly cap.
14. Run engine assembly, with radiator cap assembly
removed, until normal operating temperature is
reached (radiator inlet hose assembly becomes hot).
CAUTION: Under some conditions,
ethylene glycol in engine coolant is
flammable. To avoid being burned
when adding engine coolant, do not
spill it on the exhaust system or on hot
engine parts.
15. With engine assembly idling, add engine coolant to
radiator assembly until level reaches bottom of neck
assembly.
16. Install cap assembly.
• Arrows on cap assembly must line up with
reservoir hose assembly.
5.7L LT1 Engine
1. Park vehicle on level surface.
2. Remove coolant recovery reservoir filler cap assem-
bly.
A. Slowly rotate cap counterclockwise about 1/4
turn and then stop.
B. Wait until any remaining pressure (indicated
by hissing sound) is relieved.
C. After all hissing ceases, continue to rotate cap
assembly counterclockwise until cap is
removed.
3. Open coolant drain cock assembly.
4. Open heater air bleed vents located just above water
pump assembly on the thermostat housing and
heater outlet hose pipe. Air bleed vents should be
open two or three turns.
• Place a shop towel under the bleed valve to
prevent coolant from splashing onto distributor
assembly.
5. Remove drain hole plug and knock sensor, located
on either side of engine block.
6. Allow system to drain completely.
[I) Important
• Store used coolant in a proper fashion, i.e., in a
used coolant holding tank. NEVER POUR
USED COOLANT DOWN THE DRAIN!
Ethylene Glycol antifreeze is a very toxic
chemical; disposing of it into the sewer system
or ground water is both illegal and ecologically
unsound!
7. Close coolant drain cock valve.
8. Install ESC knock sensors and drain hole plug.
NOTICE: Use Ethylene Glycol antifreeze meeting
GM specification 2025-M to provide required freez-
ing and corrosion protection - at least SO-percent
solution, -37°C (-34 °F).
9. Fill cooling system through the radiator neck.
10. Close air bleed vent when bubbles disappear and
only coolant is visible.
11. Fill the coolant recovery reservoir assembly to the
"COLD" fill mark. This will provide the extra cool-
ant required to replace the air left in the system upon
the first couple of thermocycles.
12. Coolant recovery reservoir assembly cap.
[I] Important
• Block wheel assemblies, place transm1ss1on
assembly in "PARK" or "NEUTRAL" and set
parking brake.
13. Run engine with the coolant radiator pressure cap
off until thermostat assembly opens.

rn Important
• With the engine running, add coolant to the
radiator until the level reaches the bottom of
the filler neck.
14. Open air bleed valves. When bubbles disappear and
only coolant is visible, close heater air bleed valve.
• Place a shop towel under the bleed valves to
prevent coolant from splashing onto distributor
assembly.
CAUTION: Under some conditions, Eth-
ylene Glycol in engine coolant is flam-
mable. To avoid being burned when
adding engine coolant, do not spill it
on the exhaust system or on hot engine
parts.
15. Fill the cooling system again after these procedures
are completed.
NOTICE: Use Ethylene Glycol antifree.ze meeting
GM specification 1825-M to provide required freez-
ing and corrosion protection - at least SO-percent
solution, -37°C ( -34 °F).
[I] Important
• When refilling the engine cooling system, add two
engine coolant supplemental sealant pellets GM P/N
3634621 or equivalent) and coolant antifreeze meet~
ing GM specification 2025-M.
16. Install the radiator cap assembly.
IL•! inspect
• For leaks, after running engine until normal
operating temperature is reached.
NOTICE: "LOW COOLANT" warning/indicator
lamp may come on after this procedure. After oper-
ating vehicle so engine heats up and cools down
three times, if "LOW COOLANT" warning/indica-
tor lamp does not go out, or fails to come on at igni-
tion check and coolant is above "FULL COLD"
mark in reservoir assembly, refer to SECTION 8A.
If at any time the "TEMP" warning/indicator lamp
comes on, immediate action is required. Turn off
engine and allow vehicle to cool. Do not remove
coolant recovery reservoir cap at this time.
17. Test coolant concentration. Refer to "Testing the
Coolant Concentration" in this section.
ALUMINUM RADIATOR SERVICE
Figures 3 and 4
This radiator uses an aluminum core with plastic
side tanks. The core and side tanks can be replaced
separately. Core repair is easily made with the hot melt
adhesive method. A transmission oil cooler may be
located in one of the side tanks. The drain cock is located
on the lower part of one of the tanks.
The following components are serviceable:
- Radiator core.
COOLING AND RADIATOR 68-9
- Tanks and gaskets. (Tanks cannot be repaired if
broken or cracked).
- Oil cooler and gaskets.
- Drain cock and gaskets.
Precautions
CAUTION: Failure to follow any one of
these procedures could result in per-
sonal injury or components damage.
• Do not remove radiator cap while engine is at
normal operating temperature. Cooling system will
release scalding fluid and steam under pressure if
cap is removed while engine and radiator are still
hot.
• Do not use boil-out tanks or any tank that has been
used for copper or brass radiators.
• Do not open hood if steam or coolant can be seen
escaping from engine compartment.
• Do not remove cap on coolant recovery reservoir if
an engine over temperature is suspected.
Diagnosis
Leak Testing
Some core leaks can be detected by adding water to
the radiator. Clean the core so the damaged area is easier
to find.
On-Vehicle Pressure Testing
Figure 5
Tool Required:
J 24460-01 Cooling System Tester
1. Ensure that radiator hose clamps and heater hose
clamps are properly positioned and secured.
2. Inspect connections for leaks. Repair as required.
CAUTION: To avoid being burned, do
not remove radiator cap assembly
while engine assembly is at normal
operating temperature. The cooling
system will release scalding fluid and
steam under pressure if radiator filler
cap assembly is removed while engine
assembly and radiator assembly are
still hot.
3. Remove radiator filler cap assembly.
4. Fill cooling system to base of radiator assembly
neck.
5. Attach J 24460-01 to radiator assembly neck.
• Follow instructions supplied with J 24460-01.
6. Build up pressure to no more than 138 kPa (20 psi).
7. System should hold pressure for about two minutes.
A. If a measurable amount of pressure drops in
less than two minutes, check for leak.
B. Mark leaking area and remove radiator assem-
bly for repair. Refer to "Radiator Assembly"
in this section.
68-10 COOLING AND RADIATOR

5 2

6
=~-r
l 7

1 CORE, CROSS-FLOW RADIATOR I'', - - ,-

2 TANK, RADIATOR OUTLET ' I,
3 TANK, RADIATOR INLET

-
4 GASKET, RADIATOR SIDE TANK
5
6
COOLER ASSEMBLY, TRANSMISSION OIL
GASKET, TRANSMISSION OIL COOLER
I -
7 NUT, TRANSMISSION OIL COOLER RETAINING ~-- ·~
8 COCK ASSEMBLY, RADIATOR DRAIN
PC0002·6B-F-RP

Figure 3 - Aluminum Radiator Assembly

Figure 5 - Pressure Testing the Radiator Assembly

Off-Vehicle Leak Testing

NOTICE: Do not use boil-out tanks or any tank that
has been used for copper or brass radiator assem-
blies. The remaining solutions or chemicals in these
tanks could cause radiator assembly failure.

Figures 6 and 7
.\ Tool Required:
'I
J 24460-01 Cooling System Tester
8 COCK ASSEMBLY, RADIATOR DRAIN
9 SEALER, RADIATOR DRAIN COCK THREAD 1. Plug radiator inlet and outlet tubes. Make sure drain
10 ELBOW, RADIATOR DRAIN COCK cock is closed.
PC0003·6B-F-RP
2. Attach J 24460-01 torndiator assembly.
Figure 4 - Aluminum Radiator Drain Cock Assembly
3. Build up pressure to 138 kPa (20 psi).
4. Observe gage for any pressure loss.

A primer. The adhesive kit is reusable, has an indefinite
A PLUGS
PC0004-&B-F-RP
Figure 6 - Aluminum Radiator Assembly and Oil Cooler
Plugs
A NOTICE: Do not block off more than two tubes in
B c
D
A GASKET, RADIATOR INLET TANK
B TUBE ASSEMBLIES, RADIATOR CORE
C GASKET, RADIATOR OUTLET TANK
D GASKET, RADIATOR DRAIN COCK
E GASKETS, OIL COOLER
F JOINT BETWEEN TUBE AND HEADER
PC0005-6B-F-RP
Figure 7 - Possible Leak Areas
5. Run water over repair area and look for any bubbles.
• If a large tank is available, radiator assembly
can be submerged to check for air bubbles.
Repairable Leaks
Core leaks and gasket leaks are the two types of
leaks that can be repaired on the radiator assembly. Core
leaks can occur in a tube or in the joints between the tubes
and headers. Gasket leaks can occur between the oil
cooler fittings and the tank. Some leaks can be repaired
while the radiator assembly is on the vehicle; however, it
is more practical to remove the radiator assembly from the
vehicle.
COOLING AND RADIATOR 68-11
Repair Methods
Figures 8 through 12
The hot melt adhesive is the most effective method
of repairing the radiator core. The hot melt adhesive kit
contains adhesive sticks, cotton swabs, wire brush and
shelf life and is waste free. The sticks must be stored in a
sealed container to keep them dry.
Cooling Fin Removal
For damaged areas that are between the cooling fins,
it may be necessary to remove some of the fins. Do not
remove more fins than necessary. Usually removal of fins
6 mm ( 1/4 inch) beyond the leak or damage area is enough
to make an accurate repair.
Tube Blocking
If a tube is severely damaged, it can be blocked off.
radiator assembly. Blocking off more than two tubes
will reduce the cooling capability of the system.
The tube should be cut off 6 mm (1/4 inch) from the
header and pinched shut before it is cleaned and sealed.
Header Repair
NOTICE: To prevent damage to the tank or gasket,
the following procedures must be used when repairs
are made on or near the header.
If the header or the tube near the header requires a
repair, the side tank does not have to be removed. A damp
cloth can be placed against the side tank where the repair
has to be made. The side tank can also be submerged in a
tank of water up to the header.
General Core Repair
Figures 13 through 16
If the leak area surface is not clean, the repair
material will not stick to the surface.
1. Position core so repair area is accessible.
2. Apply wet cloth between core pipes and headers if
working near plastic tanks or joints or submerge
tank in water.
3. Heat repair area slightly with small torch or heat gun
to be sure it is dry.
• Do not use blow torch.
4. Brush area to be repaired with small steel brush that
is supplied in kit and remove dust away from repair
area.
CAUTION: To help avoid personal
injury when using the primer (which
contains trichloroethane) the follow-
ing precautions and steps should be
followed:
• If primer is swallowed, seek medi·
cal attention. '
• If primer contacts the eyes, do not
rub eyes. Splash the affected area
with large quantities of cold water
and seek medical attention.
68-12 COOLING AND RADIATOR

~~, H20005-6B

Figure 8 - Hot Melt Adhesive Repair Kit

UIJ I/ uu1,1JIHJ\HllltHJUIIII IJllWLIIIUllllUUII YYY IJIIUIIII IIUULI 1,111, uuu II UV\/ \W 11 Ii l/M II V\/ U\ fl IIU I
NWWW!WWBWVIM!oW/Ul@m111111Uum11MNmn.0n Mnn@ nnnnn~nnnnna H20008-6B

._,,,,._
0
uu1@Nrn1~wummm11wmmmmiww2 6~~~~~~~~EE~ N° g Figure 11 - Using a Wet Cloth on the Side Tank

mm1m111uwmvmijMNIMIDm@u~1rndJliw11,1,uuuuuw1w11i11:1:w111mJrm1
SUBMERGE
TANK-
KEEP
HEADER
JJ!MM!ffiflflflJIVlW1l11IW11n11m1mmi1mu111111111nnij111l~llll@llllfilillW11JilllD, ABOVE

tm1111m11wwim~mijr11100mmoo~~11@M11Wa1wi1v1mwim m@@i: j: ~h,I WATERLINE

,mrn@~@mmm1U1IDJ)Urnij(llil]UuWlJIWWfil/)l(J1' ii hOI) 1/)1) JI 11 /. /)hi 1'LIN'1i! n

1

1n/111mmnnn ,mnmm nnnmmnn1111nnnnnnnnnnnnnMr

1 1
H2ooos-se

Figure 9 - Fins Removed from Damaged Area

H20009-6B
Figure 12 - Submerging the Side Tank

Figure 1O - Tube Blocking

• If primer contacts the body, wash

thoroughly with soap and water.
• Do not mix the primer with water.
5. Open tube of primer using spurred cap or pin and
apply primer to repair area only. Use of primer
produces stronger repair.
6. Scrub repair area with cotton swab until fresh swab Figure 13 - Cleaning the Area with a Steel Brush
stays clean.
• If stick doesn't start to melt, remove it and
• Clear, yellow-brown coating does not have to reapply heat. Do not heat stick directly with
be removed. flame. High heat will burn and char adhesive.
7. Heat repair area with heat gun or by moving small 9. Continue heating until adhesive flows and wets
torch in circular pattern using soft, blue flame. entire repair area and fills joint. If a hole is in center
8. Withdraw small torch or heat gun and rub adhesive of tube, heat tube and let hot surface melt and pull in
stick on repair area. Adhesive will flow at tem- adhesive. Force of flame or heat gun will also tend to
perature of approximately 260°C (500°F). guide adhesive toward hole. For leaks between tube

H20011-6B
Figure 14 - Scrubbing the Area with Primer
H20012-6B
Figure 15 - Heating the Repair Area
Figure 16 - Applying Hot Melt Adhesive
and header, flow adhesive completely around tube
and header joint with tank installed.
10. Heat repair area until adhesive is bubble free,
smooth and has light yellow color. Curing is not
required.
COOLING AND RADIATOR 68·13
11. Test radiator assembly for leaks when cool. Refer to
"Off-Vehicle Testing" in this section. If repair area
still leaks, heat it gently to dry it. Heat and flow
adhesive or apply more as necessary to repair leak.
Radiator Side Tank Gasket Leak Repair
Figures 17 through 20
Tool Required:
J 33419-A Radiator Core Remover/Installer
.Radiator side tank gasket leaks can easily be mistak-
en for tank or header leaks. If a plastic tank leaks from the
header joint gasket, tighten the clinch tabs with
J 33419-A or locking-type pliers. If the tank still leaks,
remove and repair it.
1. Pry open clinch tabs except those under inlet, outlet
and radiator assembly neck, using J 33419-A or
screwdriver.
• Lift tabs only enough to allow removal.
NOTICE: Do not overbend tabs. Overbending tabs
could result in breaking tab. If more than three tabs
are broken on one side of header or more than two
adjacent tabs are broken, the core must be replaced.
2. Lift tank and slide it out from under remaining
clinched tab.
• Tapping tank with your hand may be required
to dislodge gasket.
3. Lift remaining tab(s) with pliers.
4. Remove and discard gasket.
l~I Clean
• Header gasket groove of dirt and old rubber.
• Sealing edge of plastic tank.
ll'l'I Inspect
• Header gasket surface and tank flange for
evidence of leaks.
• Surfaces and remove dirt, burrs and bumps.
5. Remove transmission oil cooler, if equipped, and
install it into new tank.
6. Dip or coat new gasket in engine coolant and
position it on header surface.
7. Position tank and gasket to header. Clamp it in place
and secure it by bending four clinch tabs.
8. Clamp remaining clinch tabs around header using
J 33419-A or pliers.
• Start at center and work towards end.
9. Replace core if there are more than three tabs broken
on one side or if two adjacent tabs are broken.
10. Install radiator drain cock assembly, if removed.
11. Test radiator assembly for leaks. Refer to "Off-
Vehicle Leak Testing" in this section.
TRANSMISSION OIL COOLER GASKET
Figure 21
The outlet tank must be removed to replace the
transmission oil cooler but the transmission oil cooler
gasket can be replaced without removing the outlet tank.
68-14 COOLING AND RADIATOR

H20017-68
Figure 20 - Clinching Sequence

LC0005-6B-F-RP

Figure 17 - Tightening the Clinch Tabs

SLIP J 33419-A
UNDER TAB
AND PUSH BACK

H20018-6B
Figure 21 - Removing the Transmission Oil Cooler Gasket

LC0006-6B-F-RP
Figure 18 - Opening the Clinch Tabs
BEND FOUR
CLINCH TABS
H20016-6B
Figure 19 - Seating the Tank to the Core
I. Remove radiator assembly. Refer to "Radiator
Assembly" in this section.
• Lay radiator assembly on flat surface.
2. Remove bottom transmission oil cooler pipe and
loosen top pipe connection.
3. Press transmission oil cooler into hole and remove
gasket using small hook.
4. Blow dry all surfaces on outlet tank and trans-
mission oil cooler.
5. Install new transmission oil cooler gasket without
lubrication.
• Be sure gasket is properly seated inside lip of
fitting.
6. Reach into inlet or outlet opening and push trans-
mission oil cooler into position against outlet tank.
NOTICE: See "Notice" on page 68-1 of this
section.
7. Install transmiss.ion oil cooler pipe loosely.
• To replace other gasket, follow previous steps
in order.
!~I Tighten
• Transmission oil cooler pipe connections to
20 N•m (15 lb. ft.).
- Do not overtighten.
 COOLING AND RADIATOR 68-15

8. Leak test radiator assembly. Refer to "Off-Vehicle 1. Open radiator drain cock assembly and drain engine
Leak Testing" in this section. coolant from radiator assembly to below level of
9. Install radiator assembly. Refer to "Radiator Assem- engine coolant thermostat assembly.
bly" in this section. 2. Close radiator drain cock assembly.

TRANSMISSION OIL COOLER I~! Tighten

Figure 3 • Radiator drain cock assembly to 12 N•m
(106 lb. in.).
!++! Remove or Disconnect 3. Air cleaner assembly.
1. Radiator assembly. ,Refer to "Radiator Assembly" 4. Inlet hose assembly and clamp from engine coolant
in this section. thermostat assembly.
2. Outlet tank. 5. Water outlet bolt/screw (12 or 15).
3. Transmission oil cooler retaining nuts. 6. Water outlet assembly (11 or 14).
4. Transmission oil cooler gaskets. 7. Water outlet gasket (16), if equipped.
5. Transmission oil cooler. 8. Engine coolant thermostat assembly (13 or 17).

!r,! Clean !r,! Clean

• Sealing surfaces. • Gasket surfaces of water outlet assembly and intake
manifold assembly or water pump assembly.
!++! Install or Connect !++! Install or Connect
NOTICE: See "Notice" on page 6B-1 of this
section. NOTICE: See "Notice" on page 6B-1 of this
section.
1. New transmission oil cooler gaskets without lubri-
cation. 1. Engine coolant thermostat assembly into intake
manifold assembly or water pump assembly.
2. Transmission oil cooler into outlet tank.
3. Transmission oil cooler retaining nuts. 2. New water outlet gasket (16), if equipped.
4. Outlet tank. 3. Water outlet assembly (11 or 14).
• Be careful not to loosen or misalign gaskets. 4. Water outlet bolt/screw (12 or 15).
5. Radiator assembly. Refer to "Radiator Assembly"
in this section. l~I Tighten
• Water outlet bolt/screw (12 or 15) to 28 N•m
RECORE (21 lb. ft.).
If the radiator core is damaged beyond repair and the 5. Inlet hose assembly and clamp. Refer to SECTION
other parts are serviceable, install the original inlet and lA.
outlet tanks, transmission oil cooler, radiator filler cap 6. Air cleaner assembly.
assembly and radiator drain cock assembly onto a new
core and install new gaskets. 7. Add engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section.
RADIATOR DRAIN COCK ASSEMBLY
IL'l'l tnspect
Figure 4 • For leaks, after running engine assembly to normal
If the drain cock assembly does not seal when operating temperature.
tightened snugly, remove the radiator drain cock assem-
bly, clean the drain and replace the radiator drain cock ELECTRIC ENGINE COOLANT FAN
assembly. If ':he body of the radiator drain cock assembly ASSEMBLY
is broken, remove the body from the tank by squeezing the
sides together with needle nose pliers. Figures 24 and 25
ENGINE COOLANT THERMOSTAT CAUTION: Keep hands, tools, and
clothing away from electric engine
ASSEMBLY coolant fan(s) to help prevent personal
Figures 22 and 23 injury. This/These fan is/are electric
and can come on whether or not the
I++! Remove or Disconnect engine is running. The fan(s) can start
automatically in response to a heat
NOTICE: See "Notice" on page 6B-l of this sensor with the ignition in the "ON"
section. position.
68-16 COOLING AND RADIATOR

11

19

18
A ENGINE ASSEMBLY, LT1 5.7L
B ENGINE ASSEMBLY, L32 3.4L
18 RADIATOR ASSEMBLY
11 OUTLl;T ASSEMBLY, WATER 19 FAN ASSEMBLY, ENGINE COOLANT
12 BOLT/SCREW, WATER OUTLET 20 FAN ASSEMBLY, ENGINE COOLANT
13 THERMOSTAT ASSEMBLY, ENGINE COOLANT 21 RETAINER, RADIATOR AIR SIDE DEPRESSION
(PUSH-IN)
PC0006-6B-F-RP 22 DEFLECTOR, RADIATOR AIR SIDE PC0008-&B-F-RP

Figure 22 - Engine Coolant Thermostat Assembly Figure 24 - Engine Coolant Fan Assembly
(3.4L L32 Engine)
CAUTION: If a fan blade assembly is
bent or damaged in any way, no attempt
should be made to repair and/or reuse
the damaged part. A bent or damaged
fan blade assembly should always be
replaced with a new fan blade assembly.
14 CAUTION: It is essential that the fan
blade assembly remain in proper bal-
ance. Balance cannot be assured once
a fan blade assembly has been bent or
damaged. A fan blade assembly that is
not in proper balance could fail and fly
apart during subsequent use, creating
an extremely dangerous condition.
14
15
16
OUTLET ASSEMBLY, WATER
BOLT/SCREW, WATER OUTLET
GASKET, WATER OUTLET
l++l tnstall or Connect
17 THERMOSTAT ASSEMBLY, ENGINE COOLANT NOTICE: See "Notice" on page 6B-1 of this
PC0007-6B-F·RP section.
Figure 23 - Engine Coolant Thermostat Assembly 1. Fan blade assembly (25 or 26).
(5.?L LT1 Engine)
2. Fan blade nut (23 or 24)
3. Electric engine coolant fan assembly (19 or 20).
l++I Remove or Disconnect • Electric engine coolant fan assembly ( 19 or 20)
will slide into place.
1. Air cleaner assembly. 4. Electrical connector and clips.
2. Electrical connector and clips. 5. Air cleaner assembly.
3. Electric engine coolant fan assembly ( 19 or 20).
WATER PUMP ASSEMBLY
• Electric engine coolant fan assembly ( 19 or 20)
will slide out. Figures 26, 27 and 28
4. Fan blade nut (23 or 24 ).
5. Fan blade assembly (25 or 26).
l++I Remove or Disconnect
3.4L L32 Engine
lL"'! Inspect 1. Drain radiator assembly. Refer to "Draining and Re-
• For bent or cracked fan blades. filling Cooling System" in this section.
• Mating surfaces for smoothness. Remove burrs 2. Air duct and electrical connector.
or other imperfections as necessary. 3. Top coil of coil pack.
 COOLING AND RADIATOR 68-17

A 5.7L LT1 ENGINE

B 3.4L L32 ENGINE
19 FAN ASSEMBLY, ENGINE COOLANT
20 FAN ASSEMBLY, ENGINE COOLANT
23 NUT, FAN BLADE
24 NUT, FAN BLADE
25 BLADE ASSEMBLY, FAN
26 BLADE ASSEMBLY, FAN
PC0009-6B-F-RP

Figure 25 - Fan Blade Assembly

4. Loosen tensioner pulley bolt/screw.

5. Heater hose from pump. Refer to SECTION IA.
6. Loosen water pump pulley bolts/screws (27).
7. Power steering bracket bolts/screws. Refer to
SECTION 38.
8. Serpentine belt. Refer to SECTION 6A2A and
SECTION 6A3A.
9. Water pump pulley (28).
I 0. Power steering pump bracket and pump. Refer to
SECTION 38.
11. Water pump bolts/screws (29).
12. Engine front cover bolts/screws (30).
21 N•m (16 LB. FT.)
13. Water pump cover bolts/screws (31 ). 10 N•m (89 LB. IN.)
14. Water pump assembly (32) and water pump gasket PC0018-6B-F-RP
(33).
Figure 26 - Water Pump BolVScrew Torques

!i,! Clean
(3.4L L32 Engine)

• All gasket surfaces.

• Water pump bolts/screws. l~! Tighten

!++! Install or Connect • Water pump cover bolts/screws (31) to 45 N•m

(33 lb. ft.).
NOTICE: See "Notice" on page 6B-1 of this 4. Engine front cover bolts/screws (30).
section.
1. New water pump gasket (33).
2. Water pump assembly (32).
I~! Tighten
• Engine front cover bolts/screws (30) to 21 N•m
3. Water pump cover bolts/screws (31 ). (16 lb. ft.).
68-18 COOLING AND RADIATOR

32

28

"\~~
.k / 29

27 BOLT/SCREW, WATER PUMP PULLEY, 25 N•m (18 LB. FT.)

28 PULLEY, WATER PUMP
29 BOLT/SCREW, WATER PUMP, 10 N•m (89 LB. IN.)
30 BOLT/SCREW, ENGINE FRONT COVER, 21 N•m (16 LB. FT.)
31 BOLT/SCREW, WATER PUMP COVER, 45 N•m (33 LB. FT.)
32 PUMP ASSEMBLY, WATER
33 GASKET, WATER PUMP
PC001o-&B·f·RP

Figure 27 - Water Pump Assembly (3.4L L32 Engine)

34 PUMP ASSEMBLY, WATER

35 GASKET, WATER PUMP
36 COUPLING, SHAFT
37 BOLT/SCREW, WATER PUMP COVER, 45 N•m (33 LB. FT.)
38 BOLT/SCREW, WATER PUMP, 42 N•m (31 LB. FT.)

PC0011-&B·f.RP

Figure 28 -Water Pump Assembly (5.7L LT1 Engine)

5. Water pump bolt/screw (29).

l~I Tighten
l~I Tighten
• Power steering bracket bolts/screws to 31 N•m
• Water pump bolts/screws (29) to 10 N•m (23 lb. ft.).
(89 lb. in.).
10. Heater hose to pump. Refer to SECTION IA.
6. Power steering pump and bracket. Refer to SEC-
TION 3B. 11. Top coil of coil pack.
7. Water pump pulley (28). 12. Electrical connector to alternator.
8. Serpentine belt. Refer to SECTION 6A2A or
SECTION 6A3A. 13. Air duct and electrical connector.
9. Power steering pump bracket bolts/screws. Refer to 14. Add engine coolant. Refer to "Draining and
SECTION 3B. Refilling the Cooling System" in this section.
 COOLING AND RADIATOR 68·19

9. Heater hose assemblies to water pump assembly and

IL"l'l lnspect throttle body. Refer to SECTION 1A.
10. Upper and lower radiator hose assembly to water
• For leaks, after running engine to normal operating
temperature. pump assembly.
11. Air cleaner assembly.
!++I Remove or Disconnect 12. Air intake duct.
13. Refill cooling system. Refer to "Draining and
5.7L LT1 Engine Refilling the Cooling System" in this section.
1. Electrical connector from electric engine coolant fan 14. Electrical connector to electric engine coolant fan
assembly. assembly.
2. Right electric engine coolant fan assembly. Refer to
"Electric Engine Coolant Fan Assembly" in this
section.
IL"l'I Inspect
• For leaks, after running engine assembly to normal
3. Block drain plug and knock sensor. operating temperature.
4. Drain engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section. BATTERY TRAY AND COOLANT RECOVERY
5. Install drain plug and knock sensor. RESERVOIR ASSEMBLY
6. Air intake duct. Figure 29
7. Air cleaner assembly.
8. Upper and lower radiator hose assembly from water J++I Remove or Disconnect
pump assembly. 1. Battery. Refer to SECTION 6D i.
9. Heater hose assemblies from water pump assembly 2. Coolant recovery hose assembly.
and throttle body. Refer to SECTION lA.
3. Bolt/screw (40).
10. Electrical connector from coolant sensor.
4. Battery tray and reservoir assembly (39).
11. Reposition coil and bracket.
12. Air pump and bracket. Refer to SECTION 6E3. !i:.tl Clean
13. Water pump bolts/screws (38). • Battery tray and reservoir assembly (39) with soap
14. Water pump cover bolt/screw (37). and water. Rinse thoroughly.
15. Water pump assembly (34).
16. Water pump gaskets (35).
17. Shaft coupling (36).

!S:W!Clean
• Water pump gasket surfaces.
• Water pump bolts/screws (38).

!++I Install or Connect

1. Shaft coupling (36).
2. Water pump gaskets (35).
3. Water pump assembly (34).
4. Water pump cover bolt/screw (37).

l~I Tighten
• Water pump cover bolt/screw (37) to 45 N•m
(33 lb. ft.).
5. Water pump bolts/screws (38).

l~I Tighten 39 RESERVOIR ASSEMBLY, BATTERY TRAY AND

COOLANT RECOVERY
40 BOLT/SCREW, COOLANT RECOVERY RESERVOIR,
• Water pump bolts/screws (38) to 42 N•m 12 N•m (106 LB. IN.)
(31 lb. ft.).
6. Air pump and bracket. Refer to SECTION 6E3. RC0001-68-F-RP

7. Reposition coil and bracket. Figure 29 - Battery Tray and Coolant Recovery Reservoir
8. Electrical connector to coolant sensor. Assembly
68·20 COOLING AND RADIATOR

!-++! Install or Connect

NOTICE: See "Notice" on page 6B-I of this
section.
I. Battery tray and reservoir assembly (39). 18

2. Bolt/screw (40).
43
!~I Tighten
• Bolt/screw (40) to 12 N •m ( I 06 lb. in.).
3. Coolant recovery hose assembly.
4. Battery. Refer to SECTION 6DI.
S. Add engine coolant to "FULL COLD" mark on
reservoir assembly.
18 RADIATOR ASSEMBLY
ENGINE OIL COOLER INLET AND OUTLET 42 INSULATOR, RADIATOR LOWER (LEFT HAND)
HOSE ASSEMBLIES 43 INSULATOR, RADIATOR LOWER (RIGHT HAND)
44 SEAL ASSEMBLY, RADIATOR AIR LOWER
Refer to SECTION 6A3A for service information on
inlet and outlet hose assemblies. PC0013-&B-F-RP

Figure 30 - Radiator Insulators and Seal Assembly

COOLANT LEVEL SENSOR
(5.7L LT1 Engine Only)

!+-+! Remove or Disconnect

l. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Drain engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section.
3. Lower vehicle. 45

4. Battery. Refer to SECTION 6Dl.

S. Electrical connector at sensor.
6. Sensor.

!-++I Install or Connect B~C D

I. Sensor. IVIEW B l " - E

2. Electrical connector to sensor. A PANEL ASSEMBLY, UPPER
B RADIATOR ASSEMBLY
3 Battery. Refer to SECTION 6D1. C INSULATOR, RADIATOR UPPER
4. Add engine coolant. Refer to "Draining and D INSULATOR, RADIATOR UPPER MOUNTING PANEL
Refilling the Cooling System" in this section. E FAN ASSEMBLY, ENGINE COOLING
45 BAR ASSEMBLY, FRONT BUMPER IMPACT
46 BAR ASSEMBLY, FRONT END UPPER TIE
RADIATOR ASSEMBLY 47 BOLT/SCREW, RADIATOR UPPER MOUNTING PANEL,
12 N•m (106 LB. IN.)
48 PANEL, RADIATOR UPPER MOUNTING
Figures 30 and 31
PC0014-611-F·RP

!+-+I Remove or Disconnect Figure 31 - Radiator Upper Mounting Panel Assembly

1. Air intake duct.
2. Air cleaner assembly.
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. Drain engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section.
S. Electrical connector(s) at electric engine coolant fan
assembly.
6. Electric engine coolant fan assembly. Refer to
"Electric Engine Coolant Fan Assembly" in this
section.
7. Transmission oil cooler lines. Refer to SECTION
7A.
8. Coolant level sensor, if equipped. Refer to "Coolant
Level Sensor" in this section.
 COOLING AND RADIATOR 68-21

9. Lower vehicle.
I 0. Loosen receiver dehydrator bracket. !++I Install or Connect
11. Lower radiator hose assembly at water pump I. Upper mounting panel (48).
assembly. 2. Bolts/screws (4 7).
12. Upper radiator hose assembly.
13. Overflow tube. l~I Tighten
14. Radiator from condenser. • Bolts/screws (47) to 12 N•m (106 lb. in.).
15. Radiator assembly (18).
Radiator Air Lower Baffle Assembly and
!++! Install or Connect Deflector

NOTICE: See "Notice" on page 6B-1 of this Figure 32

section.
I. Radiator assembly ( 18).
!++! Remove or Disconnect
• Make sure radiator assembly is seated on I. Radiator air lower deflector bolt/screw (52).
radiator insulators (42 and 43). 2. Radiator air lower deflector (51 ).
2. Radiator assembly to condenser. 3. Radiator air lower baffle retainers (50).
3. Overflow tube. 4. Radiator air lower baffle assembly (49).
4. Upper radiator hose.
5. Lower radiator hose assembly to water pump
!++! Install or Connect
assembly. NOTICE: See "Notice" on page 6B-1 of this
section.
6. Tighten receiver dehydrator bracket.
1. Radiator air lower baffle assembly (49).
7. Raise and suitably support vehicle. Refer to SEC-
TION OA. 2. Radiator air lower baffle retainers (50).
8. Coolant level sensor, if equipped. Refer to "Coolant 3. Radiator air lower deflector (51).
Level Sensor" in this section. 4. Radiator air lower deflector bolt/screw (52).
9. Transmission oil cooler lines. Refer to SECTION
7A. l~I Tighten
I 0. Electric engine coolant fan assembly. Refer to • Bolt/screw (52) to 1.5 N•m (13 lb. in.).
"Electric Engine Coolant Fan Assembly" in this
section.
Radiator Air Upper Baffle Assembly
11. Electrical connector(s) to electric engine coolant fan
assembly. Figure 33
12. Add engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section. !++I Remove or Disconnect
13. Lower vehicle. 1. Radiator air upper baffle retainers (54).
14. Air cleaner assembly. 2. Radiator air upper baffle assembly (53).
15. Air intake duct.
!++! Install or Connect
!L'i'I Inspect NOTICE: See "Notice" on page 6B-l of this
• For leaks, after running engine assembly until section.
normal operating temperature is reached. 1. Radiator air upper baffle assembly (53) to radiator
assembly (18).
RADIATOR AIR BAFFLE ASSEMBLIES AND 2. Radiator air upper baffle retainers (54).
DEFLECTORS
ENGINE COOLANT HOSE ASSEMBLIES
Radiator Upper Mounting Panel
!++I Remove or Disconnect
Figure 31 1. Drain radiator assembly so level of engine coolant is
below hose assembly being removed.
!++! Remove or Disconnect 2. Air cleaner assembly.
I. Bolts/screws (4 7). 3. Inlet hose assembly from radiator assembly and
2. Upper mounting panel (48). engine coolant thermostat assembly.
68-22 COOLING AND RADIATOR

50
18 RADIATOR ASSEMBLY
49 BAFFLE ASSEMBLY, RADIATOR AIR LOWER
50 RETAINER, RADIATOR AIR LOWER BAFFLE
51 DEFLECTOR, RADIATOR AIR LOWER
52 BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR 52
RC0002-6B-F-RP

Figure 32 - Radiator Air Lower Baffle Assembly

1. Outlet hose assembly and clamps to radiator

assembly and water pump assembly.
2. Inlet hose assembly to radiator assembly and engine
54 coolant thermostat assembly.
3. Add engine coolant. Refer to "Draining and
Refilling Cooling System" in this section.
4. Air cleaner assembly.

46 COOLANT AIR BLEED PIPE ASSEMBLY

l+,.! Remove or Disconnect

1. Drain coolant. Refer to "Draining and Refilling
Cooling System" in this section.
2. Transmission. Refer to SECTION 7A or SECTION
45
78.
18 RADIATOR ASSEMBLY 3. Left and right bleed pipe mounting (banjo) bolts.
45 BAR ASSEMBLY, FRONT BUMPER IMPACT • Use a backup wrench.
46 BAR ASSEMBLY, FRONT END UPPER TIE
53 BAFFLE ASSEMBLY, RADIATOR AIR UPPER 4. Lower vehicle.
54 RETAINER, RADIATOR AIR UPPER BAFFLE 5. Upper alternator bracket. Refer to SECTION 6D3.
PC0016-6B-f·RP
6. Electrical connectors and vacuum hoses, as nec-
Figure 33 - Radiator Air Upper Baffle Assembly essary, to gain access to bleed pipe.
7. Air bleed pipe mounting nut at intake manifold.
4. Outlet hose assembly from radiator assembly and 8. Coolant hose at air bleed pipe.
water pump assembly. 9. Coolant air bleed pipe assembly.

!,.+I Install or Connect !,.+I Install or Connect

NOTICE: See "Notice" on page 68-1 of this NOTICE: See "Notice" on page 68-1 of this
section. section.
 COOLING AND RADIATOR 68-23

I. Coolant air bleed pipe assembly.

2. Coolant hose at air bleed pipe.
3. Air bleed pipe mounting nut at intake manifold.

l~I Tighten
• Mounting nut to 21 N•m (15 lb. ft.).
4. Electrical connectors and vacuum hoses, as neces-
sary.
5. Upper alternator bracket. Refer to SECTION 6D3.
6. Raise and suitably support vehicle. Refer to SEC-
TION OA. RC6003-68-D-RP
7. Left and right bleed pipe mounting (banjo) bolts.
Figure 34 - Cleaning the Coolant Tester
• Use a backup wrench.

l~I Tighten
• Mounting bolts to 42 N•m (31 lb. ft.).
8. Transmission. Refer to SECTION 7 A or SECTION
7B.
9. Refill cooling system. Refer to "Draining and
Refilling Cooling System" in this section.

TESTING THE COOLANT CONCENTRATION

Figures 34 through 36
Tools Required:
J 23688-A or J 26568-A Coolant Tester
Figure 35 - Collecting the Coolant
[I] Important
• Both J 23688-A and J 26568-A automatically com-
J 23688-A OR
pensate for temperature. J 26568-A
• Make sure eyepiece of J 23688-A or J 26568-A is
totally free of solution before looking through it.
Refer to Figure 34.
• Before each use, swing plastic cover at slanted end
of J 26568-A or J 23688-A exposing measuring win-
dow and bottom of plastic cover.
• Wipe dry both prism and bottom of sample cover
with tissue or clean soft cloth. Refer to Figure 35.
• Close plastic cover.
I. Release tip of pump from J 23688-A or J 26568-A
housing.
• Do not remove clear plastic pump from
J 23688-A or J 26568-A.
RC6005-6B-D-RP
CAUTION: To avoid being burned, DO
NOT remove coolant recovery reservoir Figure 36 - Reading the Coolant Tester
cap while engine is at normal operating
temperature. The cooling system will
release scalding fluid and steam under 5. Bend tube around J 23688-A or J 23568-A so that tip
pressure if cap is removed while engine can be inserted in cover plate opening.
and radiator are still hot. This could 6. Press bulb and allow a few drops to fall onto measur-
result in a large coolant loss and pos- ing surface.
sible personal injury.
• Do not open plastic cover when taking read-
2. Remove coolant recovery reservoir cap. ings because water evaporation can change
3. Insert tube into coolant recovery reservoir assembly. readings.
• Make sure tube is below level of coolant. 7. Point J 23688-A or J 26568-A toward any light
4. Press and release bulb to get sample of coolant. source and look into eyepiece.
68·.24 COOLING AND RADIATOR

• Coolant protection reading is at point where
dividing line between light and dark crosses
scale on right.
• Temperature scale is reversed from a standard
thermometer scale. Below zero readings are on
upper half of scale.
• If readings are not clear, the measuring prism
was not cleaned and dried or there was not
enough fluid on measuring prism.
Calibrating Testers
J 23688-A and J 26568-A are factory calibrated and
sealed and should not require adjustment. If adjustment is
required, follow instructions below.
I. Make sure J 23688-A and J 26568-A is between 21
and 29 °C (70 and 85 °F).
2. Using distilled water, take a reading. If reading
departs from a 0°C (32°F) reading on scale, a
correction can be made by adjusting screw on bot-
tom of J 23688-A and J 26568-A.
3. Remove sealant covering screw.
rn Important
• Do not remove screw from J 23688-A and
J 26568-A.
4. Turn screw in direction necessary to adjust reading
to 0°C (32 °F) line.
5. Reseal the screw using a silicone sealant.

SPECIFICATIONS
GENERAL SPECIFICATIONS
Cooling System Approximate Fluid Capacities
3.4L L32 Engine
With Manual Transmission ....................................... 11.8 liters (12.5 qt.)
With Automatic Transmission .................................... 11.6 liters (12.3 qt.)
5.7L LTl Engine
With Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 liters (15.3 qt.)
With Automatic Transmission .................................... 14.3 liters (15.1 qt.)

FASTENER TIGHTENING SPECIFICATIONS

Air Bleed Pipe Mounting Bolts/Screws .................................. 42 N•m (31 lb. ft.)
Air Bleed Pipe Mounting Nut .......................................... 21 N•m (15 lb. ft.)
Battery Tray and Coolant Recovery Reservoir Bolt/Screw .................. 12 N•m (106 lb. in.)
Engine Block Coolant Drain Hole Plug .................................. 21 N•m (15 lb. ft.)
Engine Front Cover Bolt/Screw ........................................ 21 N•m (16 lb. ft.)
Knock Sensor ...................................................... 19 N•m (14 lb. ft.)
Oil Cooler Pipe Connections .......................................... 20 N•m (15 lb. ft.)
Power Steering Bracket Bolt/Screw ..................................... 31 N•m (23 lb. ft.)
Radiator Air Lower Deflector Bolt/Screw ............................... 1.5 N•m (13 lb. in.)
Radiator Drain Cock Assembly ....................................... 1.5 N•m (13 lb. in.)
Radiator Upper Mounting Panel Bolt/Screw ............................. 12 N•m (106 lb. in.)
Water Outlet Bolt/Screw .............................................. 28 N•m (21 lb. ft.)
Water Pump Bolt/Screw (3.4L L32 Engine) ............................... 10 N•m (89 lb. in.)
Water Pump Bolt/Screw (5.7L LTI Engine) .............................. 42 N•m (31 lb. ft.)
Water Pump Cover Bolt/Screw ......................................... 45 N•m (33 lb. ft.)
 COOLING AND RADIATOR 68·25

SPECIAL TOOLS

cc<t;;ma.:?::::=;:l1Q· J 24731-188
g;a.;;;1illlail:1~3~;;;;;;;;;;;i;1:)• J 24731-206
1.
2. ~J33419-A
3.

J 24460-01

1. COOLING SYSTEM TESTER 4. J 23688-A OR J 26568-A

2. TEMPIL STICKS
3. RADIATOR CORE REMOVER/INSTALLER
4. COOLANT TESTER
RC0003-68-F-RP
 ENGINE FUEL 6C-1

SECTION 6C
ENGINE FUEL
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer
to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR
components or wiring. Failure to follow CAUTIONS could result in possible air bag
deployment, personalinjury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description • • • • • • • • • • • • •• • 6C-2 Draining Fuel Tank •••••••••••••• 6C-9
Fuel Tank Filler Neck • • • • • • • • • • • •• 6C-2 Fuel Tank Replacement ••••••••••• 6C-10
Fuel Tank • • • • • • • • • • • • • • • • • • • • 6C-2 Fuel Tank Vent Valve •••••••••••• 6C-11
Fuel Tank Vent Valve Fuel Sender Assembly Replacement 6C-11
(Remote mounted} • • ••••• • • • 6C-2 Fuel Sender Assembly Service ••••••• 6C-12
Fuel Filler Cap • • • • • • • • • • • • • • • 6C-2 Fuel System Cleaning •••••••••••• 6C-13
Fuel Sender Assembly • • • • • • • • • • • • 6C-2 Fuel Tank •••••••••••••••••• 6C-13
Fuel Sender • • • • • • • • • • • • • • • • • 6C-3 Fuel Feed and Return Pipes/Hoses
Fuel Pump and Reservoir Assembly 6C-3 Replacement •••••••••••••••• 6C-14
Fuel Pump Strainer • • • • • • • • • • • • 6C-5 Rear Fuel Feed Pipe/Hose Assembly
In-Line Fuel Filter • • • • • • • • • • • • • • • 6C-5 (Fuel Tank) ••••••••••••••• 6C-14
Fuel Feed and Return Pipes/Hoses • • • • • 6C-5 Chassis Fuel Feed and Return Pipes •• 6C-14
Nylon Fuel Pipes • • • • • • • • • • • • • • 6C-5 Engine Compartment Connecting
Quick-Connect Fittings • • • • • • • • • • 6C-6 Fuel Pipes (Chassis to Engine) 6C-15
Fuel Line 0-Ri ngs • • • • • • • • • • • • • 6C-6 Engine Fuel Pipes See Section 6E3-C2
Fuel Vapor Pipes and Hoses ••• •• • • • 6C-6 Fuel Vapor Pipes and Hoses Repair/
Accelerator Controls • • • • • • • • • • • • • 6C-6 Replacement •••••••••••••••• 6C-17
Diagnosis • • • • • • • • • • • • • • • • • • • • • 6C-6 Accelerator Control Cable
Alcohol-in-Fuel • • • • • • • • • • • • • • • • 6C-6 Replacement •••••••••••••••• 6C-17
Testing Procedure • • • • • • • • • • • • • 6C-6 Accelerator Pedal Replacement •••••• 6C-18
Fuel Tank Leak Check • • • • • • • • • • • • 6C-6 Specifications ••••••••••••••••••• 6C-18
Fuel Tank Vent Valve Check • • • • • • • • 6C-6 Torque Specifications •••••••••••• 6C-18
Fuel System Pressure Test Fuel Specifications •••••••••••••• 6C-19
See Section 6E3, Chart A-7 Octane Requirements •••••••••• 6C-19
Fuel Sender Diagnosis Gasoline With Alcohol •••••••••• 6C-19
See Section 8A Methyl Tertiary-Butyl Ether (MTBE) •• 6C-19
Fuel Pump Electrical Diagnosis Ethanol ••••••••••••••••••• 6C-19
See Section 6E3 and Section 8A Methanol •••••••••••••••••• 6C-19
On-Vehicle Service • • • • • • • • • • • • • • • • 6C-7 Special Tools ... .. . . ..... .. . .. .. 6C-19
Fuel System Pressure Relief ••• • • • • • 6C-7
Servicing Quick-Connect Fittings • • • • • 6C-7
In-Line Fuel Filter Replacement • • • • • • 6C-9
6C-2 ENGINE FUEL

GENERAL DESCRIPTION
The fuel supply is stored in the fuel tank. An
electric fuel pump, attached to the fuel sender
assembly (inside the fuel tank) pumps fuel through an
in-line filter to the fuel rail assembly. The pump is
designed to provide fuel at a pressure above the
pressure needed by the injectors. A pressure regulator
keeps fuel available to the injectors at the correct
pressure. Unused fuel is returned to the fuel tank via
a separate pipe. For further information on the fuel
injection system, refer to "Fuel Metering System"
located in SECTION 6E3-C2.
Unleaded fuel must be used with all gasoline
engines for proper emission control system operation.
Using unleaded fuel will also decrease spark plug
fouling and extend engine oil life. Leaded fuel can
damage the emission control system, and its use can
result in loss of emission warranty coverage.
All vehicles with gasoline engines are equipped
with an evaporative emission system that minimizes
the escape of fuel vapors to the atmosphere. MOUNTING CLIP
Information on this system is located in SECTION
2 FUEL TANK
6E3-C3.
3 FUEL TANK VENT VALVE
FUEL TANK FILLER NECK NS 15941
Figure2
Figure 1 ~ Fuel Tank Vent Valve
To prevent refueling with leaded fuel, the fuel counterclockwise to remove. A built-in torque-
filler neck has a built-in restrictor and deflector. limiting device prevents over tightening. To install,
turn the cap clockwise two full turns until a clicking
FUEL TANK noise is heard. This signals that the correct torque has
been reached and the cap is fully seated.
The fuel tank is used to store fuel for the vehicle.
The tank is located in the rear of the vehicle and is
held in place by two metal straps that are attached to
the frame. The fuel tank is made of steel and is coated
internally with a special corrosion inhibiter.

Fuel Tank Vent Valve (Remote Mounted)

Figure 1

The fuel tank vent valve, located in the right rear [JJ FUEL FILLER CAP
of the vehicle by the fuel tank, is a pressure/vacuum
relief valve. When fuel tank pressure exceeds a W FUEL TANK FILLER NECK

specified pressure the valve will open allowing tank W FUEL FILLER DOOR
MS9071-6C
pressure to bleed off. When the fuel tank is in a
vacuum condition, the vent valve will open when the Figure 2 • Fuel Filler Cap
vacuum is within a specified range allowing fresh air NOTICE: If a fuel filler cap requires replacement,
to be pulled in. use only a cap with the same features.

Fuel Filler Cap FUEL SENDER ASSEMBLY

Figure2
The fuel sender assembly is attached to the top of
Failure to use the correct cap can result in a the tank, and extends from the top of the tank to the
serious malfunction of the system. The fuel tank filler sump located in the bottom of the tank.
neck is equipped with a non-vented threaded-type cap.
The threaded part of the cap requires several turns
 ENGINE FUEL 6C-3

The fuel sender assembly consists of the following
major components: a fuel sender, fuel pump and
reservoir assembly, fuel pump strainer and a roll-over
valve.
Fuel Sender
Figure 3
The fuel sender consists of the fuel tank cover
plate, fuel feed, return, and vent pipes, a float, wire
float arm, sensor and roll-over valve. The fuel level is
sensed by the position of the float arm, and a signal is
sent to the display in the vehicle instrument cluster.
The roll-over valve is pressed into the vapor tube of
the fuel sender and is not serviced separately. The
roll-over valve prevents fuel spilling from the fuel
sender vapor pipe if the vehicle rolls over.
Fuel Pump and Reservoir Assembly
Figure 4
An electric high pressure roller vane fuel pump is
mounted inside the fuel reservoir, which is located in
the fuel tank. The fuel is pumped to the engine at a
specified flow and pressure through the fuel feed pipe.
Excess fuel is returned to the fuel tank via the return
line. The fuel pump delivers a constant flow of fuel to
the engine even during low fuel conditions and
aggressive vehicle maneuvers. As part of the fuel
pump and reservoir assembly, three hoses are
permanently attached. The fuel pump feed hose has
the quick-connect fitting, the fuel return hose has a
square end and the fuel vapor hose is cut on an angle.
The fuel pump feed hose also acts to dampen fuel
pulses and noise generated by the fuel pump.
The electric fuel pump operation is controlled by
the Powertrain Control Module (PCM) through a fuel
pump relay.

10

QUICK-CONNECT FITTING
(FUEL FEED HOSE) 8 LOCKING TABS

2 ROLL-OVER VALVE 9 FUEL PUMP STRAINER

3 VENT HOSE RETAINER 10 FUEL SENDER ASSEMBLY

4 VENT HOSE 11 FLOAT

5 SENSOR 12 FLOAT ARM

FUEL PUMP&
9 8 6 FUEL SENDER 13 RESERVOIR ASSEMBLY
7 BUMPER 14 FUEL RETURN HOSE
NA 5094-AS

Figure 3 • Fuel Sender Assembly

6C-4 ENGINE FUEL

AS INSTALLED IN FUEL TANK

..•·
~:::
....·
;

' ---1·~ FUEL FEED

• • • •• • •)i,- FUEL RETURN

~ VAPORVENT

11-2-92
NA 5054-SY

Figure 4- Fuel Pump and Reservoir Fuel Flow·


Refer to to "Fuel Metering System" located in
SECTION 6E3-C2 and SECTION 8A of this manual
for further description and a wiring diagram of fuel
pump relay.
Fuel Pump Strainer
Figure 4
A woven plastic fuel pump strainer is attached to
the lower end of the fuel pump and reservoir assembly
in the fuel tank. The functions of the fuel pump
strainer is to filter contaminants and to wick fuel.
The life of the fuel pump strainer is generally
considered to be that of the fuel pump. The fuel pump
strainer is self-cleaning and normally requires no
maintenance. Fuel stoppage at this point indicates
that the fuel tank contains an abnormal amount of
sediment or water. In which case, the tank should be
thoroughly cleaned. (See "Fuel System Cleaning.") If
the fuel pump strainer is plugged, replace it with a
new one.
IN-LINE FUEL FILTER
Figure 5
A fuel filter is used in the fuel feed pipe ahead of
the fuel injection system and mounted directly in front
of the rear axle. The filter housing is constructed of
steel with a quick-connect inlet and threaded outlet
fittings. The threaded fitting is sealed with an 0-ring.
The filter element is made of paper, and is designed to
trap particles in the fuel that may damage the
injection system. There is no service interval for fuel
filter replacement. Only replace fuel filter if it is
restricted.
FUEL FEED AND RETURN PIPES/HOSES
The fuel feed and return pipes and hoses carry fuel
from the fuel sender assembly to the fuel rail
assembly. The fuel feed and return pipes and hoses
consist of four sections:
• The rear fuel pipe assemblies are located from the
top of the fuel tank to the chassis fuel pipes. The
rear fuel pipes are constructed of nylon.
• The chassis fuel pipes are located under the vehicle
and connect the rear fuel pipes to the engine
compartment connecting fuel pipes. These pipes
are constructed of steel.
• The engine compartment connecting fuel pipes
connect the chassis pipes to the engine fuel pipes.
These fuel pipes are routed from the chassis fuel
pipes under the vehicle and behind the front driver
side wheel house liner to the engine compartment.
These fuel pipes are constructed of nylon.
ENGINE FUEL 6C-5
-.our
3
SHELL
2 PAPER ELEMENT
3 INNER END PLATE
MA 5050-SY
Figure 5 - In-Line Fuel Filter (Typical)
Nylon Fuel Pipes
Nylon fuel pipes are designed to perform the same
job as the steel or flexible fuel lines they replace.
Nylon pipes are constructed to withstand maximum
fuel system pressure, exposure to fuel additives, and
changes in temperature. There are two sizes used:
3/8" ID for the fuel feed, and 5/16" ID for the fuel
return.
The fuel feed and return pipes are assembled as a
harness. Retaining clips hold the pipes together and
provide a means for attaching the pipes to the vehicle.
Sections of the pipes that are exposed to chafing, high
temperature or vibration are protected with heat
resistant rubber hose and/or corrugated plastic
conduit.
Nylon fuel pipes are somewhat flexible and can be
formed around gradual turns under the vehicle.
However, if forced into sharp bends, nylon pipes will
kink and restrict fuel flow. Also, once exposed to fuel,
nylon pipes may become stiffer and are more likely to
kink if bent too far. Special care should be taken when
working on a vehicle with nylon fuel pipes:
CAUTION: To Reduce the Risk of Fire and
Personal Injury:
• Always cover nylon fuel lines with a
wet towel before using a torch near
them. Also, never expose the vehicle to
temperatures higher than 115°( (239°F)
for more than one hour, or more than
90°( (194°F) for any extended period.
• Take care not to nick or scratch the
nylon fuel lines. If damaged, they must
be replaced.
6C-6 ENGINE FUEL
Quick-Connect Fittings
Quick-connect type fittings provide a simplified
means of installing and connecting fuel system
components. Depending on the vehicle model, there
are two types of quick-connect fittings, each used at
different locations in the fuel system. Each type
consists of a unique female connector and a compatible
male pipe end. 0-rings, located inside the female
connector, provide the fuel seal. Integral locking tabs
or fingers hold the fittings together.
Fuel Pipe 0-Rings
The feed and return pipe threaded connections are
sealed with 0-ring seals. Fuel system 0-ring seals are
made of special material, and should only be serviced
with the correct service part.
FUEL VAPOR PIPES AND HOSES
The fuel vapor pipe extends from the fuel sender
assembly to the charcoal canister.
ACCELERATOR CONTROLS
The accelerator control system is cable type. There
are no linkage adjustments. Therefore, the specific
cable must be used.
DIAGNOSIS
ALCOHOL-IN-FUEL
Alcohol-in-fuel can be detrimental to fuel system
components and may cause drivability problems such
as hesitation, lack of power, stall, no start, etc.
The problems may be due to fuel system corrosion
and subsequent fuel filter plugging, deterioration of
rubber components and/or air-fuel mixture leaning.
Various types and concentrations of alcohols are
used in commercial fuel. Some alcohols are more
detrimental to fuel system components than others. If
an excessive amount of alcohol in the fuel is suspected
as the cause of a drivability condition, the following
procedure may be used to detect the presence of alcohol
in the fuel.
Testing Procedure
The fuel sample should be drawn from the bottom
of the tank so that any water present in the tank will
be detected. The sample should be bright and clear. If
the sample appears cloudy, or contaminated with
water (as indicated by a water layer at the bottom of
the sample), this procedure should not be used, and the
fuel system should be cleaned see "Fuel System
Cleaning" in this section.
l. Using a 100 ml cylinder with 1 ml graduation
marks, fill with fuel to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid volume
to 100 ml and install a stopper.
3. Shake vigorously for 10 to 15 seconds.
4. Carefully loosen the stopper to release pressure.
5. Close the stopper and shake vigorously again for
10 to 15 seconds.
6. Put the graduated cylinder on a level surface for
approximately 5 minutes to allow adequate liquid
separation.
If alcohol is present in the fuel, the volume of the
lower layer (which would now contain both alcohol and
water) will be greater than 10 ml. For example, if the
volume of the lower layer is increased to 15 ml, it will
indicate at least 5 percent alcohol in fuel. The actual
amount of alcohol may be somewhat greater because
this procedure does not extract all of the alcohol from
the fuel.
FUEL TANK LEAK CHECK
rn
•
Important
Before attempting "Fuel Tank Leak Check" place
a dry chemical (Class B) fire extinguisher near
work area.
• Before removing the fuel tank for a suspected leak,
make sure fuel pipes are not leaking onto the tank.
Once removed, make sure fuel is not leaking
around fuel sender assembly 0-ring.
• This check requires a fuel sender assembly, fuel
filler cap, and a 0-ring to be installed in the fuel
tank.
1. Relieve fuel system pressure (see "Fuel System
Pressure Relief').
2. Drain fuel tank (see "Draining Fuel Tank").
3. Remove fuel tank (see "Fuel Tank Replacement").
4. Cap fuel feed tube, fuel return tube, and vapor
tube on fuel sender assembly.
5. Connect a piece of hose to the vent tube.
6. Submerge tank in water or apply soap solution to
outside of tank.
7. Apply 7 to 10 kPa (1 to 1t psi) air pressure to the
piece of hose on the fuel tank vent tube.
• Air bubbles appearing from fuel tank indicate
a leak. Replace fuel tank if it is leaking (see
"Fuel Tank Replacement").
FUEL TANK VENT VALVE CHECK
The fuel tank vent valve, located in the right rear
of the vehicle by the fuel tank, is a pressure/vacuum
relief valve. If the valve is not functioning properly it
could cause excessive pressure or vacuum to build up
in the tank. The result may be possible fuel discharge
when removing cap or possible damage to the tank or
fuel sender.
 ENGINE FUEL 6C-7

Checking procedure: SERVICING QUICK-CONNECT FITTINGS

l. Loosen fuel filler cap to relieve tank pressure. Figure 6
2. Remove tank vent valve from vehicle.
3. Wrap vent valve in shop towel and shake out Tools Required:
any remaining fuel. J 37088-A, tool set, Fuel Line Quick-Connect
4. Using the appropriate adapters, connect vent Separator
valve to a radiator pressure check device.
5. Slowly apply pressure to vent valve. The valve l+-+I Remove or Disconnect
should open at approximately 1 psi. If not,
replace vent valve.
6. Disconnect vent valve from pressure tester.
m
•
Important
Relieve fuel system pressure before servicing any
7. Using the appropriate adapters, connect vent
valve to a hand operated vacuum pump. fuel system connection (see "Fuel System Pressure
8. Slowly apply vacuum to the vent valve. The Relief').
valve should open at approximately 1-2" Hg. If • Slide dust covers from quick-connect fittings, if
not, replace vent valve. equipped.

l. Grasp both sides of fitting. Twist female

ON-VEHICLE SERVICE connector t turn in each direction to loosen any
m
•
Important
Before attempting any "On-Vehicle Service" place
dirt within fitting.

CAUTION: Safety glasses must be worn

a dry chemical (Class B) fire extinguisher near when using compressed air, as flying dirt
work area. particles may cause eye injury.
FUEL SYSTEM PRESSURE RELIEF 2. Using compressed air, blow dirt out of fitting.

Tool Required: - For plastic (Hand Releasable) Fitting-

J 34730-1, Fuel Pressure Gage
3. Squeeze plastic retainer release tabs.
CAUTION: To reduce the risk of fire and 4. Pull connection apart.
personal injury, it is necessary to relieve
the fuel system pressure before servicing -OR-
fuel system components.
After relieving system pressure, a - For Metal Fitting -
small amount of fuel may be released
when servicing fuel pipes or connections. 3. Choose correct tool from J 37088-A tool set for
In order to reduce the chance of personal size of fitting. Insert tool into female
injury, cover fuel pipe fittings with a shop connector, then push inward to release locking
towel before disconnecting, to catch any tabs.
fuel that may leak out. Place the towel in 4. Pull connection apart.
an approved container when disconnect
is completed. ~ ll•I Clean and Inspect
1. Ignition "OFF."
NOTICE: If it is necessary to remove rust or burrs
2. Disconnect negative battery cable to avoid possible
from fuel pipe: use emery cloth in a radial motion
fuel discharge if an accidental attempt is made to
with the pipe end to prevent damage to 0-ring
start the engine.
sealing surface.
3. Loosen fuel filler cap to relieve tank pressure. (Do
not tighten until service has been completed.)
• Using a clean shop towel, wipe off male pipe
4. Connect J 34730-1 to fuel pressure connection.
end.
Wrap a shop towel around fitting while connecting
• Inspect both ends of fitting for dirt and burrs.
gage to avoid spillage.
Clean or replace components/assemblies as
5. Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel required.
connections are now safe for servicing.
6. Drain any fuel remaining in gage into an approved
container.
6C-8 ENGINE FUEL

, :: nID---'
Metal Collar Quick-connect Fitting Plastic Collar Quick-connect Fitting

© Removal
CAUTION: TO REDUCE THE RISK OF FIRE
AND PERSONAL INJURY, RELIEVE FUEL
SYSTEM PRESSURE BEFORE DISCONNECTING
FUEL LINE FITTINGS.

©
OR

lnsta Ilation

c::;,~
~..--
IF EQUIPPED, REPOSITION
DUST COVER AFTER SERVICE
©
c::: >@ }
.....iE·-··- -···-~
-----~ .....iE····- -iJ-----.,
c:--::-: 4-30-92
NA5089-AS

Figure 6 - Quick-Connect Fittings

 ENGINE FUEL 6C-9

l·H·I Install or Connect

CAUTION: To Reduce the Risk of Fire and
Personal Injury:
• Before connecting fitting, always
apply a few drops of clean engine oil to
the male pipe end. This will ensure
proper reconnection and prevent a
possible fuel leak. (During normal
operation, the 0-rings located in the .....
female connector will swell and may
prevent proper reconnection if not
lubricated.)

1. Apply a few drops of clean engine oil to the male

pipe end.
2. Push both sides of fitting together to cause the
retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make
sure connection is secure.
THREADED FITTING
• Reposition dust cover over quick-connect fitting, if
equipped. 2 IN-LINE FUEL FILTER

3 QUICK-CONNECT FITTING
IN-LINE FUEL FILTER REPLACEMENT
4 IN-LINE FUEL FILTER BRACKET
Figure 7 NS 15923

[I] Important Figure 7 - In-Line Fuel Filter Replacement

• There is no service interval for fuel filter

replacement. Only replace fuel filter if it is restricted. l~I Tighten
• In-line fuel filter fitting to 27 N ·m (20 lb. ft.).
l++I Remove or Disconnect 3. Quick-connect fitting to fuel filter inlet (see
"Servicing Quick-Connect Fittings").
1. Negative battery cable.
4. Lower vehicle.
2. Relieve fuel system pressure (see "Fuel System
5. Tighten fuel filler cap.
Pressure Relief').
6. Ignition "OFF."
3. Raise vehicle.
7. Negative battery cable.
~
•
Clean
Clean both fuel feed pipe connections and
IL•I Inspect
• Turn ignition switch to "ON," position for two
surrounding areas at in-line fuel filter before
seconds, then turn to "OFF" for ten seconds.
disconnecting to avoid possible contamination
Again, turn to "ON" position and check for fuel
of the fuel system.
leaks.
4. Quick-connect fitting at fuel filter inlet (see
"Servicing Quick-Connect Fittings").
DRAINING FUEL TANK
5. Threaded outlet fitting from chassis fuel pipe.
6. Slide fuel filter from bracket.
CAUTION: Never drain or store fuel in an
IL•I Inspect open container due to the possibility of
fire or explosion.
• Fuel pipe 0-ring for cuts, nicks, swelling or
distortion. Replace if necessary. • Use a hand operated pump device to drain fuel
through the fuel filler neck. Remove fuel and
l++I Install or Connect install fuel filler cap.
1. Slide fuel filter into bracket.
2. Threaded outlet fitting to chassis fuel pipe.
 6C-10 ENGINE FUEL

FUEL TANK REPLACEMENT avoid possible contamination of the fuel

Figure 8
l++I Remove or Disconnect
CAUTION: To help avoid personal injury
wh~"! a vehicle is on a hoist, provide
add1t1onal support for the vehicle on the
opposite end from which components are
being removed. This will reduce the
po~sibility of the vehicle falling off the
hoist.
l++I Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel System
Pressure Relief").
2. Drain fuel tank (see "Draining Fuel Tank").
3. Raise vehicle.
4. Fuel filler neck shield.
5. Rear axle assembly, refer to SECTION 4B.
6. Exhaust system (pipe and muffler), refer to
SECTION6F.
7. Muffler heat shield.
(m Clean
• Clean all fuel pipe and hose connections and
surrounding areas before disconnecting to
system.
8. Rear fuel feed pipe assembly from fuel sender
assembly, fuel return, vapor, and vent hoses at fuel
sender assembly (see "Servicing Quick-Connect
Fittings").
9. Electricalconnector.
NOTICE: Do Not bend fuel tank straps, as this
may damage straps.
10. With aid of an assistant, support fuel tank, and
remove fuel tank strap front attaching bolts, fuel
tank straps and remove fuel tank.
• Fuel tank froP1 vehicle and place in a suitable
work area.
l+t+I Disassemble
1. Fuel tank insulator pads and tank strap insulator
pads if damaged, otherwise leave on.
2. Fuel sender assembly (see "Fuel Sender Assembly
Replacement").
l+;+I Assemble
1. Install fuel sender assembly (see "Fuel Sender
Assembly Replacement").
2. Install tank strap insulator pads and fuel tank
insulator pads, if needed.

UNDERBODY

2 INSULATOR
5
3 QUARTER PANEL

4 INSULATOR

5 FUEL TANK STRAP

6 BOLT

6 1 FUEL TANK ASSEMBLY 9S 5351-&E

Figure 8 - Fuel Tank Insulators and Fuel Tank Mounting

 ENGINE FUEL 6C-11

• Peel off release paper on insulators and apply the amount of leverage generated could damage
to tank and straps. the solder joints.

l•+I Install or Connect

1. Hook rear end of fuel tank straps into underbody
rn
•
Important
Always replace fuel sender assembly 0-rings,
bracket. when reinstalling fuel sender assembly.
2. With the aid of assistant, position and support fuel
tank. Position fuel tank straps and loosely install
front fuel tank strap attaching bolts.
l+•I Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel System

l~I Tighten 2.
Pressure Relief').
Drain fuel tank (see "Draining Fuel Tank").
• Front fuel tank strap attaching bolts to 34 3. Fuel tank (see "Fuel Tank Replacement").
N·m (25 lb. ft.).
3. Electrical connector. ~ Clean
4. Fuel return, vapor, and vent hoses and clamps at • Clean all fuel pipe and hose connections and
fuel sender assembly, rear fuel feed and return surrounding areas before disconnecting to avoid
pipe assemblies to fuel sender assembly (see possible contamination of the fuel system.
"Servicing Quick-Connect Fittings").
5.
6.
Muffler heat shield and attaching screws.
Exhaust system (pipe and muffler), refer to
l+t+I Disassemble
SECTION6F. 1. Fuel sender retaining nuts and retaining ring.
7. Rear axle assembly, refer to SECTION 4B. 2. Discard fuel sender 0-ring.
8. Fuel filler neck shield.
9. Lower vehicle. CAUTION: To reduce risk of fire and
10. Add fuel and install fuel filler cap. personal injury, drain fuel from fuel
11. Ignition "OFF." sender assembly into an approved
12. Negative battery cable. container.

IL'l'I Inspect ~ IL"'I Clean and Inspect

• Turn ignition switch to "ON," position for two • Fuel sender assembly 0-ring sealing surfaces.
seconds, then turn to "OFF" for ten seconds.
Again, turn to "ON" position and check for fuel l•~+I Assemble
leaks. 1. Position new fuel sender assembly 0-ring on fuel
tank.
FUEL TANK VENT VALVE

The fuel tank vent valve is located above the

rn
•
Important
Fuel pump strainer must be in a horizontal
passenger side rear tire and exhaust heat shield. position. When installing the fuel sender
assembly, assure that the fuel pump strainer
l++I Remove or Disconnect does not block full travel of float arm.
1. Ignition "OFF."
2. Negative battery cable. 2. Gently fold fuel strainer over itself.
3. Fuel filler cap. • Slowly position fuel sender assembly in fuel
4. Raise vehicle. tank so that fuel strainer is not damaged or
5. Fuel tank vent valve hose. trapped by sump walls.
6. Squeeze tabs and remove valve from bracket. 3. Install fuel sender assembly into fuel tank.

I•+! Install or Connect l~I Tighten

• Reverse removal procedure. • Fuel sender assembly retaining nuts to 7
N·m (63 lb. in.).
FUEL SENDER ASSEMBLY REPLACEMENT
Figure 9 !•+I Install or Connect
• Fuel tank and check for leaks (see "Fuel Tank
NOTICE: Do Not handle the fuel sender by the Replacement").
fuel sender pipes. Due to the length of the tubes,
6C-12 ENGINE FUEL

FUEL SENDER ASSEMBLY SERVICE 3. Quick-connect fitting on fuel feed hose (see
Figure 10 "Servicing Quick-Connect Fittings").
4. Electrical connector from fuel pump.
l++I Remove or Disconnect 5. Pry locking tabs on bottom of fuel reservoir, lift
1. Relieve fuel system pressure (see "Fuel System reservoir to clear locking tabs and pull reservoir
Pressure Relief'). downward to clear guides on fuel sender.
2. Drain fuel tank (see "Draining Fuel Tank"). 6. Bumper on fuel sender.
3. Fuel tank (see "Fuel Tank Replacement").
4. Fuel sender assembly (see "Fuel Sender Assembly l+;+I Assemble
Replacement"). 1. New bumper on fuel sender.
2. Align tabs on reservoir with guide on fuel sender,
l+t+I Disassemble push upward to stop on top of reservoir and snap
1. Support fuel sender assembly with one hand and locking tabs over ramps on bottom ofreservoir.
grasp strainer with other hand. 3. Fuel vent and return hose.
Rotate strainer in one direction and pull fuel 4. Quick-connect fitting on fuel feed hose (see
strainer off of pump. Discard strainer after "Servicing Quick-Connect Fittings").
inspection. 5. Electrical connector on fuel pump.
6. Push new fuel pump strainer onto fuel pump inlet.
IL'l'I Inspect Push on outer edge of strainer ferrule until fully
seated.
• Fuel pump strainer. If strainer is

•
contaminated, the fuel tank should be cleaned.
Fuel pump inlet for dirt and debris. If found,
1-++I Install or Connect
fuel pump and reservoir should be replaced. 1. Fuel sender assembly (see "Fuel Sender Assembly
Replacement").
- If fuel pump and reservoir is being replaced, proceed 2. Fuel tank and check for leaks (see "Fuel Tank
tostep2. - Replacement").

2. Vent hose and fuel return hose from under cover.

1/
A! ,_ • . /
2
.,....._ J.~.
/'. :::--....

RETAINING NUT

FUEL SENDER RETAINING

2 RING

3 FUEL SENDER ASSEMBLY

4 FUEL SENDER SEAL

5 FUEL TANK

NS 15922

Figure 9 - Fuel Sender Assembly Replacement

 ENGINE FUEL 6C-13

FUEL SYSTEM CLEANING

IL'l'I Inspect
rn
•
Important
Only use oil free compressed air to blow out fuel
• Fuel pump strainer. If contaminated, it must
be replaced and the fuel pump must be
pipes. inspected.
• If the in-line fuel filter is plugged, the fuel tank • Fuel pump inlet for dirt and debris. If found,
should be inspected internally and cleaned if fuel pump should be replaced.
necessary. 7. Flush fuel tank with running hot water for at least
five minutes.
Fuel Tank 8. Pour water out of fuel sender assembly opening.
(Rock tank to be sure that removal of water from
E3 Remove or Disconnect tank is complete.)
1. Ignition "OFF."
2. Negative battery cable. I++! Install or Connect
3. Relieve fuel system pressure (see "Fuel System 1. Fuel sender assembly (see "Fuel Sender Assembly
Pressure Relief''). Replacement").
4. Drain fuel tank (see "Draining Fuel Tank"). 2. Fuel tank (see "Fuel Tank Replacement").
5. Fuel tank (see "Fuel Tank Replacement"). 3. Add fuel and install fuel filler cap.
6. Fuel sender assembly (see "Fuel Sender Assembly 4. Ignition "OFF."
Replacement"). 5. Negative battery cable.

SENDER ASSEMBLY - FUEL LEVEL

2 FUEL PUMP AND RESERVIOR

ASSEMBLY
A VAPOR VENT HOSE
B FUEL FEED HOSE AND
QUICK-CONNECT FITTING
C FUEL RETURN HOSE

3 STRAINER

NA 5017-XV

Figure 10 - Fuel Sender Assembly Disassembly

6C-14 ENGINE FUEL
IL•I Inspect
• Turn ignition switch to "ON" position for two
seconds, then turn to "OFF" for ten seconds.
Again turn to "ON" position and check for fuel
leaks.
FUEL FEED AND RETURN PIPES/HOSES
REPLACEMENT
Rear Fuel Feed Pipe/Hose Assembly
(Fuel Tank)
Figure 11
NOTICE: Do Not attempt to repair rear fuel feed
pipe/hose assembly. If damaged, replace.
l++I Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel System
Pressure Relief").
2. Raise vehicle.
~ Clean
• Clean all fuel pipe and hose connections and
surrounding areas before disconnecting to
avoid possible contamination of the fuel
system.
3. Rear fuel feed pipe assembly from chassis fuel
pipes (see "Servicing Quick-Connect Fittings").
4. Fuel tank (Refer to "Fuel Tank Replacement").
5. Rear fuel pipes from fuel sender assembly (see
"Servicing Quick-Connect Fittings").
l++I Install or Connect
1. Rear fuel feed pipe assembly to fuel sender
assembly (see "Servicing Quick-Connect
Fittings").
2. Fuel tank (Refer to "Fuel Tank Replacement").
3. Rear fuel pipes to chassis fuel pipes (see "Servicing
Quick-Connect Fittings").
4. Lower vehicle.
5. Ignition "OFF."
6. Negative battery cable.
7. Tighten fuel filler cap.
IL•I Inspect
• Turn ignition switch to "ON," position for two
seconds, then turn to "OFF" for ten seconds.
Again turn to "ON" position, and check for fuel
leaks.
Chassis Fuel Feed and Return Pipes
Figure 12
NOTICE: When replacing fuel pipes, always
replace them with original equipment or parts that
meet the GM specifications for those parts. The
replacement pipes must have the same type of
fittings as the original pipes to ensure the
integrity of the connection.
• Do not use copper or aluminum tubing to
replace steel tubing. Only tubing meeting the 124-
M specification or its equivalent is capable of
meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability
standard required.
• When replacing fuel hoses or repairing fuel
pipes with hoses, always replace them with
original equipment or parts meeting GM
specifications, use only reinforced fuel-resistant
hose which is identified with the word
"Fluoroelastomer" or "GM 6163-M" on the hose.
Inside hose diameter must match outside pipe
diameter.
• Do not use rubber hose within 100 mm (4") of
any part of the exhaust system or within 254 mm
(10") of the catalytic converter.
• A minimum of 13 mm (-f') clearance must be
maintained around sharp edges such as flanges,
pinch welds, etc., to prevent contact and chaffing.
A minimum of 19 mm (r') clearance must be
maintained around all moving parts.
• If more than a 6 inch length of pipe is removed,
use a combination of steel pipe and hose so that the
total hose lengths, including the lOOmm (4")
additional length will not be more than 254 mm
(10") long. Follow the same routing as the original
pipe.
• Cut ends of pipe remaining on car square with
a tube cutter. Using the first step of a double
flaring tool, form a bead on the end of both pipe
sections. If pipe is too corroded to withstand the
beading operation without damage, the pipe
should be replaced. If a new section of pipe is used,
form a bead on both ends of it also.
• Use screw type hose clamps. Slide clamps onto
pipe and push 51 mm (2") onto each portion of fuel
pipe.
1++1 Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel System
Pressure Relief').
~ Clean
• Clean all fuel feed and return pipe/hose
connections and surrounding areas before
disconnecting to avoid possible contamination
of the fuel system.
2. Raise vehicle.
3. Engine compartment connecting fuel feed and
return pipe/hose assemblies from chassis fuel feed
and return pipes (see "Servicing Quick-Connect
Fittings").
4. Fuel feed pipe from outlet side of in-line fuel filter.
Discard 0-ring.
 ENGINE FUEL 6C-15

5. Fuel return pipe from rear fuel pipe (see "Servicing
Quick-Connect Fittings").
6. Desired fuel pipe and attaching hardware from
under body.
• Note position of fuel pipe to be removed for
installation.
8. Negative battery cable.
ll'l'I Inspect
• Turn ignition switch to "ON," position for two
seconds, then turn to "OFF" for ten seconds.
Again turn to "ON" position, and check for fuel

ll'l'I Inspect leaks.

• Pipes for bends, kinks and cracks. Repair or
replace pipe or pipes as required.
l·.+·I Install or Connect
1. Position new or repaired fuel pipe or pipes in body
clips as noted during removal and install with
attaching hardware.
2. Position new 0-ring on fuel feed pipe and connect
to outlet side of in-line fuel filter.
l~I Tighten
• Fuel feed pipe fitting to 27 N·m (20 lb. ft.).
3. Fuel return pipe to rear fuel pipes (see "Servicing
Quick-Connect Fittings").
4. Chassis fuel pipes to engine compartment
connecting fuel pipes (see "Servicing Quick-
Connect Fittings").
5. Lower vehicle.
6. Tighten fuel filler cap.
7. Ignition "OFF."
Engine Compartment Connecting Fuel Pipes
(Chassis to Engine)
Figure 13
NOTICE: Do Not attempt to repair sections of
engine compartment connecting fuel pipes. If
damaged, replace.
l++I Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel System
Pressure Relief'').
~ Clean
•Clean all engine compartment connecting fuel
pipe connections and surrounding areas before
disconnecting to avoid possible contamination
of the fuel system.
2. Quick-connect fittings at engine fuel pipes (see
"Servicing Quick-Connect Fittings").

FUEL SENDER ASSEMBLY

2 FUEL TANK

3 FUEL FILLER NECK

4 EVAPORATIVE EMISSION CANISTER

5 FUEL RETURN PIPE QUICK-CONNECT FITTING

6 IN-LINE FUEL FILTER

NS 15919
Figure 11 - Fuel and Vapor Pipe Replacement (Rear Fuel Pipes)
6(-16 ENGINE FUEL

RETAINING CLAMP

2 IN-LINEFUEL FILTER

3 EVAPORATIVE EMISSION PIPE

4 QUICK-CONNECT FITTINGS

NS 15920

Figure 12 - Fuel and Vapor Pipe Replacement (Chassis Fuel Pipes)

ENGINE COMPARTMENT CONNECTING PIPES 4 RETAINING CLAMP

2 EVAPORATIVE EMISSION PIPE 5 GROMMET (WHEELHOUSE OPENING)
3 RETAINING CLIP 6 TO CHASSIS FUEL PIPES
NS 15921

Figure 13 • Fuel and Vapor Pipe Replacement (Engine Compartment Connecting Fuel Pipes)

3. · Fuel pipes from routing clip and conduit. (note
position for installation.
4. Fuel pipes through grommet in wheel house.
5. Raise vehicle.
6. Quick-connect fittings at chassis fuel pipes (see
"Servicing Quick-Connect Fittings").
7. Fuel pipes from clips and routing bracket (note
positions for installation.)
l++I Install or Connect
1. Quick-connect fittings at chassis fuel pipes (see
"Servicing Quick-Connect Fittings").
2. Route pipes through clips, brackets, and conduits
as noted during disassembly.
3. Lower vehicle.
4. Engine compartment connecting fuel pipes to
engine fuel pipes (see "Servicing Quick-Connect
Fittings").
5. Tighten fuel filler cap.
6. Ignition "OFF."
7. Negative battery cable.
IL•! Inspect
• Turn ignition switch to "ON," position for two
seconds, then turn to "OFF" for ten seconds.
Again turn to "ON" position and check for fuel
leaks.
FUEL VAPOR PIPES AND HOSES REPAIR/
REPLACEMENT
Figures 11 through 13
NOTICE: When replacing vapor pipes, always
replace them with original equipment or parts that
meet the GM specifications for those parts.
• Do not use copper or aluminum tubing to
replace steel tubing. Only tubing meeting the
124-M specification or its equivalent is capable of
meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability
standard required.
• When replacing vapor hoses or repairing
sections of vapor pipe with vapor hoses, always
replace them with original equipment or parts
meeting GM specifications, use only reinforced
fuel-resistant hose which is identified with the
word "Fluoroelastomer" or "GM 6163-M" on the
hose. Inside hose diameter must match outside
pipe diameter.
• Do not use rubber hose within 100 mm (4") of
any part of the exhaust system or within 254 mm
(10") of the catalytic converter.
• A minimum of 13 mm (t") clearance must be
maintained around sharp edges such as flanges,
pinch welds, etc., to prevent contact and chaffing.
A minimum of 19 mm (-!") clearance must be
maintained around all moving parts.
ENGINE FUEL 6C-17
• Use screw-type hose clamps. Slide clamps onto
pipe and push 51 mm (2") onto each portion of
vapor pipe.
l++I Remove or Disconnect
1. Hardware retaining section of pipe to be replaced.
• Note location of attaching hardware for
installation.
2. Section of pipe and hoses.
IL•I Inspect
• Hoses for cuts, swelling, cracks and distortion.
Replace as required.
• Pipes for kinks and cracks. Repair or replace
sections as required.
I++! Install or Connect
[I] Important
•Follow the same routing as the original hoses
and pipes.
• Hoses and pipes must be properly secured to
prevent chafing.
1. Reverse removal procedure.
ACCELERATOR CONTROL CABLE
REPLACEMENT
Figures 14, 15and 16
!++I Remove or Disconnect
1. Lower instrument panel trim.
2. Sound insulator.
3. Accelerator cable from accelerator pedal.
4. Squeeze accelerator cable cover tangs and push
cable through bulkhead.
5. Accelerator cable retainer and accelerator cable
from throttle body lever.
6. Squeeze accelerator cable cover tangs and push
cable through accelerator cable bracket.
!++I Install or Connect
NOTICE: To prevent possible interference,
flexible components (hoses, wires, conduits, etc.)
must not be routed within 50 mm (2") of moving
parts, unless routing is positively controlled.
1. Apply Accelerator Linkage Lubricant, 1052541 or
equivalent to throttle body lever.
2. Reverse removal procedure.
IL•I Inspect
• Check for complete throttle opening and
closing positions by operating accelerator
pedal. Also check for poor carpet fit under the
accelerator pedal.
6C-18 ENGINE FUEL

Throttle should operate freely without binding

between full closed and wide open throttle.
3. Apply heavy bodied sealer around accelerator
cable at engine compartment side of bulkhead.

ACCELERATOR PEDAL REPLACEMENT

Figure 14

l++I Remove or Disconnect

----
1. Lower instrument panel trim.
2. Sound insulator.
3. Accelerator cable from accelerator pedal rod.
4. Accelerator pedal retainer nut, bolt, and
4 accelerator pedal.

l++I Install or Connect

rn
•
Important
The mounting surface between support and
dash panel must be free of insulation. The
carpet and padding in pedal and tunnel area
1 SOUND IN SULA TOR must be positioned to lay flat and be free of
2 ACCELERATOR CABLE wrinkles and bunches.
3 ACCELERATOR CABLE RETAINER
4 ACCELERATOR PEDAL ASSEMBLY NS 15917 1. Accelerator pedal and accelerator pedal retainer
nut and bolt.
Figure 14-Accelerator Controls· Pass Compartment 2. Accelerator cable on accelerator pedal.

IL'l'l lnspect
• Check for complete throttle opening and
closing positions by operating accelerator
pedal. Also, check for poor carpet fit under the
accelerator pedal.
• Throttle should operate freely without bind
between full closed and wide open throttle.
3. Sound insulator.
4. Lower instrument panel trim, lower instrument
panel trim attaching screws and nut.

SPECIFICATIONS
TORQUE SPECIFICATIONS

In-line Fuel Filter Fitting • • • 27 N ·m (20 lb. ft.)

Fuel Tank Strap Attaching
Bolts • • • • • • • • • • • • • • 34 N ·m (25 lb. ft.)
Fuel Sender Assembly Retaining
THROTTLE BODY Nuts • • • • •• • • • • • • • • 7N·m(63lb.in.)
2 ACCELERATOR CABLE BRACKET

3 ACCELERATOR CABLE

4 CRUISE CONTROL CABLE

NS15918

Figure 15 • Accelerator Controls· Engine

Compartment (3.4L VIN S)
 ENGINE FUEL 6C-19

THROTTLE BODY 3 CRUISE CONTROL CABLE

2 ACCELERATOR CABLE
NS 15916

Figure 16. Accelerator Controls - Engine Compartment (5. 7L VIN P)

FUEL SPECIFICATIONS Ethanol

The fuel must meet ASTM Standard: D4814(U.S.),
CGSB 3.5-M87 (Canada).
Octane Requirements
5.7L(VIN P)
Min. Octane Recommended: 87[(R+ M)/2) (pump)
octane Where R= research octane number, and M=
motor octane number.
Gasoline With Alcohol
NOTICE: Do Not spill fuel containing alcohol on
the vehicle. Alcohol can cause damage to the paint
finish and trim.
Methyl Tertiary-Butyl Ether (MTBE)
Fuel containing Methyl Tertiary-Butyl Ether
(MTBE) may be used, providing there is no more than
15% MTBE by volume.
Fuel containing ethanol (ethyl) or grain alcohol
may be used, providing that there is no more than 10%
ethanol alcohol by volume.
Methanol
Fuel containing methanol (methyl) or wood alcohol
may be used, providing that there is no more than 5%
methanol by volume.
NOTICE: Do not use fuel that contains more than
5% methanol. Use of a fuel (gasahol) that contains
more than 5% of methanol can corrode metal fuel
system components and damage plastic and rubber
parts.
SPECIAL TOOLS
Fuel Pressure Gage • • • • • • • • • • • • J 34730-1
Fuel Line Quick-Connect
Separator Set • • • • • • • • • • • • • • J 37088-A
6C-20 ENGINE FUEL

BLANK
 ENGINE ELECTRICAL 60-1

SECTION 60
ENGINE ELECTRICAL
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6D-1

GENERAL DESCRIPTION generator assembly (and related wiring). To diagnose and

troubleshoot system faults, refer to SECTION SA for
The engine electrical system includes the storage wiring diagrams, component locations and system checks.
battery assembly, ignition (primary and secondary), When a fault is traced to a particular component,
starter motor assembly (and related wiring) and the refer to that component's section of the service manual.
 BATIE RY 601 -1

SECTION 601

BATIE RV
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" exposed electrical terminals, disconnect the battery
negative cable assembly to help prevent personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the ignition switch must be in the "OFF" or
"LOCK" position.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 601-1 Charging Procedure . . . . . . . . . . . . . . . . . . . 601-7
Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . 601-1 Charging Time Required . . . . . . . . . . . . . . . 601-7
Battery Assembly Ratings ................ 601-2 Charging a Very Low or Completely
Reserve Capacity ..................... 601-2 Discharged Battery Assembly . . . . . . . . . . . 601-7
Cold Cranking Amps .................. 601-2 Jump Starting in Case of Emergency with
Common Causes of Failure ............... 601-2 Auxiliary (Booster) Battery Assembly .... 601-8
Electrolyte Freezing ..................... 601-2 Battery Tray Assembly Replacement ....... 601-8
Battery Tray Assembly and Hold-Down Battery Assembly Replacement ............ 601-8
Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601-2 Battery Cable Assembly Replacement
Battery Assembly Protection During and Routing . . . . . . . . . . . . . . . . . . . . . . . . . 601-9
Vehicle Storage ...................... 601-3 Negative Cable Assembly .............. 601-9
.Built-~n Hydrometer . . . . . . . . . . . . . . . . . . . . 601-3 Positive Cable Assembly .............. 601-10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601-3 Ground Straps . . . . . . . . . . . . . . . . . . . . . . . . 601-10
Battery Assembly Testing ................ 601-3 Charging Equipment ................... 601-10
Battery Assembly Electrical Drain . . . . . . . . . 601-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 601-13
Parasitic Load Test . . . . . . . . . . . . . . . . . . . . 601-4 Battery Assembly Usage ................ 601-13
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 601-6 Fastener Tightening Specifications . . . . . . . . 601-13
Battery Assembly Charging . . . . . . . . . . . . . . . 601-6 Special Tools ........................... 601-14

CAUTION: All battery assemblies gen- GENERAL DESCRIPTION

erate hydrogen gas which is extremely
flammable. If ignited by a spark or BATTERY ASSEMBLY
flame, the gas may explode violently, Figures 1 and 2
causing spraying of acid, fragmen- The maintenance-free battery assembly is standard
tation of the battery assembly and on all vehicles. See "Specifications" in this section for
possible severe personal injuries. Wear battery assembly usage applications. There are no vent
approved eye protection. Battery plugs in the cover. The battery assembly is completely
assembly fluid is corrosive acid. Flush sealed except for two small vent holes in the sides. These
any contacted area with water imme- vent holes allow the small amount of gas produced in the
diately and thoroughly. battery assembly to escape.
601 •2 BATIE RY

Cold Cranking Amps

The cold cranking amperage (CCA) test is expressed
at a battery temperature of -18°C (0°F). The current
rating is the minimum amperage which must be main-
tained by the battery assembly for 30 seconds, at the
specified temperature, while meeting a minimum voltage
requirement of 7.2 volts. This rating is a measure of cold
cranking capacity.

COMMON CAUSES OF FAILURE

The battery assembly is not designed to last indefi-
nitely; however, with proper care, it will provide many
PC6001-6D1-D-RP
years of service.
Figure 1 - Maintenance-Free Battery Assembly
If the battery assembly tests "good," but fails to
perform satisfactorily in service for no apparent reason,
the following are some of the more important factors that
may point to the cause of trouble:

j Delco Remy®
I
1. Vehicle accessories are left on overnight.
2. Slow average driving speeds for short periods.
3. The vehicle's electrical load being more than the
LOAD REPLACEMENT
: CAT. NO. generator assembly output, particularly with the
I
CCA TEST MODEL
I
I 514 525 260 75-60 1-2 addition of aftermarket equipment.
I
I
For warranty transaction, remove and attach to warranty claim. 4. Conditions in the charging system such as electrical
I
L------------------------------------------ shorts, slipping serpentine belt, faulty generator
assembly, or generator voltage regulator.
5. Battery assembly abuse, including failure to keep
PC0001·6D1-F-RP
the battery assembly terminals clean and tight, or
Figure 2 - Battery Assembly Label loose battery assembly hold-down. See "Battery
Assembly Replacement" in this section for torque
specifications.
The battery assembly has three major functions in
the electr~cal system: first, it provides a source of energy 6. Mechanical conditions in the electrical system, such
f~)f crankmg the engine; second, it acts as a voltage stabi- as shorted or pinched wires.
lizer fo_r t~e ele~trical system; and third, it provides energy 7. Extended storage of vehicles.
for a limited time when the electrical load exceeds the 8. Extended cranking periods due to plug fouling.
output of the generator assembly.
9. Incorrect interpretation of the hydrometer.
The battery assembly specifications label contains
impor:tant info_rma~ion for servicing the battery assembly. 10. Insufficient ampere-hour charge rate for a dis-
Thi~ mformation mcludes test rating and both original charged battery assembly.
eqmpment and recommended replacement part numbers. 11. Continuous current draw on the battery assembly
Refer to ''Specifications'' at the end of this section. through excessive parasitic drain.

BATTERY ASSEMBLY RATINGS ELECTROLYTE FREEZING

~ bat~ery assembly has two ratings: ( 1) a reserve
capacity ratmg and (2) a cold cranking amperage rating at
-l8°C (0°F). When replacing the battery assembly, use
these two ratings as a guide in selecting a replacement.
F?r the ~atalo~ ~umber of a replacement battery assembly
with ratmgs similar to the original battery assembly, refer
to "Specifications" at the end of this section.
Reserve Capacity
The "Reserve Capacity" is an estimate of the
maximum length of time it is possible to travel at night
with minimum electrical load and no generator assembly
output.
Expressed in minutes, it is the approximate time the
fu_lly-charged battery assembly can support a 25-amp load
without the battery assembly terminal voltage dropping
below 10.5 volts at 27°C (80°F).
The freezing point of electrolyte depends on its
specific gravity. Since freezing may ruin a battery
assembly, it should be protected against freezing by
keeping it in a charged condition.
As long as the green dot is visible in the hydrometer,
the freezing point of the battery will be somewhere below
-32°C (-25°F).
The higher the state of charge, the lower the freezing
point. A fully charged battery will not freeze until the
temperature gets below -65°C (-85°F).
BATTERY TRAY ASSEMBLY AND
HOLD-DOWN RETAINER
The battery tray assembly and hold-down retainer
should be clean and free from corrosion before installing
the battery assembly.
 BATTERY 601 -3

The battery tray assembly should be in a sound
condition so that it will hold the battery assembly securely
and keep it level. Make certain there are no parts in the
battery tray assembly before installing battery assembly.
To prevent the battery assembly from shaking in its
battery tray assembly, the hold-down retainers should be
tight, but not overtight.
BATTERY ASSEMBLY PROTECTION
DURING VEHICLE STORAGE
Today's vehicles have many high technology elec-
tronic devices which result in very small but continuous
current drains on the battery assemblies, commonly
referred to as "parasitic loads." Vehicles that are not used
for an extended period of time may develop an extremely
discharged and/or permanently damaged battery assembly
resulting from parasitic loads.
Any battery assembly discharged by parasitic load-
ing and then allowed to stand in this condition for a period
of time may not accept recharge. However, if properly
recharged, most battery assemblies will return to a good
usable condition.
An extremely discharged battery assembly can
freeze at temperatures as high as -7°C (20°F) causing
permanent damage. Permanent damage to a discharged
battery assembly can also be accelerated by high tem-
peratures.
To prevent this condition, the battery negative cable
assembly should be disconnected on vehicles which are
not going to be in service within a 30-day period, begin-
ning from the time the vehicle is shipped. If this is not
possible, battery assemblies should be recharged period-
ically (every 20-45 days) until the green dot of the built-in
hydrometer is visible.
BUILT-IN HYDROMETER
Figure 3
The maintenance-free battery assembly has a
built-in temperature compensated hydrometer in the top
of the battery assembly. This hydrometer is used with the
following diagnostic procedure.
STORAG.E STORAGE STORAGE
BATTERY BATTERY BATTERY
ASSEMBLY TOP ASSEMBLY TOP ASSEMBLY TOP
When observing the hydrometer, make sure that the
battery assembly has a clean top. A light may be required
in some poorly-lit areas. Tap the hydrometer lightly on
top to dislodge any air bubbles that might cause a false
indication.
Under normal operation, two indications can be
observed.
1. GREEN DOT VISIBLE
Any green appearance is interpreted as a "green
dot" and the battery assembly is ready for testing.
2. DARK; GREEN DOT NOT VISIBLE
If there is cranking complaint, the battery assembly
should be tested as described in the "Diagnosis" in
this section. The charging and electrical systems
should also be checked at this time.
Occasionally, a third condition may appear:
3. CLEAR OR LIGHT YELLOW
This means the fluid level is below the bottom of
the hydrometer. This may have been caused by
excessive or prolonged charging, a broken case, or
excessive tipping. When finding a battery assembly
in this condition it may indicate high charging
voltages caused by a faulty charging system, there-
fore, the charging and electrical systems may need to
be checked. If a cranking complaint exists and is
caused by the battery assembly, the battery assembly
should be replaced.
DIAGNOSIS
BATTERY ASSEMBLY TESTING
Figures 3, 4 and 5
The following procedure should be used for testing
battery assemblies:
1. VISUAL INSPECTION
Check for obvious damage, such as a cracked or
broken case or cover that could permit loss of
electrolyte. If obvious damage is noted, replace the
battery assembly. Determine the cause of damage
and correct as needed. If not, proceed to step 2.
2. HYDROMETER CHECK (Figure 3).
• GREEN DOT VISIBLE - Go to step 3.
• DARK; GREEN DOT NOT VISIBLE.
Charge the battery assembly as outlined under
"Charging Procedure" in this section and
proceed to step 3.

[iJ[jj[@J
DARKENED DARKENED LIGHT
3. LOADTEST
Load testing requires using battery assembly side
terminal adapters to ensure good connection (Figure
4). Do not load test a frozen battery assembly
INDICATOR INDICATOR YELLOW OR A. Connect a voltmeter and a battery assembly
(WITH GREEN (NO GREEN BRIGHT load tester across the battery assembly ter-
DOT) DOT) INDICATOR
minals.
PC6009-6D1-D-RP
B. Apply a 300-amp load for 15 seconds to
Figure 3 - Built-In Hydrometer remove surface charge from the battery
assembly.
 601 -4 BATTERY

Parasitic Load Test

Figures 6 and 7
Tool Required:
J 38758 Parasitic Draw Test Switch
If the battery assembly discharges while the vehicle
sits for a few hours or days, the vehicle should be diag-
nosed for parasitic loads. Simple connection of an
ammeter in series with the battery assembly may not find
the cause as the condition may not show up when power is
restored unless that particular component is repeatedly
cycled. Parasitic loads can be diagnosed using either of
the procedures below, but use of the special tool as
described in the first procedure is recommended.
NOTICE: Parasitic draw test switch should never be
PC6013-601-D-RP
turned to "OFF" position with engine running or
damage could occur to attached ammeter or vehicle
Figure 4 - Battery Assembly Side Terminal Adapters
electrical system.

ESTIMATED MINIMUM
TEMPERATURE VOLTAGE

21 °C (70°F) 9.6 3
10°C (50°F) 9.4
0°C (32°F) 9.1
-10°C (14°F) 8.8
-18°C (0°F) 8.5
BELOW: - 18°C (0°F) 8.0

NC 1004-601-F-RP

Figure 5 - Battery Assembly Voltage Drop Temperature

C. Wait 15 seconds to let the battery assembly

recover. Apply load specified on the battery A
assembly label or in "Specifications" at the
end of this section. Read voltage after 15
seconds, then remove load.
D. If voltage does not drop below the minimum D
listed in Figure 5, the battery assembly is good
and should be returned to service. The battery
assembly temperature must be estimated by -+
feel and by the temperature the battery assem-
bly has been exposed to for the past few hours.
E. If voltage drops below the minimum listed,
replace the battery assembly.

BATTERY ASSEMBLY ELECTRICAL DRAIN

Battery assembly electrical drain is a small amount
A AMMETER, HIGH CAPACITY (10A)
of current required by specific control modules that is 2 CABLE ASSEMBLY, BATTERY NEGATIVE
needed to retain system memory and system monitoring. 3 BATTERY ASSEMBLY, STORAGE
Too much electrical drain, however, can cause an
extremely discharged and/or permanently damaged bat-
tery assembly. To test the battery assembly electrical PC0002-601-f.RP
drain, refer to "Parasitic Load Test" in this section. Figure 6 - Use of Parasitic Draw Test Switch

1993 COMPONENT PARASITIC LOADS (mA)
Component
PASS-Key 11®
Voltage Regulator in Generator Assembly
HVAC Control Head
Before 2.5 hour timeout
After 2.5 hour timeout*
ECM
Radio Control Head
*After specified timeout period elapses, component switches from "AWAKE" to "ASLEEP" mode.
Figure 7 - Component Parasitic Loads
1. Tum test switch knob to "OFF" position.
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in Section OA.
2. Remove battery negative cable assembly.
3. Install parasitic draw test switch male (cable) end to
negative battery terminal.
4. Install battery negative cable assembly to female
end of test switch tool.
5. Tum test switch tool knob to "ON" position.
6. Road test vehicle while activating all accessories
(radio, A/C, etc.).
7. Tum ignition switch to "LOCK" position and
remove ignition key.
8. Set ammeter to 10-amp scale and connect to termi-
nals on test switch tool with alligator clips. Use of
10-amp scale may prevent damage to meter.
9. Tum test switch tool knob to "OFF" position to
allow current to flow through ammeter.
10. Check current reading. Allow time for reading to
stabilize. Verify that retained accessory power
(RAP) is off. If current reading is at or below two
amps, turn test tool knob to "ON" position (to main-
tain continuity in electrical system) and switch to a
lower scale for a more accurate reading, or install a
more accurate meter, if necessary. Turn test tool
knob to "OFF." If current reading is above 25 milli-
amps, refer to components parasitic load chart
(Figure 7) for specific current loads and micro-
processor "time-outs" for modules in "awake" and
"asleep" states. Total reading below 20 milliamps is
normal, and a reading below 25 milliamps is accept-
able. A zero reading indicates a problem with meter,
scale being used, or connection.
11. If current draw is above specifications listed in
component parasitic load chart, remove system
maxifuses and circuit breakers one at a time until
BATIERY 601·5
Approximate
Parasitic Draw
2
15
5
5-10
5
PC0009-6D1-f..RP
current draw returns to a value less than or equal to
specifications listed. This should be done while
monitoring ammeter so that a disruption of drain
will be evident. Perform steps 9 and 10 each time a
fuse is removed. Refer to SECTION 8A for specific
circuit schematics. Total readings in the hundreds of
milliamps may suggest grounded wires, sticking
relays, or small lamps remaining lit.
II) Important
• Always turn test switch tool knob to "ON"
position before removing each fuse to maintain
continuity in electrical system and to avoid
damaging ammeter due to accidental overload-
ing (i.e., opening door). Do not turn switch to
"OFF" while engine is running.
12. When cause of excessive current draw has been
located and repaired, repeat steps 9 and 10 to verify
the repair. Then turn test tool to "OFF," remove
tool, and reconnect battery negative cable assembly
to battery assembly negative terminal.
l~I Tighten
• Negative cable assembly to 15 N•m (11 lb. ft.).
Alternate Parasitic Load Test
Figures 4, 7 and 8
The following alternate procedure may be used
when testing for parasitic load if J 38758 is not available.
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Disconnect battery negative cable assembly.
2. Install a battery side terminal adapter, AC Delco
PIN ST-1201 or GM PIN 12303040 or equivalent,
in negative terminal of battery (See Figure 4).
601 ·6 BATIERY
® 3
3 3
+ +
ST-1201 or ST-1201 or
GM P/N 12303040 GM P/N 12303040
A
A AMMETER, HIGH CAPACITY (10A)
B NUT, 3/8-INCH
C MULTl METER
Figure 8 - Alternate Parasitic Load Diagnosis Procedure
3. Install other battery side terminal adapter or a
3/8-inch nut with standard threads (16 UNC) on
battery negative cable assembly to assure a good
electrical contact with metal face on cable for testing
(add a washer behind nut if nut does not contact
firmly). Yellow or black finish nuts are generally
non-conductive and should not be used.
4. With all lights, accessories, retained accessory
power (RAP), and ignition switch off, connect a
high capacity ammeter (at least 10 amps) from
battery negative cable assembly to side terminal
adapter. This high capacity ammeter is connected to
verify whether or not a high current draw is occur-
ring at a constant rate. It is this type of high current
draw which will blow the fuse in lower capacity
ammeters.
NOTICE: If a high capacity ammeter is not avail-
able, install a section of heavy wire (preferably
battery cable section) between existing battery
negative cable assembly and side terminal adapter.
Allow time for initial draw to occur or check for
reduced current with an inductive ammeter (current
clamp) and proceed to step 5.
5. With high capacity ammeter or battery cable section
still connected, connect digital multimeter, set on
2000 mA de range, in parallel with high reading
ammeter.
6. Disconnect high capacity ammeter and take reading
with digital multimeter.
+
c c
ST-1201 or
GM P/N 1 2303040
D
1 CABLE ASSEMBLY, BATIERY POSITIVE
2 CABLE ASSEMBLY, BATIERY NEGATIVE
3 BATIERY ASSEMBLY, STORAGE
PC0003-6D1·f·RP
If current draw is above specifications listed in
component parasitic load chart, remove system
fuses and mini-breakers one at a time until current
draw returns to a value less than or equal to specifi-
cations listed. This should be done while monitoring
ammeter so that a disruption of drain will be evident.
Refer to Figure 7 for approximate parasitic loads
for various vehicle components. Set ammeter on
maximum scale when pulling fuses to avoid
damage. Refer to SECTION 8A for specific circuit
schematics.
7. When cause of excessive draw has been located and
repaired, repeat step 6 to verify the repair. Reconnect
battery negative cable assembly to battery assembly
negative terminal.
l~I Tighten
• Negative cable assembly to 15 N•m (11 lb. ft.).
ON-VEHICLE SERVICE
BATTERY ASSEMBLY CHARGING
NOTICE: Always disconnect the negative cable
assembly when charging a battery assembly or elec-
tronic components may be damaged.
When it is necessary to charge the battery assembly,
follow these basic rules:
1. Do not charge battery assembly if hydrometer is
clear or light yellow. Replace battery assembly.

2. If the battery assembly feels hot (52°C (125°F) or
higher), or if electrolyte violently gasses or spews
through the vent holes, discontinue charging or
reduce charging rate.
3. Do not charge a battery assembly if it seems to be
frozen.
Charging Procedure
Tool Required:
A/C Delco P/N ST-1201 or GM P/N 12303040
Battery Side Terminal Adapters (Pair)
1. Battery assemblies with green hydrometer dot
showing do not require charging unless they have
justbeen discharged (such as in cranking vehicle).
2. When charging battery assembly with side termi-
nals, install adapter kit (AC Delco P/N ST-1201 or
GM P/N 12303040 or equivalent). Refer to Figure 4.
The adapter should be snugged up against the
battery assembly terminals to keep resistance
between the adapter and the battery assembly termi-
nal to a minimum. Recommended battery assembly
side terminal adapter torque is 15 N•m (11 lb. ft.).
3. Make sure all battery charger connections are clean
and tight.
4. For best results, battery assemblies should be
charged while electrolyte and plates are at room
temperature. A battery assembly that is extremely
cold may not accept current for several hours after
starting battery charger.
5. Charge battery assembly until green dot of built-in
hydrometer appears. Refer to "Charging Time
Required" in this section. Battery assembly should
be checked every half-hour while charging. Tap the
hydrometer lightly on top to dislodge any air
bubbles that might cause a false indication.
6. After charging, battery assembly should be tested.
Refer to "Diagnosis" in this section.
Charging Time Required
The time required to charge a battery assembly will
vary depending on the following factors:
• Size of Battery Assembly - A completely dis-
charged large heavy-duty battery assembly requires
more than twice the recharging as a completely dis-
charged small passenger vehicle battery assembly.
• Temperature - A longer time will be needed to
charge any battery assembly at -18°C (0°F) than at
27°C (80°F). When a fast battery charger is con-
nected to a cold battery assembly the current
accepted by the battery assembly will be very low at
first, thenin time, the battery assembly will accept a
higher rate as the battery assembly warms.
• Battery Charger Capacity - A battery charger
which can supply only five amps will require a much
longer period of charging than a battery charger that
can supply 30 amps or more.
BATTERY 601·7
• State-of-Charge - A completely discharged battery
assembly requires more than twice as much charge
as a half-charged battery assembly. Because the
electrolyte is nearly pure water and a poor conductor
in a completely discharged battery assembly, the
current accepted by the battery assembly is very low
at first. Later, as the charging current causes the elec-
trolyte acid content to increase, the charging current
will also increase.
CHARGING A VERY LOW OR COMPLETELY
DISCHARGED BATTERY ASSEMBLY
The following procedure should be used to recharge
a very low or completely discharged battery assembly.
Unless the procedure is properly followed, a per-
fectly good battery assembly may be needlessly replaced.
1. Measure voltage at battery assembly terminals with
an accurate voltmeter. If below 11 volts, the charge
current will be very low and it could take some time
before it accepts a current in excess of a few
milliamps. Such low current may be detectable on
ammeter available in the field.
2. Set battery charger on high setting.
3. Some chargers feature polarity protection circuitry
which prevents charging unless the battery charger
leads are connected to the battery terminals cor-
rectly. A completely discharged battery assembly
may not have enough voltage to activate this
circuitry even though battery charger leads are
connected properly, making it appear that the battery
assembly will not accept charging current. There-
fore, follow the specific charger manufacturer's
instructions telling how to bypass or override the
circuitry so that the charger will turn on and charge a
low-voltage battery assembly.
4. Battery chargers vary in the amount of voltage and
current they provide. The time required for the
battery assembly to accept measurable charger
current at various voltages may be as follows:
CHARGING VOLTAGE HOURS
16.0 or more Up to 4 Hours
14.0 - 15.9 Up to 8 Hours
13.9 or less Up to 16 Hours
If the charge current is still not measurable at the end
of the above charging times, the battery assembly
should be replaced.
If the charge current is measurable during the
charging time, the battery assembly is considered
good and charging should be completed in the
normal manner.
5. It is important to remember that a completely
discharged battery assembly must be recharged for a
sufficient number of ampere hours (AH) to restore it
to a usable state. As a general rule of thumb, using
the reserve capacity (RC) rating of the battery
assembly as the number of ampere hours of charge
will usually bring the green dot into view. For
reserve capacity refer to "Specifications" in this
section. If battery assembly is rated at 75 RC
minutes, it would usually be completely recharged
as follows:
601 ·8 BATTERY
10 ampere charge x 7 1/2 hours= 75 AH
or
25 ampere charge x 3 hours= 75 AH, etc.
6. It is. recommended that any battery assembly
recharged by this procedure be LOAD TESTED to
establish serviceability. Refer to "Battery Assembly
Testing" in this section.
JUMP STARTING IN CASE OF EMERGENCY
WITH AUXILIARY (BOOSTER) BATTERY
ASSEMBLY
NOTICE: Do not push or tow the vehicle to start.
Damage to the emission system and/or to other parts
of the vehicle may result.
Both auxiliary battery assembly and discharged
~attery assembly should be treated carefully when using
Jumper cables.
CAUTION: Departure from these con-
ditions or the procedure below could
result in: (1) serious personal injury
(particularly to eyes) or property
damage from such causes as battery
assembly explosion, battery assembly
acid, or electrical burns; and/or (2)
damage to electronic components of
either vehicle.
Never expose battery assembly to
open flame or electric spark - battery
assemblies generate a gas which is
flammable and explosive. Remove
rings, watches, and other jewelry. Wear
approved eye protection.
Do not allow battery assembly fluid to
contact eyes, skin, fabrics, or painted
surfaces - battery assembly fluid is a
corrosive acid. Flush any contacted
area with water immediately and thor-
oughly. Be careful that metal tools or
jumper cables do not contact the
battery assembly positive terminal (or
metal in contact with it) and any other
metal on the vehicle, because a short
circuit could occur.
1. Set parking brake lever assembly and place auto-
matic transmission assembly in "PARK." Turn off
the ignition, lamps and all other electrical loads.
2. Check the built-in hydrometer. If it is clear or light
yellow, replace the battery assembly.
NOTICE: Do not jump start a vehicle with charging
equipment unless the equipment is specifically
designed for jump starting. Using improper equip-
ment can cause serious damage to the electrical
system or electronic parts.
3. Attach the end of one jumper cable to the auxiliary
battery assembly positive terminal and the other end
of the same cable to the positive terminal of the
junction block assembly.
Do not permit vehicles to touch each other as this
could cause a ground connection and counteract the
benefits of this procedure.
CAUTION: To prevent sparking and
possibly explosion of battery g~ses, do
not connect jumper cable directly to the
battery negative terminal of the dead
battery assembly.
4. Attach one end of the remaining negative cable to
the auxiliary battery assembly negative terminal,
and the other end to a solid engine ground (such as
the compressor assembly bracket or power steering
pump bracket assembly) at least 46 cm (18 inches)
from the battery assembly of the vehicle being
started.
5. Start the engine of the vehicle that is providing the
jump start and turn off electrical accessories. Then
start the engine of the vehicle with the discharged
battery assembly.
6. Reverse these directions exactly when removing the
jumper cables. The negative cable must first be
disconnected from the engine that was jump started.
BATTERY TRAY ASSEMBLY REPLACEMENT
The battery tray is part of the coolant recovery
reservoir assembly. Refer to Section 6B for replacement.
BATTERY ASSEMBLY REPLACEMENT
Figure9
l++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in Section OA.
1. Negative cable assembly (2) from battery assembly
negative terminal.
2. Positive cable assembly (1) from battery assembly
positive terminal.
3. Battery hold-down retainer bolt/screw (5) and
battery hold-down retainer (9).
4. Battery assembly (3).
l++I Install or Connect
NOTICE: See "Notice" on page 601-l of this
section.
1. Battery assembly (3).
2. Battery hold-down retainer (9) and battery hold-
down retainer bolt/screw (5).
l~I Tighten
• Battery hold-down retainer bolt/screw (5) to
18 N•m (13 lb. ft.).
3. Positive cable assembly (1) to battery assembly
positive terminal.
l~I Tighten
• Positive cable assembly (1) to 15 N•m
(11 lb. ft.).

-
1 CABLE ASSEMBLY, BATTERY POSITIVE
2 CABLE ASSEMBLY, BATTERY NEGATIVE
3 BATTERY ASSEMBLY, STORAGE
5 BOLT/SCREW, BATTERY HOLD-DOWN RETAINER,
18 N•m (13 LB. FT.)
9 RETAINER, BATTERY HOLD-DOWN
23 TRAY ASSEMBLY, BATTERY
Figure 9 - Battery Assembly
4. Negative cable assembly (2) to battery assembly
negative terminal.
l~I Tighten
• Negative cable assembly (2) to 15 N•m
(11 lb. ft.).
BATTERY CABLE ASSEMBLY
REPLACEMENT AND ROUTING
Whenever battery cable assemblies are replaced,
always be certain to use a replacement battery c.a~le
assembly that is the same type and length. Some positive
cable assemblies have additional feed wires attached to
them and some negative cable assemblies have additional
ground straps attached.
Always be certain when replacing a battery cable
assembly to route it the same as the one being replaced.
Negative Cable Assembly
Figures 10 and 11
l++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in Section OA.
1. Battery assembly. Refer to "Battery Assembly
Replacement" in this section.
2. Nut (8) and negative cable assembly (2) from stud
(7) on wheelhouse assembly.
BATTERY 601·9
!VIEWA!
PCOOCM-8D1-F-RP
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. Using a standard screwdriver, pop open cable
assembly clip (16) and remove negative cable
assembly (2).
5. Negative cable assembly (2) from engine block.
• On 3.4L L32 engines, negative cable assembly
(2) is connected to engine block by a stud
threaded into engine block just behind crank-
shaft pulley assembly. Remove nut (10) and
then remove negative cable assembly (2).
• On 5.7L LTl engines, negative cable assembly
(2) is connected to the engine block by either
a stud (13) or nut (10) just behind the air
conditioning compressor assembly. Remove
stud (13) or nut (10) and negative cable assem-
bly (2).
l++I Install or Connect
NOTICE: See "Notice" on page 601-1 of this
section
1. Negative cable assembly (2) to engine block.
• On 3.4L L32 engines; connect negative cable
assembly (2) and nut (10) to engine block stud
just behind crankshaft pulley.
• On 5.7L LTl engines, connect negative cable
assembly (2) and either stud (13) or nut (10) to
engine block just behind air conditioning
compressor assembly.
601·10 BAnERY
l~I Tighten
• Nut (10) to 22 N•m (16 lb. ft.).
or
• Stud (13) to 33 N•m (24 lb. ft.).
2. Place negative cable assembly (2) back into cable
assembly clip (16) and snap clip closed.
3. Lower vehicle.
4. Negative cable assembly (2) and nut (8) to stud (7)
on wheelhouse assembly.
l~I Tighten
• Nut (8) to 5.5 N•m (49 lb. in.).
5. Battery assembly. Refer to "Battery Assembly
Replacement" in this section.
Positive Cable Assembly
Figures 10 and 11
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in Section OA.
l++I Remove or Disconnect
1. Battery assembly. Refer to "Battery Assembly
Replacement" in this section.
2. Positive cable assembly ( 1) from junction block.
A. Open junction block cover (4).
B. Remove nut (6) from stud (14).
C. Remove positive cable assembly ( 1) from stud
(14).
3. Positive cable assembly ( 1) from generator assem-
bly (21).
A. Move boot covering connection and slide out
of way.
B. Remove positive cable assembly (1).
• On 3.4L L32 engines, positive cable
assembly (1) is connected to generator
assembly (21) with nut (18). Remove nut
(18) and positive cable assembly (1).
• On 5.7L LTl engines, positive cable
assembly (1) is connected to generator
assembly (21) with bolt/screw (20).
Remove bolt/screw (20) and positive
cable assembly (1 ).
4. Raise and suitably support vehicle. Refer to SEC-
TION OA.
5. Using a standard screwdriver, pop open cable
assembly clip (16) and remove positive cable
assembly (1 ).
6. Bolt/screw ( 11) securing positive cable assembly ( 1)
and clip (17) to engine mount bracket.
7. Nut (12) and positive cable assembly (1) from starter
solenoid switch ( 19).
NOTICE: Before installing positive cable assembly
to starter solenoid switch, be sure solenoid terminal
is secure in cap by tightening terminal nut next to
cap. If terminal is not tight in solenoid cap, the cap
may be damaged during installation of positive
cable assembly and cause starter to fail later.
l++I Install or Connect
NOTICE: See "Notice" on page 601-1 of this
section.
1. Positive cable assembly (1) and nut (12) to starter
solenoid switch (19).
l~I Tighten
• Nut (12) to 9.5 N•m (84 lb. in.).
2. Bolt/screw ( 11) and clip ( 17) securing positive cable
assembly to engine mount bracket.
l~I Tighten
• Bolt/screw (11) to 10 N•m (89 lb. in.).
3. Place positive cable assembly (1) back into cable
assembly clip (16) and snap clip (16) closed.
4. Lower vehicle.
5. Positive cable assembly (1) to generator assembly
(21).
• On 3.4L L32 engines, positive cable assembly
(1) is connected to the generator assembly (21)
with nut (18).
l~I Tighten
• Nut (18) to 10 N•m (89 lb. in.).
• On 5.7L LTl engines, positive cable assembly
(1) is connected to generator assembly (21)
with bolt/screw (20).
l~I Tighten
• Bolt/screw (20) to 15 N•m (11 lb. ft.).
6. Carefully slide boot over positive cable assembly ( 1)
and generator assembly (21) connection.
7. Positive cable assembly (1) to junction block.
A. Place positive cable assembly (1) and nut (6)
on stud (14).
l~I Tighten
• Nut (6) to 2.0 N•m (18 lb. in.).
B. Close junction block cover (4).
8. Battery assembly. Refer to "Battery Assembly
Replacement" in this section.
• Route positive cable assembly between heater
hoses as shown in Figure 11.
GROUND STRAPS
. Additional ground straps are used to connect the
body and frame to the engine and transmission. Always
connect all ground straps to ensure a good ground path to
the battery assembly from all electrical components
CHARGING EQUIPMENT
A battery charger that is considered sufficient is
usually capable of a 16-volt output. When choosing
 BATTERY 601·11

A 3.4L L32 ENGINE A

B 5.7L LT1 ENGINE
C BLOCK, ENGINE
1 CABLE ASSEMBLY, BATTERY POSITIVE
2 CABLE ASSEMBLY, BATTERY NEGATIVE
3 BATTERY ASSEMBLY, STORAGE
4 COVER, JUNCTION BLOCK
6 NUT, BATTERY POSITIVE CABLE-TO-JUNCTION
BLOCK, 2.0 N•m (18 LB. IN.)
7 STUD, GROUND
8 NUT, BATTERY NEGATIVE CABLE GROUND,
5.5 N•m (49 LB. IN.)
10 NUT, BATTERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND, 22 N•m (16 LB. FT.)
11 BOLT/SCREW, BATTERY POSITIVE AND NEGATIVE
CABLE ASSEMBLY CLIP, 10 N•m (89 LB. IN.)
12 NUT, BATTERY POSITIVE CABLE, 9.5 N•m (84 LB. IN.)
13 STUD, BATTERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND, 33 N•m (24 LB. FT.)
14 STUD, JUNCTION BLOCK POSITIVE TERMINAL B
15 MOTORASSEMBLY,STARTER
16 CLIP, CABLE ASSEMBLY
17 CLIP, CABLE ASSEMBLY
19 SWITCH, STARTER SOLENOID
PC0005-6D1·F·RP

Figure 1O- Battery Cable Assemblies Routing (1 of 2)

601 •12 BATIE RY

15
A B

A 3.4L L32 ENGINE

B 5.7L LT1 ENGINE B
1 CABLE ASSEMBLY, BATIERY POSITIVE
3 BATIERY ASSEMBLY, STORAGE
11 BOLT/SCREW, BATIERY POSITIVE AND NEGATIVE
CABLE ASSEMBLY CLIP,.10 N•m (89 LB. IN.)
12 NUT, BATIERY POSITIVE CABLE, 9.5 N•m (84 LB. IN.)
15 MOTOR ASSEMBLY, STARTER
16 CLIP, CABLE ASSEMBLY
17 CLIP, CABLE ASSEMBLY
18 NUT, ENGINE WIRING HARNESS GENERATOR LEAD,
10 N•m (89 LB. IN.)
20 BOLT/SCREW, ENGINE WIRING HARNESS GENERATOR
LEAD, 15 N•m (11 LB. FT.)
21 GENERATOR ASSEMBLY
22 HOSE ASSEMBLY, HEATER INLET/OUTLET
PC0006·6D1·F·RP

Figure 11 - Battery Cable Assemblies Routing (2 of 2)

 BATTERY 6D1·13

a charger, the following items should be considered 4. An automatic polarity protector.

essential:
1. A 16-volt minimum output.
2. To prevent overcharging, the unit should have a
timer ( l to 2 hours) or a voltage regulator that would
regulate a maximum of 18 volts, or have an auto-
matic shut-off feature at full charge.
3. Ammeter or charging rate meter.
Some equipment that is available includes the AC
Delco MP2101-07, Associated No. 6001, the Sun 720, or
equivalent. Very few chargers have sensitive low-voltage
meters, therefore, separate voltmeters may be necessary.
A suitable load tester such as the Sun VAT-40 (or
equivalent) is available and is a very useful tool to
properly diagnose battery assembly problems.

SPECIFICATIONS
BATTERY ASSEMBLY USAGE

STORAGE BATTERY ASSEMBLY USAGE CHART

TEST COLD RESERVE

LOAD CRANKING CAPACITY REPLACEMENT
CATALOG NUMBER AMPS AMPS* MINUTES** NUMBER

514 (Std. LT1, L32) 260 525 90 75-60

*Cold Cranking= Amperage available for 30 seconds of engine cranking at -18°C (0°F).
**Reserve Capacity = The approximate time in minutes a storage battery assembly can support a 25 amp load
without the terminal voltage dropping below 10.5 volts at 27°C (80°F) in the event of a charging system failure.

PC0007·6D1·F·RP

FASTENER TIGHTENING SPECIFICATIONS

Battery Hold-Down Retainer Bolt/Screw ................................. 18 N•m (13 lb. ft.)
Battery Negative Cable Assembly-to-Battery Assembly ..................... 15 N•m (11 lb. ft.)
Battery Negative Cable Ground Body-to-Nut ............................ 5.5 N•m (49 lb. in.)
Battery Negative Cable-to-Engine Block Nut ............................. 22 N•m (16 lb. ft.)
Battery Negative Cable-to-Engine Block Stud ............................. 33 N•m (24 lb. ft.)
Battery Positive and Negative Cable Retainer Bolt/Screw .................... 10 N•m (89 lb. in.)
Battery Positive Cable Assembly-to-Battery Assembly ...................... 15 N•m (11 lb. ft.)
Battery Positive Cable-to-Generator Bolt/Screw ........................... 15 N•m (11 lb. ft.)
Battery Positive Cable-to-Generator Nut ................................. 10 N•m (89 lb. in.)
Battery Positive Cable-to-Junction Block Nut ............................ 2.0 N•m (18 lb. in.)
Battery Positive Cable-to-Starter Solenoid Switch Nut ..................... 9.5 N•m (84 lb. in.)
601·14 BATIERV

SPECIAL TOOLS

J 38758
1.

2. • ST-1201

1. PARASITIC DRAW TEST SWITCH

2. BATIERY SIDE TERMINAL ADAPTERS (PAIR)

PC0010-6D1·f·RP
 CRANKING SYSTEM 602-1

SECTION 602

CRANKING SYSTEM
CAUTION: This ve. hicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around srR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" exposed electrical terminals, disconnect the battery
negative cable assembly to help prevent personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the ignition switch must be in the "OFF" or
"LOCK" position.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 602-1
Cranking Circuit . . . . . . . . . . . . . . . . . . . . . . . 602-1
.Starte~ Motor Assembly . . . . . . . . . . . . . . . . . . 602-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602-1
On-Vehicle Service ....................... 602-2
Lubrication ............................ 602-2
Starter Motor Assembly Replacement ....... 602-2
Unit Repair .............................. 602-5
Starter Solenoid Switch Replacement ....... 602-5
No-Load Test .......................... 602-7
PG-250 Starter Motor Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 602-9
SD210 Starter Motor Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 602-10
Cleaning, Inspection and Testing (PG-250 and
SD210 Starter Motor Assemblies) ....... 602-10
Checking Pinion Clearance (PG-250 and
SD210 Starter Motor Assemblies) ....... 602-12
PG-250 Starter Motor Assembly .......... 602-13
SD210 Starter Motor Assembly ........... 602-14
Specifications ........................... 602-15
Starter Motor Assembly Usage Chart ...... 602-15
Fastener Tightening Specifications . . . . . . . . 602-16
General Specifications . . . . . . . . . . . . . . . . . . 602-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 602-16

GENERAL DESCRIPTION
CRANKING CIRCUIT
The cranking circuit consists of the battery assem-
bly, starter motor assembly, ignition switch, control cir-
cuits, starter enable relay and related electrical wiring;
these components are connected electrically. Refer to
SECTION 8A for a complete electromechanical
schematic.
STARTER MOTOR ASSEMBLY
Figure 1
When the ignition switch is moved to the start posi-
tion, battery voltage is applied to the PASS-Key II®
decoder module and resistance is read at this time. If
proper resistance is recognized and vehicle is in "PARK"
or "NEUTRAL," then the PASS-Key II® decoder module
will energize the starter enable relay. The starter enable
relay will send battery voltage to the starter solenoid
switch. The starter solenoid switch will move the starter
shift lever, causing the starter drive pinion to engage the
flywheel ring gear. After engagement, the starter solenoid
switch will close the main contacts, which results in
cranking of the engine. When the engine starts, pinion
overrun protects the armature from excessive speed until
the switch is opened, at which time the solenoid switch
plunger spring causes the pinion to disengage. To prevent
excessive overrun, the ignition switch should be opened
immediately when the engine starts.
DIAGNOSIS
Before removing any unit in a cranking circuit for
repair, perform the diagnostic procedures recommended
in Figures 2, 3 and 4, and in SECTION 8A. Then check
the following items:
602·2 CRANKING SYSTEM

12

1 CONTACT, STARTER SOLENOID SWITCH

6
2 PLUNGER, ST ARTER SOLENOID SWITCH
3 SWITCH, ST ARTER SOLENOID
4 SPRING, STARTER SOLENOID SWITCH PLUNGER
5 LEVER, STARTER SHIFT
6 BUSHING, STARTER DRIVE
7 COLLAR, ST ARTER DRIVE STOP
8 DRIVE, STARTER
9 COIL, STARTER FIELD
10 ARMATURE, ST ARTER
11 BRUSH, STARTER
12 TERMINAL, STARTER SOLENOID

10 9

Figure 1 - Starter Motor Assembly (Typical)

Battery Assembly: Determine condition of bat-
tery assembly. Follow testing procedure outlined in SEC-
TION 601.
Wiring: Inspect wiring for damage. Inspect all con-
nections to starter motor assembly, solenoid switch, igni-
tion switch, and battery assembly, including all ground
connections. Clean and tighten all connections as
required.
Ignition Switch and Control Circuits: Inspect
all switches and relays to determine condition.
Cranking or Slow Cranking: If engine assembly
does not crank, or cranks slowly, follow diagnostic proce-
dure in Figures 2, 3 and 4, and in SECTION 8A. If faulty
starter motor assembly is diagnosed, remove starter motor
assembly and follow test procedures.
Starter Motor Assembly Noise: Correct starter
motor assembly noise using the following procedure:
1. Refer to Figure 4 to determine problem.
l++I Remove or Disconnect
2. Shims are not installed during vehicle assembly.
However if complaint is similar to problem 1 or 2 in
Figure 4, correct "shimming" as follows:
• For starter motor assembly noise during crank-
ing, add one 0.38 mm (0.015 inch) single shim
(13 or 18) to outer bolt/screw only. Refer to
Figure 5.
• For high-pitched whine after engine assembly
fires, add 0.38 mm (0.015 inch) double shims
(14 or 19) until noise disappears. Number of
shims should not exceed 1.14 mm (0.045 inch).
Starter Motor Assembly: General diagnosis is
part of starter motor assembly testing procedure. If battery
assembly, wiring and switches are in satisfactory condi-
tion, engine assembly is functioning properly, and prob-
lem has been traced to starter motor assembly, remove
starter motor assembly (refer to "Starter Motor Assembly
Replacement" in this section) and proceed to "Unit
Repair" in this section.
NOTICE: Never operate the starter motor assembly
more than 30 seconds at a time without pausing to
allow it to cool for at least two minutes. Overheat-
ing, caused by excessive cranking, will seriously
damage the starter motor assembly.
ON-VEHICLE SERVICE
LUBRICATION
Starter motor assemblies do not require lubrication
except during overhaul. When the starter motor assembly
is taken apart for any reason, lubricate only as described
under "PG-250 Starter Motor Assembly" or "SD210
Starter Motor Assembly" in this section.
STARTER MOTOR ASSEMBLY
REPLACEMENT
Figures 5 and 6
rn Important
• This vehicle was designed for starter mounting
without shims. However if single shims (13 or
18) or double shims (14 or 19) have been
added to correct a noise or engagement condi-
tion, they should be reinstalled in their original
location to ensure proper pinion-to-flywheel
assembly engagement. Refer to Figure 6.
CAUTION: See "Caution" on page
602-1 of this section.
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Exhaust crossover pipe at the manifolds. Refer to
SECTION 6F.
4. Two starter mounting bolts/screws ( 16 and 17 or 21)
and lower starter motor assembly (15 or 20).
 CRANKING SYSTEM 602·3

NO CRANKING, NO SOUND FROM SOLENOID

I TURN HEADLAMPS AND DOME LAMP ON.

I LAMPS DIM OR GO OUT.
I CHECK BATTERY STATE-OF-CHARGE.
TURN KEY TO "START."
I
I I LAMPS STAY BRIGHT.
I
I I TURN ON RADIO AND HEATER.
I
I

EYE DARK GREEN EYE SHOWING I OPERATE OK I looN'TOPERATE I

CHARGE BATTERY CHECK CRANKING CHECK CONNECTIONS CHECK BULKHEAD CON-
ASSEMBLY. ANDVOLTAGEAT NECTOR, FUSIBLE LINK
VOLTAGE AT
CHECK FOR DRAIN SOLENOID "S" TERM. AND IGNITION SWITCH
AND CHECK BATTERY POSTS.
CONNECTIONS.
GENERATOR ASSEMBLY.
I I I

I
LESS THAN 9.6.VOLTS 9.6 VOLTS OR MORE

CHECK VOLTAGE FROM

LESS THAN 7 VOLTS
I 7VOLTS
OR MORE
. I
TEST BATTERY

I
ENGINE BLOCK ASSEMBLY REPAIR STARTER
ASSEMBLY. TO BATTERY NEGATIVE POST. KEY IN MOTOR ASS EMBLY.
IF OK, REPAIR STARTER "START" POSITION. (POSITIVE LEAD
MOTOR ASSEMBLY. ON ENGINE BLOCK ASSEMBLY).
I WITH KEY IN "START"' CHECK VOLTAGE AT
IGNITION SWITCH SOLENOID TERMINAL.
I
o: 5 VOLT OR MORE LESS THAN 0. 5 VOLT
I
CLEAN AND TIGHTEN CHECK CRANKING I 7 VOLTS OR MORE I I LESS THAN 7 VOLTS I
GROUND CABLE
CONNECTION AND/OR
REPLACE CABLE ASSEMBLY.
VOLT AGE AT ST ARTER
"B" TERMINAL. I REPAIR WIRE FROM
IGNITION SWITCH.
I REPLACE IGNITION
SWITCH.
I
I
LESS THAN 9 VOLTS 9 VOLTS OR MORE

CLEAN AND TIGHTEN CHECK FUSIBLE LINK

BATTERY POSITIVE AND BULKHEAD
CABLE TERMINALS CONNECTOR.
AND/OR REPLACE
CABLE ASSEMBLY.

PC0002-6D2-B-RP

Figure 2 - Electrical System General Diagnosis (1 of 2)

602·4 CRANKING SYSTEM

SLOW CRANKING. SOLENOID CLICKS OR CHATTERS

CHECK: BATTERY ASSEMBLY FOR GREEN INDICATOR.

VISUAL CONDITION OF BATTERY CABLE ASSEMBLIES AND
CONNECTIONS.
IF BATTERY ASSEMBLY NEEDS CHARGING, MAKE GENERATOR AND
BATTERY DRAIN CHECK, CHARGE BATTERY ASS EMBLY AND CHECK
CRANKING. IF PROBLEM HAS NOT BEEN FOUND, DO THE FOLLOWING:

I
REMOVE BATTERY LEAD FROM DISTRIBUTOR OR IGNITION MODULE.
MAKE ALL VOLTMETER READINGS WITH KEY IN "START" POSITION.

I
MEASURE CRANKING VOLTAGE AT BATTERY TERMINAL POSTS.

I
I
I 9.6 VOLTS OR MORE.
I LESS THAN 9.6 VOLTS.

I
MEASURE VOLTAGE FROM BATTERY
NEGATIVE TERMINAL TO ENGINE CHARGE AND LOAD TEST
BLOCK ASSEMBLY. (POSITIVE LEAD BATTERY ASSEMBLY.
ON ENGINE BLOCK ASSEMBLY.)

I
I I I
0.5 VOLT OR MORE. LESS THAN 0.5 VOLT. OK FAULTY
-
I I I
REPAIR GROUND MEASURE VOLTAGE REPAIR
REPLACE
CABLE AND AT SOLENOID "B" STARTER
BATTERY
CONNECTIONS. TERMINAL, CLEAN MOTOR
ASSEMBLY.
AND TIGHTEN ASSEMBLY.
CONNECTIONS
AT STARTER
MOTOR ASSEMBLY.
I
I I
9 VOLTS OR MORE. LESS THAN 9 VOL TS.

I I
REPAIR STARTER CLEAN AND TIGHTEN POSITIVE CABLE CONNECTIONS
MOTOR ASSEMBLY. IF OK, REPLACE CABLE.

THIS PROCEDURE IS DESIGNED FOR USE ON

ENGINE AND BATTERY ASSEMBLIES
AT ROOM OR NORMAL OPERATING TEMPERATURES.
IT ALSO ASSUMES THERE ARE NO ENGINE ASSEMBLY
DEFECTS WHICH WOULD CAUSE CRANKING PROBLEMS.
TO USE IT UNDER OTHER CONDITIONS MIGHT RESULT
IN AN IMPROPER DIAGNOSIS.

PC0003-602-B-RP

Figure 3 - Electrical System General Diagnosis (2 of 2)


PROBLEM
1. HIGH PITCHED WHINE DURING CRANKING
(BEFORE ENGINE FIRES) BUT ENGINE CRANKS
AND FIRES OK.
2. HIGH PITCHED "WHINE" AFTER ENGINE
FIRES, AS IGNITION KEY IS BEING
RELEASED. ENGINE CRANKS AND FIRES OK.
THIS INTERMITTENT COMPLAINT IS OFTEN
DIAGNOSED AS "STARTER HANG-IN" OR
"SOLENOID WEAK."
3. A LOUD "WHOOP" AFTER THE ENGINE
FIRES BUT WHILE THE STARTER DRIVE
PINION IS STILL HELD ENGAGED. SOUNDS
LIKE A SIREN IF THE ENGINE IS REVVED
WHILE STARTER DRIVE PINION IS
ENGAGED.
4. A "RUMBLE," "GROWL" OR (IN SEVERE
CASES) A "KNOCK" AS THE STARTER
MOTOR ASS EMBLY IS COASTING DOWN TO
A STOP AFTER STARTING THE ENGINE.
Figure 4 - Starter Motor Assembly Noise Diagnosis
5. Electrical leads from starter motor assembly
(15 or 20).
• Note position of wires before disconnecting.
6. Starter motor assembly (15 or 20).
l++I Install or Connect
NOTICE: See "Notice" on page 602-1 of this
section.
NOTICE: Before attaching electrical leads, tighten
inner nuts on the solenoid terminals. If the nuts are
not tight, solenoid cap may be damaged during
installation of leads. Tighten inner nut of ''.BAT"
terminal to 9 N•m (80 lb. in.) on both PG-250 and
SD210 starter motor assemblies.
1. Electrical leads to starter motor assembly ( 15 or 20).
l~I Tighten
• Starter solenoid switch "BAT" terminal outer
nut to 9 N•m (80 lb. in.).
• Starter solenoid switch "S" terminal nut to
2.5 N•m (22 lb. in.).
2. Starter motor assembly (15 or 20) to engine
assembly.
3. Bolts/screws (16 and 17 or 21).
l~I Tighten
• Bolts/screws (16 and 17 or 21) to 47 N•m
(35 lb. ft.).
l@I Measure
• Pinion-to-flywheel clearance (see Figure 6).
Add shims (13 and 14 or 18 and 19) if
necessary.
CRANKING SYSTEM 602·5
CAUSE
DISTANCE TOO GREAT BETWEEN STARTER DRIVE
PINION AND FLYWHEEL ASSEMBLY.
DISTANCE TOO SMALL BETWEEN STARTER DRIVE
PINION AND FLYWHEEL ASSEMBLY. FLYWHEEL
ASSEMBLY RUNOUT CONTRIBUTES TO THE
INTERMITTENT NATURE.
A NEW STARTER DRIVE ASSEMBLY WILL OFTEN
CORRECT THIS PROBLEM.
MOST PROBABLE CAUSE IS A BENT OR
UNBALANCED STARTER ARMATURE. A NEW
STARTER ARMATURE WILL OFTEN CORRECT THIS
PROBLEM.
PC6004-6D2·D-RP
4. Exhaust crossover pipe to the manifolds. Refer to
SECTION 6F.
5. Lower vehicle.
6. Battery negative cable assembly.
l~I Tighten
• Battery negative cable assembly to 15 N•m
(11 lb. ft.).
UNIT REPAIR
STARTER SOLENOID SWITCH
REPLACEMENT
5.7L LT1 Engine
Figure 7
When a "no crank and no sound" starter motor
assembly condition exists, check solenoid switch (23)
before disassembling starter motor assembly. Solenoid
switch (23) can be checked without removal. Refer to
"Cleaning, Inspection and Testing" in this section. Sole-
noid switch (23) must be replaced with drive housing
(36). For removal and installation procedures, refer to
"PG-250 Starter Motor Assembly Disassembly" and
"PG-250 Starter Motor Assembly" in this section.
3.4L L32 Engine
Figures
l++I Remove or Disconnect
1. Starter solenoid switch nut (61).
2 Field lead from solenoid switch "M" terminal.
3. Nuts (62) and solenoid switch heat shield (71).
4. Starter solenoid switch clamp bolts/screws (63) and
clamp (66).
5. Starter solenoid switch (56).
602-6 CRANKING SYSTEM

13

1 17
A

18

B
13
14
15
A 5.7L LT1 ENGINE
3.4L L32 ENGINE
SHIM, STARTER MOTOR SINGLE
SHIM, STARTER MOTOR DOUBLE
MOTOR ASSEMBLY, STARTER
1/
16 BOLT/SCREW, STARTER MOTOR, 47 N•m (35 LB. FT.)
17 BOLT/SCREW, STARTER MOTOR, 47 N•m (35 LB. FT.)
18 SHIM, STARTER MOTOR SINGLE
19 SHIM, STARTER MOTOR DOUBLE
20 MOTOR ASSEMBLY, STARTER 21
21 BOLT/SCREW, STARTER MOTOR, 47 N•m (35 LB. FT.)
PC0005-6D2·f·RP

Figure 5 - Mounting Starter Motor Assembly

l++I Install or Connect

NOTICE: See "Notice" on page 6D2-1 of this
section.
1. Starter solenoid switch (56).
84
2. Clamp (66) and starter solenoid switch clamp
bolts/screws (63).
85
l~.J Tighten
• Starter solenoid switch clamp bolts/screws
(63) to 11 N•m (97 lb. in.).
A INSERT 0.5 mm (0.20") WIRE
GAGE HERE TO CHECK 3. Solenoid switch heat shield (71) and nuts (62).
84 FLYWHEEL ASSEMBLY
85 PINION, STARTER DRIVE
l~I Tighten
PC0006-6D2·B-RP
• Nuts (62) to 8 N•m (71 lb. in.).
Figure 6 - Flywheel Assembly-to-Pinion Clearance
 CRANKING SYSTEM 602-7

23

28 31
Bl
~~;;,
24

I ---~---------_1---~---~·-,:.1 ---------
40 37
41 I
I

42
~
..--A' ""~----ll'HI
...._ _ __,_),.,,.,]Jl)-- - --
J
38 39

A SHAFT 33 COLLAR, STARTER DRIVE STOP

B CLUTCH, STARTER DRIVE 34 RETAINER, STARTER DRIVE STOP COLLAR
C DRIVE AND SHAFT ASSEMBLY, STARTER 35 COLLAR, STARTER DRIVE THRUST
23 SWITCH, STARTER SOLENOID 36 HOUSING, STARTER DRIVE
24 DRIVE ASSEMBLY, STARTER 37 FRAME AND FIELD
25 BEARING, STARTER DRIVE SHAFT DRIVE END 38 HOLDER ASSEMBLY, BRUSH
26 ARMATURE, STARTER 39 SPRING, BRUSH
27 BEARING, COMMUTATOR END BALL 40 FRAME, STARTER COMMUTATOR END
28 SHIELD, PLANETARY GEARS 41 BOLT/SCREW, BRUSH HOLDER ATTACHMENT, 6.5 N•m
29 SHAFT AND GEAR ASSEMBLY (58 LB. IN.)
30 BUSHING 42 THROUGH-BOLT/SCREW, STARTER, 8.5 N•m (75 LB. IN.)
31 GEAR, INTERNAL TOOTH 43 PIN, SHIFT COLLAR
32 NUT, STARTER SOLENOID SWITCH OUTER, 8 N•m ' 44 TUBE, DRAIN
(71 LB. IN.) -
PCOOOHID2-F-RP

Figure 7 - PG-250 Starter Motor Assembly Disassembled View

NOTICE: Before attaching field lead, tighten inner
nut on the solenoid switch "M" terminal. If inner
nut is not tight, solenoid cap may be damaged during
installation of outer nut. Tighten inner nut on the
solenoid switch "M" terminal to 9 N•m (80 lb. in.).
4. Field lead to solenoid switch "M" terminal.
5. Starter solenoid switch outer nut (61).
l~I Tighten
• Starter solenoid switch outer nut (61) to
10 N•m (89 lb. in.).
NO-LOAD TEST
Figure9
With carbon pile "OFF," make connections as
shown in Figure 9. Close the switch, adjust carbon pile to
obtain 10 volts, and compare the RPM, current and volt-
age readings with "Specifications" listed at the end of
this section.
Make disconnections only with the switch open.
Use the test results as follows:
1. Rated current draw and no-load speed indicates nor-
mal starter motor assembly condition.
2. Low free speed and high current draw indicates:
• Too much friction. This can be caused by tight,
dirty or worn bearings, or bent armature shaft
allowing armature to drag.
• Shorted armature. This can be further checked
on growler after disassembly.
• Grounded armature or fields. Check further
after disassembly.
3. Failure to operate with high current draw indicates:
• Direct ground in terminal or fields.
• "Frozen" bearings (this should have been
determined by hand turning armature).
4. Failure to operate with no current draw indicates:
• Open field circuit. After disassembly inspect
internal connections and tracing circuit with
test lamp.
602·8 CRANKING SYSTEM

54
51

49 FRAME, STARTER COMMUTATOR END

50 BEARING, STARTER ARMATURE COMMUTATOR END
51 FRAME KIT, STARTER WITH FIELD
52 ARMATURE, STARTER
53 DRIVE ASSEMBLY, STARTER
54 HOUSING, STARTER DRIVE
55 BEARING, STARTER DRIVE SHAFT DRIVE END
56 SWITCH, STARTER SOLENOID
57 LEVER, STARTER SHIFT
58 COLLAR, STARTER DRIVE STOP
59 RETAINER, STARTER DRIVE STOP COLLAR
60 COLLAR, STARTER DRIVE THRUST
61 NUT, STARTER SOLENOID SWITCH OUTER,
10 N•m (89 LB. IN.)
62 NUT, STARTER MOTOR ASSEMBLY HEAT SHEILD,
8 N•m (71 LB. IN.)
63 BOLT/SCREW, STARTER SOLENOID SWITCH CLAMP,
11 N•m (97 LB. IN.)
64 WASHER, STARTER ARMATURE BRAKE COMMUTATOR
END
65 BOLT/SCREW, COMMUTATOR END FRAME,
8.5 N•m (75 LB. IN.)
66 CLAMP, STARTER SOLENOID SWITCH
67 PLUG, STARTER SHIFT LEVER RETAINER
68 PLUNGER, STARTER SOLENOID SWITCH
69 RETAINER, STARTER SHIFT LEVER
70 SHIELD, STARTER DRIVE HOUSING
71 SHIELD, STARTER MOTOR ASSEMBLY HEAT
72 SPRING, STARTER SOLENOID SWITCH PLUNGER
73 TUBE, STARTER DRAIN

PCOOOS-602-F-RP

Figure 8 - SD210 Starter Motor Assembly Disassembled View


22
A---.--'
E --.~---1
A CARBON PILE
B AMMETER
C VOLTMETER
D SWITCH
E RPM INDICATOR
15 MOTOR ASSEMBLY, STARTER {PG-250)
20 MOTOR ASSEMBLY, STARTER {SD210)
22 BATTERY ASSEMBLY, STORAGE
23 SWITCH, STARTER SOLENOID {PG250)
56 SWITCH, STARTER SOLENOID {SD210)
Figure 9 - No-Load Test
• Open armature coils. Inspect commutator for
badly burned bars after disassembly.
• Broken brush springs, worn brushes, high
insulation between commutator bars or other
causes which would prevent good contact
between brushes and commutator.
5. Low no-load speed and low current draw indicates:
• High internal resistance due to poor connec-
tions, defective leads, dirty commutator and
causes listed above under number 4.
6. High free speed and high current draw usually indi-
cate shorted fields. If shorted fields are suspected,
replace field coil assembly. Also check for shorted
armature, using growler.
PG-250 STARTER MOTOR ASSEMBLY
DISASSEMBLY
Figures 7 and 10
Tool Required:
J 28509-A Counter Gear Bearing Remover
Ii) Disassemble
1. Field lead from solenoid switch terminal by remov-
ing nut (32).
2. Through-bolts/screws (42).
3. Bolts/screws (41) and end frame (40) from starter
motor assembly. Brush holder assembly (38) and
bearing (27) remain on armature (26).
CRANKING SYSTEM 602-9
B c
23
D
OR
56
15
OR
20
PC0009-6D2·F-RP
CAUTION: Magnets in frame and field
have strong attraction to armature.
Keep fingers clear of pinch points to
avoid personal injury.
4. Armature (26) from frame and field (37).
5. Frame and field (37) and shield (28) from housing
(36).
6. Bearing (27) from armature (26), using J 28509.
A. Bearing (27) is press-fit over shaft.
NOTICE: Before removing brush holder assembly,
lift each brush spring and rest against side of brush;
this prevents brush damage or contamination when
brush holder assembly is pulled off of commutator.
7. Brush holder assembly (38) from armature (26).
8. Slightly separate shaft and gear assembly (29) and
drive assembly (24) from housing (36) and use a
screwdriver to pry plastic shift lever off of pins (43).
9. Shaft and gear assembly (29) and drive assembly
(24) from housing (36).
10. Collar (35) from shaft.
11. Slide deep socket over shaft and tap socket to drive
collar (33) off of retainer (34).
12. Retainer (34), collar (33) and drive assembly (24)
from shaft.
13. Gear (31) and bushing (30) from shaft and gear
assembly (29). Bushing (30) is press-fit into gear
(31), and should only be removed if damaged.
602-10 CRANKING SYSTEM
CLEANING, INSPECTION AND TESTING
(PG-250 AND SD210 STARTER MOTOR
ASSEMBLIES)
Figures 7 through 14
26 ARMATURE, STARTER
27 BEARING, COMMUTATOR END BALL
38 HOLDER ASSEMBLY, BRUSH
PC001o-&D2·f.RP
Figure 1O - Removing Commutator End Ball Bearing
SD210 STARTER MOTOR ASSEMBLY
DISASSEMBLY
Figure 8
1±1 Disassemble
1. Nuts (62) and heat shield (71), if equipped, from
clamp bolts/screws (63).
2. Nut (61) and field lead from solenoid switch (56).
3. Clamp bolts/screws (63) and solenoid switch (56)
with clamp (66) from drive housing (54).
4. Bolts/screws (65) from starter motor assembly.
5. Commutator end frame (49), brake washer (64), and
frame kit (51) from armature (52) and drive housing
(54).
6. Plug (67) from drive housing (54).
7. Armature (52) with drive assembly (53), shift lever
(57), plunger (68), and return spring (72) from drive
housing (54).
8. Return spring (72) from plunger (68).
9. Plunger (68) from shift lever (57).
10. Shift lever (57) from drive housing (54) by spread-
ing lever arms slightly to disengage.
11. Thrust collar (60) from armature shaft.
12. Retainer (59) by pushing pinion stop collar (58) off
of retainer (59) and sliding it off of armature shaft.
• Discard retainer (59).
13. Pinion stop collar (58) and drive assembly (53) from
armature shaft.
NOTICE: Do not use grease dissolving solvents for
cleaning the overrunning clutch or armature. Sol-
vents dissolve the grease packed in the clutch and
damage armature and field coil insulation.
1. Clean all starter motor assembly parts. Wipe parts
with a clean shop cloth.
2. Test drive assembly (24 or 53) action. Pinion should
turn freely in overrunning direction. Check pinion
teeth for chipping, cracking or excessive wear.
Replace drive assembly (24 or 53) if necessary.
Badly chipped pinion teeth may indicate chipped
teeth on ring gear; replace if necessary.
3. On SD210 starter motor assembly, check drive
assembly (53) for slipping by leaving drive assem-
bly (53) attached to armature (52). Wrap armature
(52) with shop towel and clamp in vice. Using
12-point deep socket and torque wrench, put socket
on pinion and turn counterclockwise. Drive should
not slip up to 68 N•m (50 lb. ft.) of torque. If it does,
replace drive assembly (53).
4. Starter drive assembly (24 or 53) requires no
lubrication; however, drive assembly (24 or 53)
should be wiped clean.
5. Inspect armature commutator. If commutator is
dirty, clean with 400 grit polishing cloth. If commu-
tator is rough, replace armature (26 or 52). Do not
undercut or turn commutators. Inspect points where
armature conductors join commutator bars to make
sure they have good connection. Burned commuta~
tor bar is usually evidence of poor connection.
6. Inspect brushes and brush holder assemblies. When
brushes appear excessively worn when compared to
new brushes they should be replaced. Make sure
brush holder assemblies are clean and brushes are
not binding in brush holder assemblies. Full brush
surface should ride on commutator to give proper
performance.
• Check to ensure that brush springs are giving
firm contact between brushes and commutor.
When brush springs are distorted or discol-
ored, they should be replaced.
- On PG-250 starter motor assembly, brush
holder (38) and springs (39) are available
as separate items.
- On SD210 starter motor assembly, all
brush and brush holder parts are part of
the frame kit (51).
7. If test equipment is available:
A. Check armature (26 or 52) for short circuits by
placing on growler and holding hacksaw blade
over armature core while armature is rotated. If
saw blade vibrates, armature (26 or 52) is
shorted. Replace armature (26 or 52).
 CRANKING SYSTEM 602-11

A SERIES COIL CONNECTION

B SELF POWERED TEST LIGHT
C INSULATED BRUSH
PC1010·6D2·B·RP

Figure 12 - Testing Series Coil for Open

A LUBRICATED GEAR TEETH
B GEAR, STARTER ARMATURE
24 DRIVE ASSEMBLY, STARTER
26 ARMATURE, STARTER
29 SHAFT AND GEAR ASSEMBLY
31 GEAR, INTERNAL TOOTH
43 PIN, SHIFT COLLAR THIS TERMINAL MUST
NOT TOUCH
GROUND
PC0011·6D2·F·RP DURING TEST

Figure 11 - Starter Armature and Starter Drive Assembly

B. On SD210 starter motor assembly, check field

windings by using self-powered test lamp.
Place one lead on field lead terminal and other
lead on one insulated brush. If lamp fails to
light, series coil is open and will require repair
or replacement. Perform this test for each insu-
lated brush to check brush and lead continuity
(Figure 12). B

C. On SD210 starter motor assembly, using self-

powered test lamp, place one lead on grounded
brush holder assembly and other lead on either
insulated brush. If lamp lights, grounded series
coil is indicated and frame kit (51) must be
replaced (Figure 13).
A SELF-POWERED TEST LAMP
D. Check armature (26 or 52) for grounds using a B HOLDER, STARTER INSULATOR BRUSH
self-powered test lamp. Place one lead on com- C HOLDER, STARTER GROUND BRUSH
mutator and other lead on armature core or PC0017·602·F·RP

shaft. If lamp lights, armature (26 or 52) is Figure 13 - Testing Series Coil for Ground
grounded and must be replaced.
602-12 CRANKING SYSTEM

E. Check current draw of solenoid windings as

follows:
a. If solenoid switch (23 or 56) is not
removed from starter motor assembly,
field lead must be removed from "M"
terminal on solenoid switch (23 or 56)
before making these tests. Complete tests
in minimum of time to prevent overheat-
ing of solenoid switch (23 or 56).
b. To check hold-in winding, connect F
ammeter in series with 12-volt battery
and "S" terminal on solenoid switch (23
or 56). Connect voltmeter to "S" termi-
nal and to ground. Connect carbon pile
across battery. Adjust voltage to 10 volts
and note ammeter reading. Reading B
should be 10 to 20 amperes.
c. To check both windings, connect as for
previous test. Ground solenoid "M" ter-
minal. Adjust voltage to 10 volts and note
ammeter reading. Reading should be 60
to 85 amperes.
A CARBON PILE
[I) Important B
C
AMMETER
VOLTMETER
• Current will decrease as windings heat up. D SWITCH
F GROUND
• Current draw readings that are over spec- 22 BATTERY ASSEMBLY, STORAGE
PC0012-6D2-B-RP
ifications indicate shorted turns or a
ground in the windings of the solenoid Figure 14 - Testing Solenoid Windings
switch (23 or 56) and the solenoid switch
(23 or 56) should be replaced. No or low
current draw readings that are under
specifications indicate excessive resis-
tance. A zero reading indicates an open
circuit. Check connections, then replace A. Secure starter motor assembly in vise or equiv-
solenoid switch (23 or 56) if necessary. alent fixture so that opening in drive housing is
accessible for measurement.
8. On SD210 starter, solenoid switch (56) is serviced as
an assembly. On PG-250 starter, solenoid switch (23) B. Disconnect field lead from solenoid switch
and drive housing (36) are serviced as an assembly. "M" terminal and insulate it carefully. ·
C. Connect one 12-volt battery lead to solenoid
Checking Pinion Clearance (PG-250 and switch "S" terminal and the other to starter
frame.
SD21 OStarter Motor Assemblies)
D. Flash jumper lead momentarily from solenoid
Figure 15 switch "M" terminal to starter frame. This will
shift pinion into cranking position and it will
NOTICE: When the starter motor assembly has remain so until battery is disconnected.
been disassembled or the solenoid switch has been
replaced, it is necessary to check the pinion clear- E. Push pinion back as far as possible to take up
ance. Starter motor assembly may not engage prop- any movement, and check clearance with
erly if pinion clearance is incorrect. feeler gage. Clearance should be 0.25 mm to
4.06 mm (0.010 inch to 0.160 inch).
l@I Measure F. Means for adjusting pinion clearance is not
provided on starter motor assembly. If clear-
• Pinion clearance as follows:
ance does not fall within limits, check for
CAUTION: Keep fingers, tools, and improper installation and replace all worn
other objects away from opening in parts.
drive housing while making electrical
connections during this procedure. G. Disconnect 12-volt battery leads from solenoid
The strong shifting action of the sole- switch "S" terminal and starter frame.
noid switch could cause personal H. Reconnect field lead. Refer to "Starter Motor
injury or damage as the drive pinion Assembly PG-250" or " Starter Motor Assem-
moves into cranking position. bly SD210" in this section.
 CRANKING SYSTEM 602·13

22
24
OR
5:3 85

33
OR
58

0.25 mm TO 4.06 mm
(0.010" TO 0.160")
PINION
CLEARANCE
c
A LEAD, FIELD (DISCONNECTED) 33 COLLAR, STARTER DRIVE STOP (PG-250)
B MOMENTARY GROUND 53 DRIVE ASSEMBLY, STARTER (SD210)
C GAGE, FEELER 58 COLLAR, STARTER DRIVE STOP (SD210)
22 BATTERY ASSEMBLY, STORAGE 85 PINION, STARTER DRIVE
24 DRIVE ASSEMBLY, STARTER (PG-250)
PC0013-602-F-RP

Figure 15 - Electrical Connections and Checking Pinion Clearance

PG-250 STARTER MOTOR ASSEMBLY
Figures 7, 11, 16 and 17
ll•l 1nspect
• Bushing (30), bearing (25), shaft and gear assembly
(29) and bearing (27). When dry, bushing (30), and
shaft and gear assembly (29) may be lightly lubri-
cated with GM lubricant 10497186 or equivalent.
Bearings (25 and 27) are permanently lubricated -
do not add lubricant. If dry, replace the bearings
(25 and 27). Replace bushing or bearings when
damaged.
5. New retainer (34) into groove on shaft. Do not reuse
old retainer (34).
6. Collar (35) to end of shaft with flange toward
retainer (34). Use pliers as shown in Figure 16 to
snap collar (33) over retainer (34).
7. Drive assembly (24) and shaft and gear assembly
(29) into housing (36).
• Use screwdriver to gently guide shift lever
over pins (43) on drive assembly (24).
8. Shield (28) and frame and field (37) into housing
(36).

l+!+I Assemble
ll•l 1nspect
NOTICE: See "Notice" on page 602-1 of this
section.
1. Bearing (25) to drive housing (36). Press bearing
(25) to 0.35 mm (0.014 inch) below face of casing.
Refer to Figure 17.
2. Lubricate gear (31), planetary gear of the shaft and
gear assembly (29), and armature shaft gear teeth
lightly with GM lubricant 10497186 or equivalent.
Refer to Figure 11.
3. Gear (31) and drive assembly (24) over shaft and
gear assembly (29) with pinion away from armature
(26).
4. Collar (33) onto shaft.
• Brushes. Replace if damaged or excessively
worn.
9. Brush holder assembly (38) onto armature (26).
• Release brushes onto commutator by sliding
springs to ends of brushes.
10. Bearing (27) onto armature (26) by pressing on inner
race until bearing (27) rests against shoulder on
armature shaft.
CAUTION: Magnets in frame and field
have strong attraction to armature.
Keep fingers clear of pinch points to
avoid personal injury.
11. Armature (26) to frame and field (37).
602·14 CRANKING SYSTEM

12. End frame (40) to brush holder assembly (38) using

bolts/screws (41 ).

l~I Tighten
• Bolts/screws (41) to 6.5 N•m (58 lb. in.)
13. Through-bolts/screws (42).

l~I Tighten
• Through-bolts/screws (42) to 8.5 N•m
(75 lb. in.).

l@I Measure
• Pinion clearance. Refer to "Checking Pinion
Clearance" in this section.
NOTICE: When installing electrical connections to
starter motor assembly, the inner nut on the solenoid
switch "M" terminal must be tightened before field
lead is installed. If inner nut is not tight, cap may be
33 COLLAR, STARTER DRIVE STOP (PG-250)
damaged during installation of electrical connector.
34
35
58
RETAINER, STARTER DRIVE STOP COLLAR (PG-250)
COLLAR, STARTER DRIVE THRUST (PG-250)
COLLAR, STARTER DRIVE STOP (50210)
l~I Tighten
59 RETAINER, STARTER DRIVE STOP COLLAR (50210) • Starter solenoid switch "M" terminal inside
60 COLLAR, STARTER DRIVE THRUST (50210) nut to 9 N•m (80 lb. in.).
14. Field lead to solenoid switch ''M" terminal.
PC0014-6D2-F-RP 15. Nut (32).
Figure 16 - Installing Pinion Stop Collar
l~I Tighten
• Nut (32) to 8 N•m (71 lb. in.).

SD210 STARTER MOTOR ASSEMBLY

Figures 8 and 16

l•!•I Assemble
NOTICE: See "Notice" on page 602-1 of this
section.
1. Drive assembly (53) onto armature shaft.
2. Pinion stop collar (58) onto armature shaft with flat
RECESS STARTER
side toward drive assembly (53).
DRIVE BEARING 3. New retainer (59) onto armature shaft and slide it
0.35 mm (0.014") down shaft until seated in shaft groove.
INTO CASTING
4. Thrust collar (60) onto armature shaft with flange
toward retainer (59).
• Use two sets of pliers and squeeze pinion stop
collar (58) and thrust collar (60) to snap pinion
stop collar (58) onto retainer (59).

IL•l1nspect
• End bearing (55). If bearing (55) has no
25 BEARING, STARTER DRIVE SHAFT DRIVE END
lubrication visible or appears damaged, replace
36 HOUSING, STARTER DRIVE bearing (55).
• Press bearing (55) from drive housing
(54) and then press in new bearing (55)
PC0015-602-F-RP until recessed 1.6 mm (1/16 inch ) into
drive housing casting. Bearing (55) is
Figure 17 - Starter Drive Shaft Drive End Bearing pre-lubricated and no additional lubrica-
tion is needed.
 CRANKING SYSTEM 602-15

5. Shift lever (57) to drive assembly (53) by spreading appears damaged, press in a new bearing (50)
arms slightly. until recessed 2 mm (0.08 inch) into commuta-
6. Plunger (68) to other end of shift lever (57) by tor end frame (49). Bearing (50) is pre-lubri-
snapping into place. cated and no additional lubrication is needed.
7. Armature shaft into end bearing (55) while sliding 13. Washer (64) onto armature shaft.
lever retainer (69) into slot in drive housing (54). 14. Commutator end frame (49) onto armature shaft and
8. Plug (67) into slot in drive housing (54). seat into frame kit (51).
9. Return spring (72) over plunger (68). 15. Identification tag over bolt/screw hole in commuta-
tor end frame (49) with fluted end around bearing
10. Solenoid switch (56) with clamp (66) to drive well.
housing (54).
16. Bolts/screws (65) to starter motor assembly.
• Align motor terminal and solenoid switch (56)
with field lead.
11. Clamp bolts/screws (63).
l~I Tighten
• Bolts/screws (65) to 8.5 N•m (75 lb. in.).
l~I Tighten NOTICE: Before attaching electrical leads, tighten
inner nuts on solenoid switch terminals. If nuts are
• Clamp bolts/screws (63) to 11 N•m (97 lb. in.).
not tight, solenoid cap may be damaged during
Iii Clean
installation of leads. Tighten inner nuts on "S" ter-
minal to 2.5 N•m (22 lb. in.). Tighten inner nut at
• Contact surface of frame kit brushes and "BAT" terminal to 10 N•m (89 lb. in.).
armature commutator with soft cloth. 17. Nut (61) to solenoid switch (56).
12. Frame kit (51) onto armature (52) and drive housing
(54) by pushing in and holding brushes and aligning
notch in frame kit (51) with locator on drive housing
l~l Tighten
(54). When in place, release brushes and make sure • Nut (61) to 10 N•m (89 lb. in.).
they move freely and contact commutator. 18. Heat shield (71) and nuts (62) onto protruding end.s
of clamp bolts/screws (63).
ll'l'I Inspect
l~I Tighten
• Bearing (50) in commutator end frame (49). If
bearing (50) has no visible lubrication or • Nuts (62) to 8 N•m (71 lb. in.).

SPECIFICATIONS

STARTER MOTOR ASSEMBLY USAGE CHART

3.4L L32 Engine
Starter Type ................................................................. SD210
No-Load Test at 10 Volts
Amps-Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Amps-Maximum ............................................................. 75
RPM at Drive Pinion
Minimum ................................................................ 6,000
Maximum .............................................................. 11,000
Starter Solenoid Switch
Hold-in Windings at 10 Volts ............................................. 10-20 Amps
Both Windings at 10 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-85 Amps

5.7L LTl Engine

Starter Type ................................................................. PG-250
No-Load Test at 10 volts
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-95 Amps
Starter Drive Pinion Speed ........................................... 2750-3250 RPM
Starter Solenoid Switch
Hold-in Windings at 10 Volts ............................................. 10-20 Amps
Both Windings at 10 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-85 Amps
602-16 CRANKING SYSTEM

FASTENER TIGHTENING SPECIFICATIONS

Battery Negative Cable Assembly ...................................... 15 N•m (11 lb. ft.)
Starter Motor Assembly Heat Shield Nut .................................. 8 N•m (71 lb. in.)
Starter Motor Bolt/Screw ............................................. 47 N•m (35 lb. ft.)
Starter Motor Brush Holder Bolt/Screw (PG-250) ......................... 6.5 N•m (58 lb. in.)
Starter Motor Commutator End Frame Bolt/Screw ........................ 8.5 N•m (75 lb. in.)
Starter Solenoid Switch "BAT" Terminal Inner Nut ......................... 9 N•m (80 lb. in.)
Starter Solenoid Switch "BAT" Terminal Outer Nut ......................... 9 N•m (80 lb. in.)
Starter Solenoid Switch Clamp Bolt/Screw ............................... 11 N•m (97 lb. in.)
Starter Solenoid Switch Inner Nut ....................................... 9 N•m (80 lb. in.)
Starter Solenoid Switch Outer Nut (PG-250) ............................... 8 N•m (71 lb. in.)
Starter Solenoid Switch Outer Nut (SD210) ............................... 10 N•m (89 lb. in.)
Starter Solenoid Switch "S" Terminal Nut .............................. 2.5 N•m (22 lb. in.)
Starter Through-Bolt/Screw (PG-250) .................................. 8.5 N•m (75 lb. in.)

GENERAL SPECIFICATIONS
Pinion Clearance .................................. 0.25 mm to 4.06 mm (0.010" to 0.160")

SPECIAL TOOLS

1. J 28509-A

1. COUNTER GEAR BEARING REMOVER

PC6016·6D2-D-RP
 CHARGING SYSTEM 603·1

SECTION 603

CHARGING SYSTEM
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in SECTION 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" exposed electrical terminals, disconnect the battery
negative cable to help prevent personal injury and/or damage to the vehicle or components.
Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 6D3-1
Charging Circuit . . . . . . . . . . . . . Refer to Section 8A
CS-130 and CS-144 Generator Assemblies ... 6D3-l
Diagnosis ............................... 6D3-2
CS Generator Assembly
On-Vehicle Check .................... 6D3-2
CS Generator Assembly Bench Check ...... 6D3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 6D3-3
Generator Assembly Replacement .......... 6D3-3
CS-130 105-Amp Generator Assembly
(3.4L L32 Engine) .................. 6D3-3
CS-144 124-Amp or 140-Amp Generator
Assembly (5.7L LTl Engine) ......... 6D3-6
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-6
CS-130 105-Amp Generator Assembly
(3.4L L32 Engine) .................... 6D3-6
CS-144 124-Amp or 140-Amp Generator
Disassembly, Test and Reassembly
(5.7L LTl Engine) ................. 6D3-7
Specifications ........................... 6D3-11
Generator Assembly Usage Chart ......... 6D3-11
Fastener Tightening Specifications . . . . . . . . 6D3- l 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3- l 2

GENERAL DESCRIPTION
CHARGING CIRCUIT
Refer to SECTION 8A for operation and additional
charging circuit diagnosis.
CS-130 AND CS-144 GENERATOR
ASSEMBLIES
The charging system generator assemblies use a
built-in voltage regulator with fault detection, a stator,
rectifier bridge, and rotor with slip rings and brushes. A
conventional pulley and fan is used to cool the slip ring
end frame, rectifier bridge and voltage regulator.
These generator assemblies use only two connec-
tions - battery positive and "L" terminal, in addition to
the ground path through the generator bracket. Use of
"P," "I" and "S" terminals is optional. The "P" terminal
is connected to the stator and may be connected externally
to a tachometer or other device. The "I" terminal can be
connected directly to battery voltage to power the genera-
tor assemblies instead of, or in addition to, the "L" termi-
nal which must be stepped down. The "S" terminal may
be connected to an external voltage source, such as volt-
age near the battery assembly, for voltage control. If the
"S" terminal is not used, internal generator voltage is
used for control.
The voltmeter reads battery voltage when the engine
is not running and reads charging system voltage when the
engine is running. The normal indication is between 11
volts and 16 volts.
The regulator voltage setting varies with tempera-
ture and limits system voltage by controlling rotor field
current. While the field current is "on," this regulator
actually switches rotor field current on and off at a fixed
frequency of about 400 cycles per second to help control
radio noise. By varying the overall on-off time, correct
average field current for proper system voltage control
can be obtained. At high speeds, the on-time may be 10
percent and the off-time 90 percent. At low speeds, with
high electrical loads, on-off time may be 90 percent and
IO percent respectively.
603·2 CHARGING SYSTEM
DIAGNOSIS
CS GENERATOR ASSEMBLY ON-VEHICLE
CHECK
Tool Required:
J 39200 Digital Multimeter
When the CS charging system is operating normally,
the voltmeter will read between 11 volts and 16 volts
when the engine is running. If the voltmeter operates
abnormally, or if an undercharged or overcharged battery
assembly condition occurs, the following procedure may
be used to diagnose the charging system. Remember that
an undercharged battery assembly is often caused by
accessories being left on overnight, or by a hood or instru-
ment panel compartment lamp that stays on.
Noise from a generator assembly may be caused by a
loose drive pulley, loose mounting bolts/screws, worn or
dirty bearings, faulty diode or faulty stator. A magnetic
whining noise may be heard from vehicles equipped with
the CS-130 alternator. This is a normal condition.
To avoid damage to the electrical equipment, always
observe the following precautions:
• Do not reverse connections to generator assembly.
• Do not short across or ground any of the terminals in
charging circuit, except as directed by instructions.
• NEVER disconnect generator "BAT" terminal with
generator assembly operating.
• When connecting charger or booster battery assem-
bly to battery assembly, refer to SECTION 6Dl.
• In some vehicles, voltmeter may be used instead of
indicator lamp. In this case, steps l through 4 per 0
taining to faulty indicator lamp operation, should be
omitted from troubleshooting procedure.
• Do not attempt to disassemble CS-130 generator
assembly. Damage to generator assembly could
result.
Trouble in the charging system will show up as one
or more of the following conditions:
• Faulty voltmeter operation.
• Undercharged battery assembly, as evidenced by
slow cranking or dark hydrometer.
• Overcharged battery assembly, as evidenced by
spewing of electrolyte from vents or a yellow
hydrometer.
To diagnose the CS-130 or CS-144 charging system,
use the following procedure:
(]] Important
• Only the CS-144 generator assembly may be
repaired.
1. Visually check serpentine drive belt and wiring.
2. Battery assembly undercharged or overcharged
(voltage lower than 11 volts or higher than 16 volts).
A. Detach wiring harness connector from genera-
tor assembly.
B. With ignition switch "ON" and engine assem-
bly not running, connect J 39200 as voltmeter
from ground to "L" terminal in wiring harness
connector. Connect to "F" or "I" terminal for
gage equipped vehicles. At least one terminal
should have battery voltage.
C. Zero volts indicates open circuit between ter-
minal and battery assembly. Correct as
required.
D. Reconnect harness connector to generator
assembly.
CAUTION: Disconnect battery negative
cable assembly before installing or
removing a series-type ammeter at gen-
erator battery terminal.
CAUTION: See "Caution" on page
603-1 of this section.
E. Install ammeter at generator output terminal.
With load off, install carbon pile load test
across battery terminals. Start engine assembly
and run at 2500 rpm. Make sure this is done at
ambient temperature.
F. Measure voltage across battery assembly,
using J 39200. If voltage is above 16 volts,
replace or repair generator assembly.
G. Turn on accessories and load battery assembly
with carbon pile to obtain maximum generator
assembly output. Maintain voltage at 13 volts
or above. Use am.meter to check amperage.
Compare output to ampere rating in "Specifi-
cations" at the end of this section.
• If within 15 amps of rated output, genera-
tor assembly is OK.
• If not within IS amps of rated output,
repair or replace generator assembly.
CS GENERATOR ASSEMBLY BENCH
CHECK
Figure 1
Tool Required:
J 39200 Digital Multimeter
The following bench check may be used to simulate
operation on a vehicle. Use the bench check to verify
operation of a CS-144 generator assembly that has been
repaired.
1. Mount generator assembly in suita?l~ test ~tand
according to test stand manufacturer s mstruct10ns.
Test stand must be capable of driving generator
assembly at 6,500 rpm.
2. Make connections as shown in Figure 1. Be sure car-
bon pile is turned off. Ground polarity of generator
assembly and battery assembly must be same. Bat-
tery assembly must be fully charged. Use a 30-500
ohm resistor between battery assembly and "L" ter-
minal of generator assembly.
3. Slowly increase generator assembly speed and
observe voltage using J 39200.

B
A two are as follows:
6 10480111) is equipped with a plastic and metal fan
c to the "BAT" terminal.
5 Figure 2
D j++I Remove or Disconnect
A CARBON PILE
B VOLTMETER
C RESISTOR (30-5000)
D AMMETER
E CONNECTOR RESISTOR TO "L" TERMINAL
5 GENERATOR ASSEMBLY
6 BATIERYASSEMBLY, STORAGE
PC6001 ·6D3:D-RP
Figure 1 - Generator Assembly Bench Che.ck
I]] Important
• The battery assembly must be fully charged
when making this test.
• The engine must be run at 2500 rpm and at
ambient temperature.
4. If voltage is uncontrolled and increases above 16
volts, repair or replace generator assembly.
5. If voltage is below 16 volts, increase speed and con-
nect and adjust carbon pile to obtain maximum
amperage output. Maintain voltage above 13 volts.
6. Use ammeter to check amperage. If output is within
15 amps of rated output, generator assembly is good.
7. lfoutput is not within 15 amps ofrated output, repair
or replace generator assembly.
I]] Important
• Only the CS-144 generator assembly may be
repaired.
ON-VEHICLE SERVICE
The CS generator assembly does not require peri-
odic lubrication. The rotor shaft is mounted on perma-
nently lubricated bearings. At periodic intervals, check
mounting bolts/screws for tightness and check serpentine
drive belt tension. Refer to SECTION 6A2A or 6A3A.
The charging system could be equipped with two
different CS-144 generators. The reason for this is the
CHARGING SYSTEM 603-3
CS-144 124-amp generator is being replaced by the
CS-144 140-amp generator. The differences between the
• The CS-144 124-amp generator (part number
l 0480131) is equipped with a metal fan mounted at
the front of the generator and a bolt used to attach the
battery positive cable assembly to the generator
"BAT" terminal.
• The CS-144 140-amp generator (part number
mounted at the front of the generator and uses a stud
and nut to attach the battery positive cable assembly
GENERATOR ASSEMBLY REPLACEMENT
CS-130 105-AMP Generator Assembly
(3.4L L32 Engine)
CAUTION: See "Caution" on page
603-1 of this section.
1. Battery negative cable assembly from battery termi-
nal.
2. Serpentine drive belt. Refer to SECTION 6A2A or
6A3A.
3. Battery positive cable assembly from generator
"BAT" terminal.
4. Electrical connector from generator assembly (5).
5. Nuts (2 and 25) and bolt/screw (21).
6. Generator rear inner brace ( 1).
7. Bolts/screws (9 and 17).
8. Generator assembly (5) from accessory mounting
bracket (7).
!++I Install or Connect
NOTICE: See "Notice" on page 6D3-l of this sec-
tion.
1. Generator assembly (5) to accessory mounting
bracket (7).
2. Bolts/screws (9 and 17).
l~I Tighten
• Bolt/screw (9) to 25 N•m (18 lb. ft.).
• Bolt/screw (17) to 50 N•m (37 lb. ft.).
3. Generator rear inner brace (1).
4. Nuts (2 and 25) and bolt/screw (21).
l~I Tighten
• Nut (2) to 25 N•m (18 lb. ft.).
• Nut (25) to 50 N•m (37 lb. ft.).
• Bolt/screw (21) to 50 N•m (37 lb. ft.).
5. Electrical connector to generator assembly (5).
6. Battery positive cable assembly to generator "BAT"
terminal.
6D3·4 CHARGING SYSTEM

/)
21

17

1 BRACE, GENERATOR REAR INNER

2 NUT, GENERATOR BRACE, 25 N•m (18 LB. FT.)
5 GENERATOR ASSEMBLY
7 BRACKET, ACCESSORY MOUNTING
9 BOLT/SCREW, GENERATOR REAR BRACE,
25 N•m (18 LB. FT.)
17 BOLT/SCREW, GENERATOR, 50 N•m (37 LB. FT.)
21 BOLT/SCREW, GENERATOR, 50 N•m (37 LB. FT.)
25 NUT, GENERATOR, 50 N•m (37 LB. FT.)

PC0001-6D3-F-RP

Figure 2- CS-130 105-Amp Generator Assembly Mounting (3.4L L32 Engine)

 CHARGING SYSTEM 603-5

10

5 GENERATOR ASSEMBLY
7 BRACKET, ACCESSORY MOUNTING
9 BOLT/SCREW, GENERATOR REAR BRACE, 50 N•m (37 LB. FT.)
10 BRACE ASSEMBLY, GENERATOR REAR OUTER 61
12 NUT, GENERATOR REAR BRACE, 33 N•m (24 LB. FT.)
17 BOLT/SCREW, GENERATOR, 50 N•m (37 LB. FT.)
21 BOLT/SCREW, GENERATOR, 25 N•m (18 LB. FT.)
61 NUT, GENERATOR ASSEMBLY

RC0001 ·6D3·F·RP
Figure 3 - CS-144 Generator Assembly Mounting (5.7L LT1 Engine) (Typical)
603·6 CHARGING SYSTEM

6. Battery positive cable assembly to generator "BAT"

I~! Tighten terminal.
• Cable nut to 14 N•m (124 lb. in.).
7. Serpentine drive belt. Refer to SECTION 6A2A or
I~! Tighten

6A3A. • Cable bolt/screw to 14 N•m (124 lb. in.), if

equipped with 124-amp alternator.
8. Battery negative cable assembly to battery terminal.
• Cable nut to 20 N •m (15 lb. ft.), if equipped
I~! Tighten
with 140-amp alternator.
7. Raise and suitably support vehicle. Refer to SEC-
• Battery negative cable bolt/screw to 15 N•m TION OA.
( 11 lb. ft.).
8. Serpentine drive belt. Refer to SECTION 6A2A or
6A3A.
CS-144 124-Amp or 140-Amp Generator
Assembly (5.7L LT1 Engine) 9. Battery negative cable assembly to battery terminal.

Figure 3 I~! Tighten

• Battery negative cable bolt/screw to 15 N•m
!+-+I Remove or Disconnect (11 lb. ft.).
CAUTION: See "Caution" on page
603-1 of this section. UNIT REPAIR
I. Battery negative cable assembly from battery termi-
nal. CS-130105-AMP GENERATOR ASSEMBLY
2. Serpentine drive belt. Refer to SECTION 6A2A or (3.4L L32 Engine)
6A3A. NOTICE: Do not attempt to disassemble a CS-130
3. Lower vehicle. generator assembly. Damage to the generator assem-
bly could result. The CS-130 generator assembly is
4. Battery positive cable assembly from generator replaced as a complete assembly.
"BAT" terminal.
5. Electrical connector from generator assembly (5).
6. Bolts/screws (9, 17 and 21) and nut (61) at generator
assembly (5).
7. Nut (12) at generator rear outer brace (10).
8. Generator rear outer brace (10).
9. Generator assembly (5) from accessory mounting
bracket (7).

!-++! Install or Connect

NOTICE: See "Notice" on page 6D3-1 of this sec-
tion.
1. Generator assembly .(5) to accessory mounting
bracket (7).
2. Generator rear outer brace ( 10).
3. Nut (12) at generator rear outer brace (10).

I~! Tighten
• Nut (12) to 33 N•m (24 lb. ft.).
4. Bolts/screws (9, 17 and 21) and nut (61) at generator
assembly (5).

I~! Tighten
A "P" "L" "I" "S" TERMINALS
26 THROUGH-BOLT/SCREW, GENERATOR
27 TERMINAL, GENERATOR BATTERY
• Bolts/screws (9 and 17) to 50 N•m (37 lb. ft.).
• Bolt/screw (21) to 25 N•m (18 lb. ft.). PC6003-6D3-D-RP

5. Electrical connector to generator assembly (5). Figure 4 - Generator Through-Bolt/Screw Location

 CHARGING SYSTEM 603-7

32 BOLT/SCREW, REGULATOR ATTACHING

A OHMMETER CHECK FOR GROUNDS 33 REGULATOR, GENERATOR VOLTAGE
B OHMMETER CHECK FOR SHORTS AND OPENS 34 HOLDER, GENERATOR BRUSH
C RING, SLIP 35 NUT, STATOR LEAD ATTACHING
D RING, SLIP 36 STATOR,GENERATOR
31 ROTOR,GENERATOR 57 BOLT/SCREW, GENERATOR BRUSH HOLDER

PC6004-6D3-D-RP PC6005-603-D-RP

Figure 5 - Testing Generator Rotor Figure 6 - Generator Slip Ring End Frame View

CS-144124-AMP OR 140-AMP GENERATOR

DISASSEMBLY, TEST AND REASSEMBLY
(5.7L LT1 Engine)
Figures 4 through 12

!+f+I Disassemble
1. Make scribe marks on slip ring end frame (43) and
drive end frame (59) to ease reassembly.
2. Through-bolts/screws (26) and separate slip ring end
frame (43) and drive end frame (59).
3. End frame bearing (28) from rotor shaft.

!~I Measure
• Rotor (31) for grounds, opens and shorts (Fig-
ure 5).

[I) Important
• Test should be performed at approximately
21 °C (70°F). A different temperature may
result in inaccurate ohmmeter readings.
A. Connect ohmmeter to slip ring and clean
metal grounding surface on frame of A OHMMETER CHECK FOR GROUNDS
rotor (31) to check for grounds. B TERMINAL, GENERATOR STATOR
C LAMINATIONS
• Ohmmeter should read infinity 36 STATOR.GENERATOR
( open). If not, replace rotor (31 ).
PC6006-6D3-D-RP
B. Connect ohmmeter to both slip rings to
check for shorts and opens. Figure 7 - Testing Generator Stator
603·8 CHARGING SYSTEM

38

A CONNECTION, SOLDERED
A
B CONNECTION, SOLDERED
C STRAP, REGULATOR ATTACHING A OHMMETER
32 BOLT/SCREW, REGULATOR ATTACHING B SINK, GROUNDED HEAT
33 REGULATOR, GENERATOR VOLTAGE C SINK, INSULATED HEAT
34 HOLDER, GENERATOR BRUSH D STRAP, GENERATOR CAPACITOR
38 STRAP, REGULATOR CONNECTOR 39 CAPACITOR, GENERATOR
53 BRIDGE, GENERATOR RECTIFIER

PC6007-6D3-D-RP PC6008-6D3-D-RP

Figure 8 - Removing Generator Voltage Regulator and Figure 9 - Testing Generator Rectifier Bridge
Generator Brush Holder

• Ohmmeter should read 1.7 to 2.1

ohms. If not, replace rotor (31 ).
4. Nuts (35).
5. Stator (36) from slip ring end frame (43). l@I Measure

l@I Measure
• Stator (36) for grounds (Figure 7).
A. Connect ohmmeter to stator terminal and
to clean metal ground on laminations.
B. If ohmmeter reading is low, replace stator
(36). Stator (36) cannot be checked for
opens and shorts with ohmmeter.
6. Unsolder connections at connector strap (38) and
brush holder (34) to voltage regulator (33).
7. Bolt/screw (32) and bolt/screw (57).
8. Voltage regulator (33) and brush holder (34) with
dust shield (60) from slip ring end frame (43).
• Tap plastic retaining pin from dust shield
retaining clip. Be sure to keep pin for reas-
sembly.
9. Brushes (41) and dust shield (60) from brush holder
(34).
Ir,! Clean
• Brushes (41) with soft, dry cloth.
• Rectifier bridge (53) for continuity (Figure 9).
A. Connect ohmmeter to grounded heat sink
and flat metal clip at rectifier bridge (53).
B. Reverse leads. One reading should be
high (open) and one low (continuity). If
both readings are the same, replace recti-
fier bridge (53).
C. Repeat test between grounded heat sink
and clips at two other bridge terminals.
D. Repeat test between insulated heat sink
and at bridge terminals.
10. Capacitor (39) and rectifier bridge (53).
11. Washers (55) and bolts/screws (56 and 58).
12. Bearing (28) from slip ring end frame (43) by push-
ing through to inside.
13. Nut (49), using hex wrench to hold rotor shaft.
14. Washer (47), pulley (48), fan collar (46), fan (45)
and outside collar (50).
15. Rotor (31) from drive end frame (59).
16. Inside collar (52) from rotor (31).
 CHARGING SYSTEM 603·9

45 FAN, GENERATOR 50 COLLAR, GENERATOR ROTOR DRIVE END BEARING OUTSIDE

46 COLLAR, GENERATOR ROTOR DRIVE END FAN 52 COLLAR, GENERATOR ROTOR DRIVE END BEARING INSIDE
47 WASHER, GENERATOR ROTOR SHAFT DRIVE END 59 FRAME, GENERATOR ROTOR DRIVE END BEARING
48 PULLEY, GENERATOR
49 NUT, GENERATOR ROTOR SHAFT DRIVE END,
100 N•m (75 LB. FT.)

RC0002-603-F-RP

Figure 1O- Generator Rotor Drive End Bearing

A. Rectifier bridge (53).

l+!+I Assemble B. Capacitor (39).
NOTICE: See "Notice" on page 603-1 of this sec- C. Washers (55).
tion. D. Bolts/screws (56 and 58).
1.
2.
3.
Inside collar (52) onto rotor (31 ).
Rotor (31) to drive end frame (59).
Outside collar (50), fan (45), fan collar (46), pulley
rn Important
• The capacitor (39) has an insulator mate-
(48) and washer (47) onto rotor shaft. rial on one side which must rest against
4. Nut (49). the drive end frame (59) (ground).
• The capacitor/rectifier bridge insulated
l~I Tighten attaching bolt/screw (58) must be
installed in the proper hole, attaching the
• Nut (49) to 100 N•m (75 lb. ft.). capacitor strap and rectifier bridge (53) to
5. Bearing (28) into slip ring end frame (43) from out- the slip ring end frame (43).
side, until flush with outside shoulder of slip ring E. Brushes (41) into brush holder (34) with
end frame (43).
retaining pin (40).
6. Slip ring end frame electrical components.
F. Dust shield (60) onto brush holder (34).
OJ Important G. Voltage regulator (33), and brush holder (34)
with dust shield (60), brushes (41) and retain-
• Installation of the slip ring end frame electrical ing pin (40) installed into slip ring end frame
components must be done in the following (43).
order to insure proper operation of the unit.
Assembly in any other manner will result in
either no output from generator assembly (5)
or a direct internal ground in the generator
rn Important
• The metal side of the capacitor strap must
assembly (5). be against the regulator connection.
603-10 CHARGING SYSTEM

43

28

-0-

A CLIPS, SOLDER
B STRAP, GENERATOR CAPACITOR
C METALSIDE
D INSULATED SIDE
E PIN, PLASTIC RETAINING
F CLIP, 'DUST SHIELD RETAINING
28 BEARING, GENERATOR ROTOR SLIP RING END FRAME
32 BOLT/SCREW, REGULATOR ATTACHING
33 REGULATOR, GENERATOR VOLTAGE
34 HOLDER,GENERATORBRUSH
35 NUT, STATOR LEAD ATTACHING
38 STRAP, REGULATOR CONNECTOR
39 CAPACITOR, GENERATOR
40 PIN, BRUSH RETAINING
41 BRUSH.GENERATOR
43 FRAME, GENERATOR SLIP RING END
53 BRIDGE, GENERATOR RECTIFIER
54 NUT, GENERATOR BATTERY TERMINAL
55 WASHER, GENERATOR RECTIFIER BRIDGE
56 BOLT/SCREW, GENERATOR RECTIFIER BRIDGE
57 BOLT/SCREW, GENERATOR BRUSH HOLDER
58 BOLT/SCREW, GENERATOR CAPACITOR/RECTIFIER
BRIDGE
INSULATED ATTACHING
60 SHIELD, DUST
PC1010-603-B-RP

Figure 11 - Generator Slip Ring End Frame Components

 CHARGING SYSTEM 603-11

34

----

34 HOLDER, GENERATOR BRUSH

40 PIN, BRUSH RETAINING
41 BRUSH.GENERATOR
60 SHIELD, DUST
PC6009-603-D-RP

Figure 12 - Generator Brushes Retained in Generator Brush Holder

H. Tap plastic retaining pin on dust shield (60)
into retaining clip.
• Be sure brush retaining pin (40) goes
through access hole to outside of slip ring
end frame (43) for removal after genera-
tor is assembled.
I. Bolt/screw (32) and bolt/screw (57).
J. Connector strap (38) to voltage regulator sol-
der clip, and brush holder connection to other
voltage regulator solder clip.
• Crimp and solder voltage regulator solder
clip connections.
NOTICE: Avoid excessive heat when soldering
connections, as this can cause voltage regulator
damage.
K. Stator (36), placing stator terminals over recti-
fier bridge terminals.
L. Nuts (35).
M. Slip ring end frame (43) and drive end frame
(59), noting scribe marks.
N. Slip ring end bearing outer race into bearing
well in slip ring end frame casting.
0. Through-bolts/screws (26).
P. Remove retaining pin (40) to release brushes
(41) against slip rings.

SPECIFICATIONS
GENERATOR ASSEMBLY USAGE CHART
ENGINE EQUIPMENT MODEL PART NUMBER RATED AMPERES
3.4L L32 ALL CS-130 105
5.7L LT! ALL CS-144 10480131 124
5.7L LTl ALL CS-144 10480111 140
603·12 CHARGING SYSTEM

FASTENER TIGHTENING SPECIFICATIONS

CS-130 105-Amp Generator Assembly (3.4L L32 Engine)
Battery Negative Cable Assembly-to-Battery Terminal . . . . . . . . . . . . . . . . . . . . 15 N •m (11 lb. ft.)
Battery Positive Cable Assembly-to-Generator Nut ...................... 14 N•m (124 lb. in.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Lower) ............. 50 N•m (37 lb. ft.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Upper) ............. 50 N•m (37 lb. ft.)
Generator-to-Generator Brace Bolt/Screw .............................. 25 N•m (18 lb. ft.)
Generator-to-Generator Brace Nut (Lower) ............................. 50 N•m (37 lb. ft.)
Generator-to-Generator Brace Nut (Upper) ............................. 25 N•m (18 lb. ft.)
CS-144 124-Amp or 140-Amp Generator Assembly (5.7L LTl Engine)
Battery Negative Cable Assembly-to-Battery Terminal .................... 15 N•m (11 lb. ft.)
Battery Positive Cable Assembly-to-Generator Bolt/Screw ................ 14 N•m (124 lb. in.)
Battery Positive Cable Assembly-to-Generator Nut ....................... 20 N•m (15 lb. ft.)
Generator Outer Brace Mounting Nut ................................. 33 N•m (24 lb. ft.)
Generator Rotor Shaft Drive End Nut ................................ 100 N•m (75 lb. ft.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Lower) ............. 50 N•m (37 lb. ft.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Upper) ............. 50 N•m (37 lb. ft.)
Generator-to-Generator Lower Brace Bolt/Screw ........................ 25 N•m (18 lb. ft.)
Generator-to-Generator Upper Brace Bolt/Screw ......................... 50 N•m (37 lb. ft.)

SPECIAL TOOLS

1 DIGITAL MULTIMETER RC0003-&D3-f.RP

 IGNITION SYSTEM 604·1

SECTION 604

IGNITION SYSTEM
CAUTION: Before removing or installing any electrical unit or when a tool or equipment
could easily come in contact with "live" exposed electrical terminals, disconnect the nega-
tive battery cable to help prevent personal injury and/or damage to the vehicle or compo-
nents. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK"
position.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 6D4-1
Ignition System (5.7L LTl Engine) ......... 6D4-1
Ignition System (3.4L L32 Engine) ......... 6D4-2
Camshaft Position Sensor Assembly
(3.4L L32 Engine) ................. , 6D4-2
24X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine) .......... 6D4-2
3X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine) .......... 6D4-2
Spark Plug Wire Harness Assembly . . . . . . . . 6D4-2
Spark Plugs ........................... 6D4-3
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . 6D4-3
Knock Sensor System . . . . . . . . . . . . . . . . . . . 6D4-3
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . 6D4-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D4-3
Ignition System . . . . . . . . . . . . Refer to Section 6E3
Spark Plugs ........................... 6D4-3
Spark Plug Wire Harness Assembly . . . . . . . . 6D4-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 6D4-4
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6D4-4
Spark Plug Wire Harness
Assembly Replacement . . . . . . . . . . . . . . . . 6D4-5
Spark Plugs ........................... 604-5
Distributor (5.7L LTI Engine) ............. 6D4-6
Ignition Coil Assembly (5.7L LTl Engine) ... 604-7
Ignition Coil Assembly (3.4L L32 Engine) ... 604-7
3X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine) ............ 604-8
24X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine) ............ 604-8
Camshaft Position Sensor Assembly ·
(3.4L L32 Engine) .................... 6D4-8
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604-9
Ignition Coil and Ignition Coil Module
(5.7L LTl Engine) .................... 604-9
Ignition Coil Assembly (3.4L L32 Engine) .. 604-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D4- I l
Fastener Tightening Specifications . . . . . . . . 604-11

GENERAL DESCRIPTION The distributor assembly is mounted directly to the

The ignition system controls fuel combustion by
providing a spark to ignite the compressed air/fuel mix-
ture at the correct time. To provide improved engine per-
formance, fuel economy, and control of exhaust
emissions, the powertrain control module (PCM) controls
distributor spark advance (timing) with an ignition control
system.
IGNITION SYSTEM (5.7L LT1 ENGINE)
The 5.7L LT! engine ignition system consists of a
distributor assembly, control circuits for ignition timing in
the powertrain control module (PCM), a separate ignition
coil/ignition control module assembly, primary and sec-
ondary wiring, and the spark plugs. All ignition timing is
controlled by the PCM; there is no "bypass" mode built
into the ignition control module as in other ignition sys-
tems.
camshaft assembly next to the water pump assembly. It
directs the spark from the ignition coil assembly to the
proper spark plug secondary wire through a rotor. The
secondary output connectors in the distributor cap are
each connected to an indi victual spark plug. The connec-
tors in the cap are arranged for convenience in routing
spark plug wire harness assemblies. The corresponding
cylinder number is molded into the distributor cap next to
each output connector.
The distributor assembly also contains a signal disk
and two optical camshaft position (CMP) sensor assem-
blies that provide signals to the PCM for timing control.
One CMP sensor assembly senses 360 equally-spaced
slots in the signal disk to provide 720 signals per camshaft
revolution for high-resolution timing control. The other
CMP sensor assembly senses eight disk slots of variable
length, providing a low-resolution signal that tells the
PCM which spark plug is being fired. Power for the opti-
cal CMP sensor assemblies, a system ground, and the two
604-2 IGNITION SYSTEM
CMP sensor assembly signals are transferred between the
PCM and the distributor assembly through a shielded har-
ness connected to the four-terminal connector on the dis-
tributor.
The ignition system supplies two timing inputs to
the PCM, a high resolution signal (360 pulses per one
camshaft revolution) and a low resolution signal (eight
pulses per one camshaft revolution). The PCM can deter-
mine if one of the timing inputs is not being received by
comparing the two inputs. If the PCM detects one timing
pulse without detecting the other timing pulse, diagnostic
trouble code I 6 will set.
The reference signals toggle between O and 5 volts
as the camshaft assembly turns. Therefore, an open, a
short to voltage, a short to ground, or a defective sensor
inside the distributor assembly can prevent the voltage
from pulsing at the PCM.
The ignition coil/ignition control module assembly
provides spark to the distributor assembly, timed by sig-
nals from the PCM. Power (B+) for the ignition coil pri-
mary circuit and the ignition control module is supplied
by the ignition switch. The PCM combines the camshaft
position information supplied by the distributor with other
system parameters and calculates the required spark
advance and coil dwell. The PCM signals the ignition
control module, which turns on the primary current to the
ignition coil by grounding the primary circuit, and then
turns it off by removing the ground. When the primary
current flow stops, high voltage induced in the ignition
coil secondary winding becomes the spark voltage for the
spark plug. The spark voltage is delivered to the distribu-
tor assembly through the coil output (secondary) wire,
and then directed to the proper spark plug connector by
the distributor rotor.
IGNITION SYSTEM (3.4L L32 ENGINE)
The 3.4L L32 engine ignition system uses a "waste
spark" method of spark distribution. Each cylinder is
paired with its opposing cylinder in the firing order, so
that one cylinder on compression fires simultaneously
with its opposing cylinder on exhaust. Since the cylinder
on the exhaust requires very little of the available voltage
to fire its plug, most of the voltage is used to fire the cylin-
der on compression. The process reverses when the cylin-
ders reverse roles. There are three coils for this electronic
ignition (EI) system.
Components of the EI system include an ignition
coil, ignition coil module, 3X signal crankshaft position
sensor assembly, camshaft position sensor assembly, 24X
signal crankshaft position sensor assembly, crankshaft
reluctor ring, crankshaft balancer assembly with inter-
rupter rings, and the PCM. The coil pack consists of three
separate, interchangeable, ignition coils. The ignition coil
module is located above the power steering pump assem-
bly and is connected to the PCM. The ignition coil module
controls the primary circuit to the coils, turning them on
and off.
This system also uses a magnetic crankshaft position
sensor assembly which protrudes into the engine block,
within approximately 1.27 mm (0.050 inch) of the crank-
shaft reluctor. The reluctor is a special wheel cast on the
crankshaft assembly that has seven machined slots, six of
which are equally spaced (60 degrees apart). The seventh
slot is spaced IO degrees from one of the other slots. As
the reluctor rotates with the crankshaft, the slots change
the magnetic field of the crankshaft position sensor
assembly, causing an induced voltage pulse.
By counting the time between pulses, the ignition
control module can recognize the pulse of the seventh slot
(sync pulse). Based on this sync pulse, the ignition control
module sends the reference signal to the PCM to calculate
crankshaft position (used to fire coils in correct sequence)
and engine speed.
To properly control timing, the PCM relies on the
following information:
• Engine load (manifold pressure or vacuum).
• Atmospheric (barometric) pressure.
• Engine temperature.
• Intake air temperature.
• Crankshaft position.
• Engine speed (rpm).
For further information refer to SECTION 6E3.
Camshaft Position Sensor Assembly (3.4L
L32 Engine)
The camshaft position sensor assembly is located on
the engine block behind the water pump assembly near the
lower intake manifold assembly.
The camshaft position sensor assembly is used for
timing the injectors for sequential injection. This sensor is
a hall-effect type switch. Refer to SECTION 6E3 for more
information.
24X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine)
The 24X signal crankshaft position sensor assembly
is mounted to the engine front cover assembly and is par-
tially behind the crankshaft balancer assembly. This sen-
sor reads 24 notches in the crankshaft balancer assembly
for crankshaft position and is .used for ignition control
during engine cranking and improved idle control. The
ECM uses the 24X signal crankshaft position sensor
assembly to improve spark accuracy at speeds below 1200
rpm, and influence fuel delivery at speeds below 2000
rpm. This is a hall-effect sensor. For additional informa-
tion, refer to SECTION 6E3.
3X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine)
The 3X signal crankshaft position sensor assembly
inserts through the right side of the engine block at mid-
engine, near the crankshaft reluctor ring. Notches in the
crankshaft reluctor ring trigger the magnetic pickup sen-
sor to provide timing information to the PCM. This is also
a hall-effect sensor. For additional information, refer to
SECTION 6E3.
SPARK PLUG WIRE HARNESS ASSEMBLY
The spark plug wire harness assemblies used with
both ignition systems use carbon impregnated cord con-
ductors, encased in 8 mm (5/16-inch) diameter silicone
jackets. The silicone jackets withstand very high tempera-
tures and also provide excellent insulation for the high

voltage of the system. Silicone spark plug boots form a
tight seal to the spark plugs.
SPARK PLUGS
Figure 1
Resistor type, tapered seat spark plugs are used on
all engine assemblies. No gasket is used on these tapered-
seat spark plugs. Refer to SECTION OB for spark plug
type and gap size. When replacing spark plugs, use only
the type specified.
Normal service is assumed to be a mixture of idling,
slow speed, and high speed driving. Occasional or inter-
mittent high-speed driving is needed for good spark plug
performance. It gives increased combustion heat, burning
away carbon or oxides that have built up from frequent
idling, or continual stop-and-go driving.
Spark plugs are protected by insulating nipples
made of special heat-resistant materials, which cover the
spark plug terminals and extend downward over a portion
of the plug insulators. These nipples prevent flash-over,
which causes engine misfiring. Do not mistake corona
discharge for flash-over, or a shorted insulator. Corona is a
steady blue light appearing around the insulator, just
above the shell crimp. It is the visible evidence of a high-
tension field and has no effect on ignition performance.
Usually it can be detected only in darkness. This discharge
may repel dust particles, leaving a clear ring on the insula-
tor just above the shell. This ring is sometimes mistakenly
regarded as evidence that combustion gases have blown
out between shell and insulator.
IGNITION SWITCH
The mechanical key and lock cylinder ignition
switch is located in the steering column assembly on the
right-hand side,just below the steering wheel. The electri-
cal switching portion of the assembly is separate from the
key and lock cylinder. However, both are synchronized
and work in conjunction through the action of the actuator
rod assembly.
A and ignites the mixture before the spark jumps. This is
A TYPICAL IDENTIFICATION NUMBER PC6012-6D4·D-RP
Figure 1 - Spark Plug Identification
IGNITION SYSTEM .604-3
For a complete explanation of the key and lock cyl-
inder, and the actuator rod assembly, refer to SECTION
3F or SECTION 3F5B. For electrical switching informa-
tion, refer to SECTION 8A.
KNOCK SENSOR SYSTEM
The knock sensor system retards the spark advance
when detonation occurs. Further information is found in
SECTION 6E3.
IGNITION TIMING
The base timing is preset when the engine is
manufactured, no adjustment is possible. Timing advance
and retard are accomplished through the PCM with igni-
tion control and knock sensor systems.
DIAGNOSIS
IGNITION SYSTEM
Diagnosis for the ignition system is in SECTION
6E3.
SPARK PLUGS
Worn or dirty spark plugs may give satisfactory
operation at idling speed, but frequently fail at higher
rpm. Faulty spark plugs may cause poor fuel economy,
power loss, loss of speed, hard starting and generally poor
engine performance. Follow the scheduled maintenance
services recommendations given in SECTION OB, to
assure satisfactory spark plug performance.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the portion of the spark
plug that projects into the cylinder area. A small amount
of red-brown, yellow, and white powdery material may
also be present on the insulator tip around the center elec-
trode. These deposits are normal combustion by-products
of fuels and lubricating oils with additives. Some elec-
trode wear will also _occur.
Engine assemblies which are not running properly
are often referred to as "misfiring." This means the igni-
tion spark is not igniting the fuel/air mixture at the proper
time. While other ignition and fuel system causes must
also be considered, possible causes include spark plug
conditions which allow the spark voltage to reach ground
in some other manner than by jumping across the air gap
at the tip of the spark plug, leaving the fuel/air mixture
unburned. Refer to SECTION 6E3. Misfiring may also
occur when the tip of the spark plug becomes overheated
referred to as "pre-ignition."
Spark plug misfiring may be indicated in a number
of ways: poor fuel economy, power loss, loss of speed,
hard starting, and/or generally poor engine performance.
Worn or dirty plugs may give satisfactory operation at
idling speed, but will misfire under other operating condi-
tions. Spark plugs may also misfire due to fouling, exces-
sive gap, or a cracked or broken insulator. Should
misfiring occur before the recommended replacement
interval, locate and correct the cause.
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds
 604-4 IGNITION SYSTEM
under light engine loads can keep the spark plug tempera-
tures so low that these deposits are not burned off. Over-
rich fuel mixtures or poor ignition system output may also
be the cause. Refer to SECTION 6E for diagnosis.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. Thi1, may be caused by
oil getting past worn piston rings. This condition also may
occur during break-in of new or newly overhauled engine
assemblies.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of combus-
tion by-products become sufficient to cause misfiring. In
some cases, these deposits may melt and form a shiny
glaze on the insulator around the center electrode. If the
fouling is found in only one or two cylinders, valve stem
clearances or intake valve seals may be allowing excess
lubricating oil to enter the cylinder, particularly if the
deposits are heavier on the side of the spark plug that was
facing the intake valve.
Excessive gap means that the air space between the
center and side electrodes at the bottom of the spark plug
is too wide for consistent firing. This may be due to
improper gap adjustment or to excessive wear of the elec-
trodes during use. A check of the gap size and comparison
to the gap specified for the vehicle in SECTION OB, will
tell if the gap is too wide. Excessive gap wear can be an
indication of continuous operation at high speeds or with
-- ~engine-loads, causing the spark plug to run too hot.
Another possible cause is an excessively lean fuel mix-
ture.
Low or high spark plug installation torque or
improper seating can result in the spark plug running too
hot and cause excessive gap wear. The plug and cylinder
head seats must be in good contact for proper heat transfer
and spark plug cooling. Dirty or damaged threads in the
head or on the spark plug can keep it from seating even
though the proper torque is applied. Once spark plugs are
properly seated, tighten to torque shown under "Specifi-
cations" in this section. Low torque may result in poor
contact of seats due to a loose spark plug. Over-tightening
may cause spark plug shell to be stretched and also result
in poor contact between seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug regap-
ping, or heat shock to the insulator material. Upper insula-
tors can be broken when a poorly fitting tool is used
during installation or removal, or when the spark plug is
hit from the outside. Cracks in the upper insulator may be
inside the shell and not visible. Also, the breakage may
not cause problems until oil or moisture penetrates the
crack later.
A broken or cracked lower insulator tip (around the
center electrode) may result from damage during regap-
ping or from "heat shock" (spark plug suddenly operat-
ing too hot).
Damage during regapping can happen if the gapping
tool is pushed against the center electrode or the insulator
around it, causing the insulator to crack. When regapping
a spark plug, make the adjustment by only bending the
side electrode, keeping the tool clear of other parts.
"Heat shock" breakage in the lower insulator tip
generally occurs during severe engine operating condi-
tions (high speeds or heavy loading) and may be caused
by over-advanced timing or low grade fuels. Heat shock
refers to a rapid increase in the tip temperature that causes
the insulator material to crack.
Spark plugs with less than the recommended amount
of service can sometimes be cleaned and regapped, then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.
SPARK PLUG WIRE HARNESS ASSEMBLY
Spark plug wire harness assemblies can be checked
by connecting an ohmmeter to the ends of each wire in
question. If the meter reads over 30,000 ohms, replace the
wire.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
• Allow engine assembly to cool before removing
spark plugs. Attempting to remove spark plugs from
a hot engine assembly may cause spark plugs to
seize, causing damage to cylinder head threads.
--------.--erem, spark plug 1ecess area before removing spark
plug. Failure to do so can result in engine damage
due to dirt or foreign material entering cylinder head
assembly, or in contamination of cylinder head
threads. Contaminated threads may prevent proper
seating of new spark plug.
• Do not install spark plugs that are either "hotter" or
"colder" than the heat range specified for the
vehicle. Refer to SECTION OB, for spark plug usage
information. Today's technology requires a specific
spark plug heat range for each engine type. Instal-
ling spark plugs of any other heat range can severely
damage the engine assembly.
• When disconnecting connectors, do not use a screw-
driver or other tool to release the locking tab, as it
may break.
• Care should be exercised when connecting a timing
light or other pick-up equipment. Do not force any-
thing between the boots and wiring, or through the
silicone jackets. Connections should be made in par-
allel using an adapter. The tachometer terminal must
never be allowed to touch ground, as damage to the
PCM and/or ignition coil assembly can result.
• The material used to construct spark plug wires is
very soft. This wire will withstand more heat and
carry a higher voltage, but chaffing and cutting
become easier. The spark plug wires must be routed
correctly to prevent chaffing or cutting. See "Spark
Plug Wire Harness Assembly Replacement" in the
following procedure, for routing. When removing a
spark plug wire from a spark plug, twist the boot on
the spark plug one-half turn while pulling on the
boot.
 IGNITION SYSTEM 604·5

SPARK PLUG WIRE HARNESS ASSEMBLY SPARK PLUGS

REPLACEMENT
Figures 2 and 3
Figures 2 and 3
NOTICE: The boots should be twisted one-half turn
while removing. Do not pull on the wires to remove
them from the spark plugs. Pull on the boots, or use a
tool designed for this purpose.
When replacing spark plug wire harness assemblies
!++! Remove or Disconnect
(secondary wiring), route the wires correctly and through
the proper retainers. Failure to route the wires properly
can lead to radio ignition noise and crossfiring of the
spark plugs, or shorting of the leads to ground.
For location and routing of the spark plug wire har-
ness assemblies refer to Figures 2 and 3. Note the posi-
tions and locations of wires, retainers, studs, etc. for ease
of installation.
CAUTION: If you smokewhile handling
coated spark plugs, wear gloves to pre-
vent transfer of the coatinQ to ciga-
rettes and subsequent burning of the
coating. Wash hands after installing
spark plugs.
1. Be sure ignition switch is in "OFF" or "LOCK"
position.
NOTICE: The boots should be twisted one-half turn
while removing. Do not pull on the wires to remove
them from the spark plugs. Pull on the boots, or use a
tool designed for this purpose.
2. Spark plug wire harness assembly from spark plugs.
• Note positions of wires before removing.

FRTt

D c B A
F

A CYLINDER 2
B CYLINDER 4
C CYLINDER 6
D CYLINDER 8
E CYLINDER 1
F CYLINDER 3
G CYLINDER 5
H CYLINDER 7
1 DISTRIBUTOR ASSEMBLY, IGNITION

PC0002·6D4-F-RP

Figure 2 - Spark Plug Wire Harness Assembly Routing (5.7L LT1 Engine)
604:6 IGNITION SYSTEM

. A F

F
A" CYLINDER 2
B CYLINDER 4
C CYLINDER 6
D CYLINDER 1
E CYLINDER 3
F CYLINDER 5
2 IGNITION COIL ASSEMBLY
RC0001-o04-F-RP

Figure 3 - Spark Plug Wire Harness Assembly Routing (3.4L L32 Engine)

2. Water pump assembly. Refer to SECTION 6B.

[I] Important
• Clean dirt and debris from spark plug recess
areas.
3. Spark plugs from cylinder head assemblies.
!·++·! Install or Connect
NOTICE: Be sure spark plugs thread smoothly into
cylinder head assemblies and are fully seated. Cross-
threading or failing to fully seat spark plugs can
cause overheating of spark plugs, exhaust blow-by,
or thread damage. Follow recommended torque
specifications carefully. Over or under-tightening
can also cause severe damage to cylinder head
assemblies or spark plugs.
Spark plugs to cyJi"!der head assemblies.
I~! Tighten
• Spark plugs to 15 N•m (11 lb. ft.).
2. Spark plug wire harness assemblies, routed properly
as note during removal.
DISTRIBUTOR (5.7L LT1 ENGINE)
Figure 4
l+--+I Remove or Disconnect
I. Be sure ignition switch is in "OFF" or "LOCK"
position.
3. Crankshaft balancer assembly. Refer to SECTION
6A3A.
4. Spark plug wire harness assemblies from distributor
assembly (1 ).
5. Four-terminal PCM connector from distributor
assembly (I).
6. Distributor bolts/screws (3).
7. Distributor assembly (1 ).
A. Pull distributor assembly forward until drive-
shaft (4) disengages from end of camshaft
assembly.
B. Mark top surface of driveshaft (4 ), for align-
ment during installation.
I-++! Install or Connect
NOTICE: See "Notice" on page 6D4-l of this sec-
tion.
1. Distributor driveshaft (4) into distributor assembly
(1 ), if removed.
• Turn driveshaft (4) until alignment mark made
during removal is on top.
2. Distributor assembly (1) into position with drive-
shaft (4) in end of camshaft assembly.
3. Distributor bolts/screws (3).
l~I Tighten
• Bolts/screws (3) to 11 N•m (97 lb. in.).
 IGNITION SYSTEM 604·7

1. Spread silicone grease on metal mounting face of

ignition coil bracket (14) if necessary, and position
ignition coil assembly (8) to cylinder head assembly.
2. Stud (5).

!~I Tighten
• Stud (5) to 25 N•m (18 lb. ft.).
3. Bolt/screw (6).

!~I Tighten
• Bolt/screw (6) to 25 N•m (18 lb. ft.).
4. Ignition coil harness.
5. Ignition coil wiring connectors.
6. Four-terminal PCM connector to ignition coil mod-
ule.
IGNITION COIL ASS EMBLY (3.4L L32
1 DISTRIBUTOR ASSEMBLY ENGINE)
3 BOLT/SCREW, DISTRIBUTOR
4 DRIVESHAFT, DISTRIBUTOR PC0018-6A3B-F-RP
Figure 6
Figure 4- Distributor Assembly (5.7L LT1 Engine) !++I Remove or Disconnect
4. Four-terminal PCM connector to distributor assem- 1. Be sure ignition switch is in "OFF" or "LOCK"
bly (I). position.
5. Spark plug wire harness assemblies to distributor 2. Spark plug wire harness assembly from ignition coil
assembly (1 ). assembly (2).
6. Crankshaft balancer assembly. Refer to SECTION 3. Electrical connectors.
6A3A. 4. Nuts ( 16).
7. Water pump assembly. Refer to SECTION 6B. 5. Ignition coil assembly (2).

IGNITION COIL ASSEMBLY (5.7L LT1

ENGINE)
Figure 5

!++I Remove or Disconnect 7

I. Be sure ignition switch is in "OFF" or "LOCK"

L
position.
2. Four-terminal PCM connector at ignition coil mod-
ule.

~r
3. Ignition coil wiring connectors.
4. Ignition coil harness.
5. Bolt/screw (6).
6. Stud (5).
7. Ignition coil assembly (8).
• Do not wipe silicone grease from bottom of 5
ignition coil assembly (8) if it is to be rein-
stalled.

!++I Install or Connect 5 STUD, IGNITION COIL

NOTICE: See" Notice" on page 6D4-l of this sec- 6 BOLT/SCREW, IGNITION COIL
tion. 7 RETAINER, FUEL CANISTER PURGE TUBE
8 IGNITION COIL ASSEMBLY
NOTICE: If a new ignition coil assembly is to be
installed, a package of silicone grease will be
included in the box. This grease is necessary for PC0005-6D4-f.RP
ignition coil assembly cooling.
Figure 5- Ignition Coil Assembly (5.7L LT1 Engine)
604·8 IGNITION SYSTEM

l++l lnstall or Connect

NOTICE: See "Notice" on page 604-1 of this sec-
tion.
1. Lubricate sensor 0-ring with engine oil.
2. Sensor assembly (25) to the engine block.
3. Bolt/screw (26).

l~I Tighten
• Bolt/screw (26) to 10 N•m (89 lb. in.).
4. Sensor electrical connector.

24X SIGNAL CRANKSHAFT POSITION

SENSOR ASSEMBLY (3.4L L32 ENGINE)
Figure 7

16
l++I Remove or Disconnect
1. Be sure ignition switch is in "OFF" or "LOCK"
2 IGNITION COIL ASSEMBLY position.
16 NUT, IGNITION COIL ASSEMBLY 2. Crankshaft balancer assembly. Refer to SECTION
17 BRACKET, IGNITION COIL AND POWER STEERING
6A2A.
PUMP
3. Bolts/screws (24).
4. Sensor (23).
PC0007-6D4-F-RP

Figure 6 - Ignition Coil Assembly (3.4L L32 Engine) l++l lnstall or Connect
NOTICE: See "Notice" on page 604-1 of this sec-
tion.
l++l lnstall or Connect 1. Sensor (23).
2. Bolts/screws (24).
NOTICE: See "Notice" on page 604-1 of this sec-
tion.
1. Ignition coil assembly (2).
l~I
Tighten
• Bolts/screws (24) to 1.9 N•m (17 lb. in.).
2. Nuts (16). 3. Crankshaft balancer assembly. Refer to SECTION
l~I Tighten
6A2A.
CAMSHAFT POSITION SENSOR ASSEMBLY
• Nuts (16) to 10 N•m (89 lb. in.). (3.4L L32 ENGINE)
3. Electrical connectors. Figure 7
4. Spark plug wire harness assembly.
3X SIGNAL CRANKSHAFT POSITION
I++! Remove or Disconnect
SENSOR ASSEMBLY (3.4L L32 ENGINE) 1. Be sure ignition switch is in "OFF" or "LOCK"
position.
Figure 7 2. Electrical connector from sensor assembly (27).
3. Bolt/screw (28).
l++I Remove or Disconnect NOTICE: Be careful not to damage sensor assem-
bly when prying at its base during removal.
1. Be sure ignition switch is in "OFF" or "LOCK"
position. 4. Sensor assembly (27) using a small-bladed screw-
driver to gently pry between sensor assembly (27)
2. Sensor electrical connector. and engine block.
3. Bolt/screw (26). • Pry from alternate sides to loosen sensor
4. Sensor assembly (25) from engine block. assembly (27) in its mounting boss.

ll•l1nspect !l•l1nspect
• Sensor 0-ring for wear, cracks or leakage. Replace if • Sensor 0-rings for wear, cracks or leakage. Replace
necessary. if necessary.
 '
IGNITION SYSTEM 604·9

r-~
26 25

23 SENSOR ASSEMBLY, CRANKSHAFT POSITION (24X SIGNAL)

24 BOLT/SCREW, CRANKSHAFT POSITION SENSOR
25 SENSOR ASSEMBLY, CRANKSHAFT POSITION (3X SIGNAL)
26 BOLT/SCREW, CRANKSHAFT POSITION SENSOR
27 SENSOR ASSEMBLY, CAMSHAFT POSITION
28 BOLT/SCREW, CAMSHAFT POSITION SENSOR
PC0009·6D4-F-RP

Figure 7 - Crankshaft and Camshaft Position Sensor Assemblies (3.4L L32 Engine)

l++I Install or Connect

NOTICE: See "Notice" on page 6D4-1 of this sec-
tion. 11
I. Lubricate sensor 0-rings with engine oil.
13
2. Sensor (27) in engine block.
3. Bolt/screw (28).

l~I Tighten
• Bolt/screw (28) to 1.9 N•m (17 lb. in.).
4. Sensor electrical connector.

UNIT REPAIR
IGNITION COIL AND IGNITION COIL
MODULE (5.7L LT1 ENGINE}
Figure 8
\ 9

l+!+I Disassemble 9
10
RIVET, BRACKET ATTACHMENT
COIL, IGNITION
I. Coil (10) from brackets (13 and 14) by drilling out 11 MODULE, IGNITION COIL
rivets (9). 12 BOLT/SCREW, IGNITION COIL MODULE
13 BRACKET, IGNITION COIL
2. Bolts/screws (12). 14 BRACKET, IGNITION COIL
3. Ignition coil module ( 11 ).
PC000&-604-F·RP

!•!+I Assemble Figure 8 - Ignition Coil and Ignition Coil Module

(5.7L LT1 Engine)
NOTICE: See "Notice" on page 6D4-1 of this sec-
tion.
 604-10 IGNITION SYSTEM

NOTICE: A package of silicone grease is included 2. Ignition coils ( 18).

with a new ignition coil module. This grease is nec- 3. Seals (19).
essary for ignition coil module cooling.
4. Module (20) from bracket (21).
I. Spread silicone grease on metal face of ignition coil
module (11) and on bracket (13) where it seats, and
position ignition coil module ( 11) to bracket (13). f+!+I Assemble
2. Bolts/screws (12). NOTICE: See "Notice" on page 604-1 of this sec-
tion.
l~I Tighten 1. Module (20) to bracket (21 ).
• Bolts/screws (12) to 1.7 N•m (15 lb. in.). 2. Seals ( 19).
3. Coil ( 10) to brackets (13 and 14) using bolts/screws 3. Ignition coils ( 18).
provided with replacement coil ( 10). 4. Bolts/screws (22).

f~I Tighten f~I Tighten

• Bolts/screws to 2.8 N•m (25 lb. in.). • Bolts/screws (22) to 4.5 N•m (40 lb. in.).
IGNITION COIL ASSEMBLY (3.4L L32
ENGINE)
Figure 9

l+!+I Disassemble
I. Bolts/screws (22).

18

18

21

18 COIL, IGNITION
19 SEAL, IGNITION COIL
20 MODULE, IGNITION COIL 18
21 BRACKET, ELECTRONIC IGNITION COIL MODULE
22 BOLT/SCREW, IGNITION COIL

PC0008-6D4-F-RP

Figure 9 - Ignition Coils and Ignition Coil Module (3.4L L32 Engine)
 IGNITION SYSTEM 604-11

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Camshaft Position Sensor Assembly Bolt/Screw (3.4L L32 Engine) . . . . . . . . . . 1.9 N•m (17 lb. in.)
Distributor Bolt/Screw (5.7L LTl Engine) ................................ 11 N•m (97 lb. in.)
Ignition Coil Assembly Bolt/Screw (3.4L L32 Engine) ..................... 4.5 N•m (40 lb. in.)
Ignition Coil Assembly Bolt/Screw (5.7L LTl Engine) ...................... 25 N•m (18 lb. ft.)
Ignition Coil Assembly Nut (3.4L L32 Engine) ............................ 10 N•m (89 lb. in.)
Ignition Coil Assembly Stud (5.7L LTl Engine) ........................... 25 N•m (18 lb. ft.)
Ignition Coil Bolt/Screw (5.7L LTl Engine) ............................. 2.8 N•m (25 lb. in.)
Ignition Coil Module Bolt/Screw (5.7L LTl Engine) ...................... 1.7 N•m (15 lb. in.)
Spark Plugs ........................................................ 15 N•m (11 lb. ft.)
3X Signal Crankshaft Position Sensor Assembly
Bolt/Screw (3.4L L32 Engine) ....................................... 10 N•m (89 lb. in.)
24X Signal Crankshaft Position Sensor Assembly
Bolt/Screw (3.4L L32 Engine) ...................................... 1.9 N•m (17 lb. in.)
 ENGINE WIRING 605-1

SECTION 605
ENGINE WIRING
CONTENTS
Right-Hand Side Engine Wiring Harness
Assembly (3.4L L32) . . . . . . . . . . . . . . . . . . . . 6D5-2
Left-Hand Side Engine Wiring Harness
Assembly (3.4L L32) .................... 6D5-3
Rear View Engine Wiring Harness
Assembly (3.4L L32) . . . . . . . . . . . . . . . . . . . . 6D5-4
Right-Hand Side Engine Wiring Harness
Assembly (5.7L LTl) .................... 6D5-5
Left-Hand Side Engine Wiring Harness
Assembly (5.7L LTl) .................... 6D5-6
Transmission Engine Wiring Harness
Assembly (All) . . . . . . . . . . . . . . . . . . . . . . . . . 6D5-7

The following figures illustrate engine wiring harness routing and the various electrical/electronic components that
have terminal connectors attached to them. In the illustration legends, the connectors are identified with the component
name that completes their connection. Refer to SECTION 8A for detailed diagnostics.
605-2 ENGINE WIRING

B D

A CONNECTOR, OXYGEN SENSOR ELECTRICAL

B CONNECTOR, EXHAUST GAS RECIRCULATION
SOLENOID ELECTRICAL
C TUBE, VACUUM
N D CONNECTOR, INJECTOR ELECTRICAL
E CONNECTOR, GENERATOR ELECTRICAL
F CONNECTOR, IDLE AIR CONTROL STEPPER MOTOR
ELECTRICAL
G CONNECTOR, IDLE AIR TEMPERATURE SENSOR
ELECTRICAL
H CONNECTOR, THROTILE POSITION SENSOR
ELECTRICAL
J TERMINAL, ENGINE GROUND
K CONNECTOR, A/C COMPRESSOR CLUTCH ELECTRICAL
L CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
SENSOR ELECTRICAL
M CONNECTOR, CRANKSHAFT SENSOR ELECTRICAL
N CONNECTOR, KNOCK SENSOR ELECTRICAL
1 HARNESS ASSEMBLY, ENGINE WIRING
2 NUT, ENGINE WIRING HARNESS GROUND
3 NUT, ENGINE WIRING HARNESS START LEAD
4 WASHER, ENGINE WIRING HARNESS START LEAD
6 LEAD, ENGINE WIRING HARNESS START
15 SENSOR ASSEMBLY, MANIFOLD ABSOLUTE
PRESSURE
PCOOOl-805-F-RP

Figure 1 - Right-Hand Side Engine Wiring Harness Assembly (3.4L L32)

 ENGINE WIRING 605·3

A CONNECTOR, DISTRIBUTOR SENSOR INPUT/OUTPUT

ELECTRICAL
B CONNECTOR, DISTRIBUTOR POWER INPUT
ELECTRICAL
C CONNECTOR, ENGINE COOLANT TEMPERATURE GAGE
SENSOR ELECTRICAL
D CONNECTOR, CANISTER PURGE SOLENOID VALVE
ELECTRICAL
E CONNECTOR, CAMSHAFT POSITION SENSOR
ELECTRICAL
F CONNECTOR, OXYGEN SENSOR ELECTRICAL
G CONNECTOR, OIL PRESSURE SENSOR ELECTRICAL
H CONNECTOR, OIL LEVEL SENSOR ELECTRICAL
J STRAP, RIGHT FRONT GROUND
K CONNECTOR, POWER STEERING PRESSURE SWITCH
ELECTRICAL
L CONNECTOR, CRANKSHAFT POSITION SENSOR
ELECTRICAL
M CONNECTOR, CRANK SENSOR INPUT ELECTRICAL
I HARNESS ASSEMBLY, ENGINE WIRING
5 NUT, ENGINE WIRING HARNESS CLAMP

PC0002-6D5-F-RP

Figure 2 - Left-Hand Side Engine Wiring Harness Assembly (3.4L L32)

605-4 ENGINE WIRING

1 HARNESS ASSEMBLY, ENGINE WIRING

7 BOLT/SCREW, ENGINE WIRING HARNESS CLAMP
8 BOLT/SCREW, FLYWHEEL HOUSING
PC0003-605-F-RP

Figure 3 - Rear View Engine Wiring Harness Assembly (3.4L L32)

 ENGINE WIRING 605·5

A B c D

H 11

14 12
13

A CONNECTOR, IGNITION DISTRIBUTOR ELECTRICAL
B CONNECTOR, CANISTER PURGE SOLENOID VALVE
ELECTRICAL
C CONNECTOR, INJECTOR ELECTRICAL
D CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
SENSOR ELECTRICAL
E CONNECTOR, GENERATOR ELECTRICAL
F CONNECTOR, NC COMPRESSOR CLUTCH ELECTRICAL
G TUBE, VACUUM
H CONNECTOR, KNOCK SENSOR ELECTRICAL
J TERMINAL, ENGINE GROUND
K CONNECTOR, IDLE AIR CONTROL STEPPER MOTOR
ELECTRICAL
!VIEWB I
L CONNECTOR, THROTTLE POSITION SENSOR
ELECTRICAL
M CONNECTOR, OXYGEN SENSOR ELECTRICAL
9 BOLT/SCREW, ENGINE WIRING HARNESS CLAMP
10 HARNESS ASSEMBLY, ENGINE WIRING
11 NUT, ENGINE WIRING HARNESS GROUND
12 NUT, ENGINE WIRING HARNESS START LEAD
13 WASHER, ENGINE WIRING HARNESS START LEAD
14 LEAD, ENGINE WIRING HARNESS START
15 SENSOR ASSEMBLY, MANIFOLD ABSOLUTE
PRESSURE

PC0004-8D5-f..RP

Figure 4 - Right-Hand Side Engine Wiring Harness Assembly (5. ?L LT1)

605-6 ENGINE WIRING

A CONNECTOR, IGNITION COIL DRIVER ELECTRICAL jv1ewA I 17

B CONNECTOR, INJECTOR ELECTRICAL
C CONNECTOR, EXHAUST GAS RECIRCULATION
SOLENOID VALVE ELECTRICAL
D. CONNECTOR, OXYGEN SENSOR ELECTRICAL
E CONNECTOR, OIL PRESSURE SENSOR ELECTRICAL
F CONNECTOR, OIL LEVEL SENSOR ELECTRICAL
G CONNECTOR, ENGINE COOLANT TEMPERATURE GAGE
SENSOR ELECTRICAL
H STRAP, RIGHT FRONT GROUND
J CONNECTOR, IGNITION COIL ELECTRICAL
K CONNECTOR, ENGINE COOLANT TEMPERATURE
SENSOR ELECTRICAL
L TERMINAL, GROUND
10 HARNESS ASSEMBLY, ENGINE WIRING
16 NUT, ENGINE WIRING HARNESS CLAMP
17 NUT, ENGINE WIRING HARNESS GROUND

Figure 5 - Left-Hand Side Engine Wiring Harness Assembly (5.7L LT1)

 ENGINE WIRING 605-7

J
c
A TRANSMISSION ASSEMBLY, AUTOMATIC (MOS)
B TRANSMISSION ASSEMBLY, MANUAL (5-SPEED M49)
C TRANSMISSION ASSEMBLY, MANUAL (6-SPEED MM6)
D CONNECTOR, ELECTRONIC SWITCH
E CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
F CONNECTOR, BACKUP SWITCH ELECTRICAL
G CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
H CONNECTOR, BACKUP SWITCH ELECTRICAL
J CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
K CONNECTOR, REVERSE LOCKOUT SOLENOID ELECTRICAL
L CONNECTOR, SKIP SHIFT SOLENOID
1 HARNESS ASSEMBLY, ENGINE WIRING
RC0001-6D5-F-RP

Figure 6 - Transmission Engine Wiring Harness Assembly (All)

 EXHAUST SYSTEM 6F·1

SECTION 6F

EXHAUST SYSTEM
NOTICE: All new GM vehicles are certified by the United States Environmental Protection Agency as conform-
ing to the requirements of the regulations for the control of air pollution from new motor vehicles. This certification
is contingent on certain adjustments being set to factory standards, thus, these adjustment points either have been
permanently sealed and/or made inaccessible to prevent indiscriminate adjustment in the field. For this reason, the
factory procedure for temporarily removing plugs, caps, etc., for the purpose of servicing the product must be
strictly followed and, where practical, returned to the original intent of the design.

NOTICE: Exhaust system components must have enough clearance from the underbody to prevent overheating of
the floor panel assembly and possible damage to the passenger compartment, insulation and trim materials.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Exhaust Crossover Pipe Assembly . . . . . . . . . . 6F-1
Catalytic Converter Assembly . . . . . . . . . . . . . . 6F-1
Exhaust Muffler Assembly . . . . . . . . . . . . . . . . 6F-2
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
_Clam~s and Welded Connections ........... 6F-2
Diagnosis ................................ 6F-2
Testing for Restricted
Exhaust . . . . . . . . . . . . . . . . . Refer to Section 6E2
On-Vehicle Service ........................ 6F-3
Component Replacement .................. 6F-3
Exhaust Crossover Pipe Assembly . . . . . . . . . . 6F-3
Catalytic Converter Assembly . . . . . . . . . . . . . . 6F-4
Exhaust Pipe Assembly . . . . . . . . . . . . . . . . . . . 6F-5
Exhaust Muffler Assembly ................ 6F-6
Exhaust Tailpipe Extension Assembly
(5.7L LTl Engine) ..................... 6F-6
Catalytic Converter Hanger Assembly . . . . . . . 6F-7
Exhaust Muffler Hanger Assemblies . . . . . . . . . 6F-9
Exhaust Muffler Interior Bracket
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-10
Catalytic Converter Heat Shield . . . . . . . . . . . 6F- l 1
Exhaust Heat Shield . . . . . . . . . . . . . . . . . . . . . 6F-11
Exhaust Pipe Heat Shield Assembly and
Exhaust Muffler Heat Shield . . . . . . . . . . . . 6F-12
Exhaust System Clearance Dimensions . . . . . . 6F-13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Fastener Tightening Specifications . . . . . . . . . 6F-16

GENERAL DESCRIPTION muffler assembly must be replaced whenever a new

exhaust muffler assembly is installed.
NOTICE: When inspecting or replacing exhaust
system components, make sure there is adequate EXHAUST CROSSOVER PIPE ASSEMBLY
clearance from all points on the underbody to pre-
vent overheating of the floor panel assembly and On the 3.4L L32 engine, the exhaust crossover pipe
possible damage to the passenger compartment, assembly can be removed from the catalytic converter
insulation and trim materials. assembly. On the 5. 7L LTl engine, the exhaust crossover
pipe and catalytic converter assembly must be replaced as
Periodic maintenance of the exhaust system is not a complete assembly.
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust CATALYTIC CONVERTER ASSEMBLY
system.
Figure 1
Check complete exhaust system, nearby body areas
and rear compartment lid for broken, damaged, missing or CAUTION: Prolonged operation with a
mispositioned parts, open seams, holes, loose connections misfiring or flooded engine may cause
or other deterioration that could permit exhaust fumes to the catalytic converter to overheat.
seep into the rear compartment or passenger compart- This could cause damage either to the
ment. Dust or water in the rear compartment may indicate catalyst itself or the operating vehicle
a problem in one of these areas. Any faulty areas should and possible personal injury.
be corrected immediately. To help ensure continued NOTICE: When jacking or lifting vehicle from
integrity, the exhaust system pipe rearward of the exhaust frame side rails, be certain lift pads do not contact
6F·2 EXHAUST SYSTEM

catalytic converter or damage to catalytic c;onverter HANGERS

may result.
The catalytic converter assembly is an emission
control device added to the exhaust system to reduce
pollutants from the exhaust gas stream.
NOTICE: The catalytic converter requires the use
of unleaded fuel only, or damage to the catalyst may
result.
A single bed monolith catalytic converter is used in
combi~ati<?n with two different types of catalyst. These
are ox1dat10n catalyst and three-way (reduction/oxida-
tion) catalyst.
[I) Important
• The installation of exhaust system supports is very
important, as improperly installed supports can
cause annoying vibrations that can be difficult to
diagnose.
Two types of hangers are used to support the exhaust
system. One type is a conventional rubber strap. The
second type is a "rubber block." The rubber block type
provides a rigid hanger along with a feature that continues
to support the exhaust system if a rubber insulator block is
broken.

The catalysts have coatings that contain platinum
and palladium. The oxidation catalyst lowers the level of
hydrocarbons (HC) and carbon monoxide (CO). The
three-way catalyst lowers the levels of oxides of nitrogen
(N03) as well as HC and CO.
EXHAUST MUFFLER ASSEMBLY
The muffler assembly is a tri-flow design. The muf-
fler assembly has a slot in the inlet pipe. The slot indexes
to a key (tab) welded on the exhaust pipe assembly to help
maintain alignment.
CLAMPS AND WELDED CONNECTIONS
CAUTION: Coat slip joints with exhaust
system sealer before assembly to pre-
vent exhaust from entering the vehicle
and causing personal injury.
Two methods are used for connecting exhaust
system slip joints: clamps and welds. When servicing a
welded connection it should be cut and the new connec-
tion clamped when installing replacement parts.
Three types of clamps are used for connecting
exhaust system slip joints: guillotine, saddle/U-bolt and
single nut compression.

DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
Leaking Exhaust Gases Leaks at pipe joints. Tighten nuts or bolts/screws at leaking
joints to specifications.
Exhaust Noises 1. Exhaust pipes contacting heat 1. Tighten heat shield bolts/screws to
shields, or loose heat shields. Inspect 2.0 N•m (18 lb. in.). Align exhaust
when cold and after warmup. system if necessary. Refer to
"Exhaust System Clearance
Dimensions" in this section.
2. Leaks at manifold assembly or pipe 2. Tighten clamps at leaking
connections. connections to specifications.
3. Burned or blown-out muffler 3. Replace muffler assembly.
assembly.
4. Burned or rusted out exhaust pipe 4. Replace exhaust pipe assembly.
assembly.
5. Leaking exhaust crossover pipe 5. Tighten exhaust crossover pipe nuts
assembly at manifold flange. to 35 N•m (26 lb. ft.).
6. Cracked or broken manifold 6. Replace manifold assembly.
assembly.
7. Leak between manifold assembly 7. Tighten manifold-to-cylinder head
and cylinder head. stud nuts or bolts/screws to specifi-
cations. Refer to SECTION 6A2A
or 6A3A.
 EXHAUST SYSTEM 6F-3

CONDITION POSSIBLE CAUSE CORRECTION

Exhaust Vibrations
Loss of Engine Power and/or
Internal Rattles in Muffler
Assembly
1. Transmission shims are between cat- 1.
alytic converter assembly and trans-
mission support assembly.
2. Inadequate clearance, less than 3 mm 2.
(1/8 inch), between transmission
support assembly and floor panel
assembly.
3. Inadequate clearance, less than 3 mm 3.
(1/8 inch), between catalytic
converter hanger assembly and
transmission support assembly.
Dislodged turning tubes and/or baffles in
muffler assembly, catalytic converter
assembly or exhaust pipe assembly.
Reposition shims so they are
between transmission assembly and
catalytic converter bracket.
Replace transmission support
assembly. Refer to SECTION 11.
Loosen catalytic converter hanger
bolts/screws and reposition catalytic
converter hanger assembly.
Replace muffler assembly, catalytic
converter assembly or exhaust pipe
assembly.

ON-VEHICLE SERVICE EXHAUST CROSSOVER PIPE ASSEMBLY

3.4L L32 Engine
COMPONENT REPLACEMENT
Exhaust system service includes replacement of the Figures 1 and 2
following items:
• Exhaust crossover pipe assembly (3.4L L32 engine)
l++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
• Catalytic converter assembly (with crossover pipe
TION QA.
for 5.7L LTl engine)
2. Exhaust crossover pipe nuts (2).
• Exhaust pipe assembly
3. Exhaust crossover pipe assembly (4) from studs on
• Exhaust muffler assembly (with tailpipe(s)) exhaust manifold assembly (1).
• Complete exhaust system 4. Lower exhaust system.
• Catalytic converter and exhaust muffler hanger 5. Exhaust crossover pipe seal (3) from exhaust man-
assemblies ifold assembly (1 ).
• Catalytic converter heat shield 6. Support catalytic converter assembly (7) and
exhaust system.
• Exhaust heat shield
7. Catalytic converter clamp assembly (8).
• Exhaust pipe heat shield assembly 8. Catalytic converter assembly (7) from exhaust
• Exhaust muffler heat shield crossover pipe assembly (4).

A
A RIGHTSIDE
B LEFT SIDE
C STUD
1 MANIFOLD ASSEMBLY, EXHAUST 2
2 NUT, EXHAUST CROSSOVER PIPE, 35 N•m (26 LB. FT.)
3 SEAL, EXHAUST CROSSOVER PIPE
4 PIPE ASSEMBLY, EXHAUST CROSSOVER PC0001 ·BF·F-RP

Figure 1 - Exhaust Manifold Attachments (3.4L L32 Engine)

6F-4 EXHAUST SYSTEM

9--
4

31

!VIEWA!

4 PIPE ASSEMBLY, EXHAUST CROSSOVER

7 CONVERTER ASSEMBLY, CATALYTIC
8 CLAMP ASSEMBLY, CATALYTIC CONVERTER, 11
68 N•m (50 LB. FT.)
11 BOLT/SCREW, EXHAUST PIPE, 20 N•m (15 LB. FT.)
12 PIPE ASSEMBLY, EXHAUST
30 HANGER ASSEMBLY, CATALYTIC CONVERTER
31 BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 N•m (30 LB. FT.) . PC0003-6F·F·RP

Figure 2 - Catalytic Converter Assembly (3.4L L32 Engine)

CATALYTIC CONVERTER ASSEMBLY

l++I Install or Connect
NOTICE: See "Notice" on page 6F-1 of this
section.
1. Exhaust crossover pipe assembly (4) to catalytic
converter assembly (7).
2. Catalytic converter clamp assembly (8).
l~I Tighten
• Catalytic converter clamp assembly (8) to 68
N•m (50 lb. ft.).
3. Exhaust crossover pipe seal (3).
4. Raise exhaust crossover pipe assembly (4).
5. Exhaust crossover pipe assembly (4) to studs on
exhaust manifold assembly (1).
6. Exhaust crossover pipe nuts (2).
l~I Tighten
• Exhaust crossover pipe nuts (2) evenly to 35
N•m (26 lb. ft.).
7. Lower vehicle.
5.7L LT1 Engine
The crossover pipe is welded to the catalytic con-
verter assembly. The crossover pipe and catalytic convert-
er assembly are replaced as a unit. Refer to "Catalytic
Converter Assembly" in the following procedure.
3.4L L32 Engine
Figure 2
l++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Catalytic converter clamp assembly (8) at exhaust
crossover pipe assembly (4).
3. Exhaust pipe bolts/screws (11 ).
4. Exhaust pipe assembly (12) from catalytic converter
assembly (7).
5. Catalytic converter hanger bolts/screws (31).
6. Catalytic converter assembly (7).
l++I Install or Connect
NOTICE: See "Notice" on page 6F-1 of this sec-
tion.
1. Catalytic converter assembly (7) to catalytic con-
verter hanger assembly (30).
2. Catalytic converter hanger bolts/screws (31).
l~I Tighten
• Catalytic converter hanger bolts/screws (31) to
41 N•m (30 lb. ft.)
3. Exhaust pipe assembly (12) to catalytic converter
assembly (7).
4. Exhaust pipe bolts/screws ( 11 ).
 EXHAUST SYSTEM 6F·5

3. Exhaust crossover pipe from studs on exhaust man-

l~I Tighten ifold assembly (5).
4. Exhaust pipe bolts/screws (13).
• Exhaust pipe bolts/screws (11) to 20 N•m (15
lb. ft.). 5. Catalytic converter assembly (10) from exhaust pipe
assembly (14).
5. Catalytic converter clamp assembly (8) at exhaust
crossover pipe assembly (4). 6. Catalytic converter hanger bolts/screws (40).
7. Catalytic converter assembly (10).
l~I Tighten
!++I. Install or Connect
• Catalytic converter clamp assembly (8) to 68
N•m (50 lb. ft.). NOTICE: See "Notice" on page 6F-1 of this sec-
6. Lower vehicle. tion.
1. Catalytic converter assembly (10) to catalytic con-
5.7L LT1 Engine verter hanger assembly (35).
2. Catalytic converter hanger bolts/screws (40).
Figures 3 and 4

l++I Remove or Disconnect l~I Tighten

• Catalytic converter hanger bolts/screws (40) to
1. Raise and suitably support vehicle. Refer to SEC- 41 N•m (30 lb. ft.).
TION OA.
3. Exhaust pipe assembly (14) to catalytic converter
2. Exhaust crossover pipe nuts (2). assembly (10).
4. Exhaust pipe bolts/screws (13).

FRTJ I~! Tighten

• Exhaust pipe bolts/screws (13) to 20 N•m (15
lb. ft.).
5. Exhaust crossover pipe to studs on exhaust manifold
5 assembly (5).
6. Exhaust crossover pipe nuts (2).
c
D l~I Tighten
• Exhaust crossover pipe nuts (2) to 35 N•m (26
lb. ft.).
7. Lower vehicle.

2 5 EXHAUST PIPE ASSEMBLY

Figures 2 and 4 through 6

l++I Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
c 2. Exhaust pipe bolts/screws (11 or 13) at catalytic con-
verter assembly (7 or 10).
3. Exhaust pipe hanger nut (19 or 22).
4. Muffler clamp assembly (17 or 23).
5. Exhaust pipe assembly (12 or 14) from exhaust muf-
fler assembly (15 or 20).
6. Exhaust pipe assembly (12 or 14), sliding it out of
A RIGHTSIDE exhaust pipe hanger bracket assembly (18 or 21).
B LEFTSIDE
C
D
2
STUD
PIPE, EXHAUST CROSSOVER
NUT, EXHAUST CROSSOVER PIPE, 35 N•m (26 LB. FT.)
!++I Install or Connect
5 MANIFOLD ASSEMBLY, EXHAUST NOTICE: See "Notice" on page 6F-1 of this
section.
PC0002·Bf·F·RP
1. Exhaust pipe assembly (12 or 14) to exhaust pipe
Figure 3 - Exhaust Manifold Attachments (5.7L LT1 Engine) hanger bracket assembly (18 or 21).
6F-6 EXHAUST SYSTEM

A PIPE, EXHAUST CROSSOVER

10 CONVERTER ASSEMBLY, CATALYTIC
13 BOLT/SCREW, EXHAUST PIPE, 20 N•m (15 LB. FT.) 14
14 PIPE ASSEMBLY, EXHAUST
35 HANGER ASSEMBLY, CATALYTIC CONVERTER
40 BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 N•m (30 LB. FT.) PCOOfM.6F-F-RP

Figure 4- Catalytic Converter Assembly (5.7L LT1 Engine)

2. Exhaust pipe assembly ( 12 or 14) to exhaust muffler

assembly (15 or 20).
3. Muffler clamp assembly (17 or 23).
l++I Install or Connect
NOTICE: See "Notice" on page 6F-l of this
l~I Tighten
section.
1. Exhaust muffler assembly (15 or 20).
• Muffler clamp assembly (17 or 23) to 68 N•m
2. Tailpipe to exhaust muffler hanger assembly (16 or
(50 lb. ft.).
24).
4. Exhaust pipe hanger nut (19 or 22).
3. Exhaust pipe assembly (12 or 14) at exhaust muffler
l~I Tighten
assembly ( 15 or 20).
4. Muffler clamp assembly (17 or 23).
• Exhaust pipe hanger nut (19 or 22) to 15 N •m
(11 lb. ft.).
5. Exhaust pipe bolts/screws (11 or 13) to catalytic
l~I Tighten

converter assembly (7 or 10). • Muffler clamp assembly (17 or 23) to 68 N•m

(50 lb. ft.).
l~I Tighten 5. Exhaust muffler hanger nut (26), if equipped.
• Exhaust pipe bolts/screws (11 or 13) to 20 N•m
(15 lb. ft.). l~I Tighten
6. Lower vehicle. • Exhaust muffler hanger nut (26) to 25 N•m ( 18
lb. ft.).
EXHAUST MUFFLER ASSEMBLY 6. Lower vehicle.

Figures 5 and 6 EXHAUST TAILPIPE EXTENSION ASSEMBLY

l++I Remove or Disconnect
(5.7L LT1 ENGINE)

1. Raise and suitably support vehicle. Refer to SEC-

TION OA.
l++I Remove or Disconnect
1. Loosen exhaust tailpipe extension clamp assembly.
2. Exhaust muffler hanger nut (26), if equipped. 2. Exhaust tailpipe extension assembly from tailpipe.
3. Muffler clamp assembly (17 or 23).
4. Exhaust pipe assembly ( 12 or 14) at exhaust muffler
assembly ( 15 or 20).
l++I Install or Connect
NOTICE: See "Notice" on page 6F-1 of this sec-
5. Tailpipe from exhaust muffler hanger assembly (16 tion.
or 24). 1. Exhaust tailpipe extension assembly to tailpipe until
6. Exhaust muffler assembly (15 or 20). stop position is reached.
 EXHAUST SYSTEM 6F·7

12

16

!VIEWB I

A TAILPIPE
12 PIPE ASSEMBLY, EXHAUST
15 MUFFLER ASSEMBLY, EXHAUST
16 HANGER ASSEMBLY, EXHAUST MUFFLER
17 CLAMP ASSEMBLY1 MUFFLER, 68 N•m (50 LB. FT.)
18 BRACKET ASSEMBLY, EXHAUST PIPE HANGER
19 NUT, EXHAUST PIPE HANGER 15 N•m (11 LB. FT.) 12
PC0007-6F-F-RP

Figure 5 - Exhaust Muffler Assembly (3.4L L32 Engine)

2. Align exhaust tailpipe extension assembly to rear 4. Rear axle torque arm outer bracket bolt/screw (34),
fascia assembly and tighten exhaust tailpipe exten- if equipped.
sion clamp assembly. 5. Rear axle torque arm bracket nuts (29 or 39) from
rear axle torque arm inner bracket bolts/screws (28
l~I Tighten or 36).
• Exhaust tailpipe extension clamp assembly to 6. Catalytic converter hanger bracket assembly (32, 33
70 N•m (52 lb. ft.). or 38) with catalytic converter hanger assembly (30
or 35) away from rear axle torque arm inner bracket
assembly (27 or 37).
CATALYTIC CONVERTER HANGER
ASSEMBLY 7. Catalytic converter hanger assembly (30 or 35) from
catalytic converter hanger bracket assembly (32, 33
or 38).
Figures 7 and 8

l++I Remove or Disconnect l++I Install or Connect

NOTICE: See "Notice" on page 6F-1 of this sec-
1. Raise and suitably support vehicle. Refer to SEC-
tion.
TION OA.
1. Catalytic converter hanger assembly (30 or 35) to
2. Support catalytic converter assembly (7 or 10). catalytic converter hanger bracket assembly (32, 33
3. Catalytic converter hanger bolts/screws (31 or 40). or 38).
6F-8 EXHAUST SYSTEM

20

14

24

21

!VIEWB I

24

A TAILPIPE
14 PIPE ASSEMBLY, EXHAUST
20 MUFFLER ASSEMBLY, EXHAUST
21 BRACKET ASSEMBLY, EXHAUST PIPE HANGER
22 NUT, EXHAUST PIPE HANGER, 15 N•m (11 LB. FT.)
23 CLAMP ASSEMBLY, MUFFLER, 68 N•m (50 LB. FT.)
24 HANGER ASSEMBLY, EXHAUST MUFFLER
26 NUT, EXHAUST MUFFLER HANGER, 25 N•m (18 LB. FT.)

PC0008·6f·F·RP

Figure 6 - Exhaust Muffler Assembly (5.7L LT1 Engine)

 EXHAUST SYSTEM 6F·9

A WITH MANUAL FIVE-SPEED TRANSMISSION

ASSEMBLY
B WITH AUTOMATIC TRANSMISSION ASSEMBLY
7 CONVERTER ASSEMBLY, CATALYTIC
27 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER
28 BOLT/SCREW, REAR AXLE TORQUE ARM INNER
BRACKET
29 NUT, REAR AXLE TORQUE ARM BRACKET,
41 N•m (30 LB. FT.)
30 HANGER ASSEMBLY, CATALYTIC CONVERTER
31 BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 N•m (30 LB. FT.)
32 BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
33 BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
34 BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
BRACKET, 27 N•m (20 LB. FT.)

PC0009-6F-F-RP

Figure 7 - Catalytic Converter Hanger Assembly to Transmission Assembly (3.4L L32 Engine)

2. Catalytic converter hanger bracket assembly (32, 33 l~I Tighten

or 38) with catalytic converter hanger assembly (30 • Catalytic converter hanger bolts/screws (31 or
or 35) to rear axle torque arm inner bracket assembly 40) to 41 N•m (30 lb. ft.).
(27 or 37). 6. Remove support from catalytic converter assembly
3. Rear axle torque arm bracket nuts (29 or 39) to rear (7 or 10).
axle torque arm inner bracket bolts/screws (28 or 7. Lower vehicle.
36).
EXHAUST MUFFLER HANGER ASSEMBLIES
l~I Tighten Figures 5, 6 and 9
• Rear axle torque arm bracket nuts (29 or 39) to
41 N•m (30 lb. ft.). 3.4L L32 Engine

4. Rear axle torque arm outer bracket bolt/screw (34),

if equipped.
!++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
l~I Tighten
TION OA.
2. Support exhaust muffler assembly (15).
• Rear axle torque arm outer bracket bolt/screw 3. Exhaust muffler hanger bracket bolts/screws (42)
(34) to 27 N•m (20 lb. ft.).
4. Exhaust muffler hanger assembly (16) by sliding it
5. Catalytic converter hanger bolts/screws (31 or 40). off of tailpipe.
6F·10 EXHAUST SYSTEM

6. Exhaust muffler hanger assembly (57).

l++I Install or Connect

NOTICE: See "Notice" on page 6F-1 of this sec-
tion.
1. Exhaust muffler hanger assembly (57).
2. Exhaust muffler hanger bracket bolts/screws (41).

l~I Tighten
• Exhaust muffler hanger bracket bolts/screws
(41) to 15 N•m (11 lb. ft.).
3. Exhaust muffler hanger assembly (24).
4. Exhaust muffler hanger nut (26).

l~I Tighten
37 • Exhaust muffler hanger nut (26) to 25 N•m (18
10 CONVERTER ASSEMBLY, CATALYTIC lb. ft.).
35 HANGER ASSEMBLY, CATALYTIC CONVERTER 5. Remove support from exhaust muffler assembly
36 BOLT/SCREW, REAR AXLE TORQUE ARM INNER
BRACKET (20).
37 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER 6. Lower vehicle.
38 BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
39 NUT, REAR AXLE TORQUE ARM BRACKET, EXHAUST MUFFLER INTERIOR BRACKET
41 N•m (30 LB. FT.) ASSEMBLY
40 BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 N•m (30 LB. FT.) PC0011-6F-F-RP Figures 5, 6 and 9
Figure 8 - Catalytic Converter Assembly to Transmission
Assembly (5.7L LT1 Engine- Manual Transmission
Assembly Shown, Automatic Transmission Assembly Similar)
l++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Support exhaust muffler assembly (15 or 20) and
exhaust pipe assembly (12 or 14).
l++I Install or Connect 3. Exhaust pipe hanger nut (19 or 22).
NOTICE: See "Notice" on page 6F-1 of this sec- 4. Exhaust pipe hanger bracket assembly (18 or 21).
tion. 5. Exhaust muffler interior hanger bolts/screws (44).
1. Exhaust muffler hanger assembly (16 or 24) to tail- 6. Exhaust muffler interior bracket assembly (43).
pipe and underbody.
2. Exhaust muffler hanger bracket bolts/screws (42). l++I Install or Connect

l~I Tighten
NOTICE: See "Notice" on page 6F-1 of this sec-
tion.
• Exhaust muffler hanger bracket bolts/screws 1. Exhaust muffler interior bracket assembly (43).
(42) to 15 N•m (11 lb. ft.).
2. Exhaust muffler interior hanger bolts/screws (44 ).
3. Remove support from exhaust muffler assembly
(15)
4. Lower vehicle.
l~I Tighten
• Exhaust muffler interior hanger bolts/screws
(44) to 15 N•m (11 lb. in.).
5.7L LT1 Engine
3. Exhaust pipe hanger bracket assembly (18 or 21).
l++I Remove or Disconnect 4. Exhaust pipe hanger nut (19 or 22).

1. Raise and suitably support vehicle. Refer to SEC-

TION OA.
l~I Tighten
• Exhaust pipe hanger nut (19 or 22) to 15 N•m
2. Support exhaust muffler assembly (20).
(11 lb. in.).
3. Exhaust muffler hanger nut (26). 5. Remove support from exhaust muffler assembly (15
4. Exhaust muffler hanger assembly (24). or 20) and exhaust pipe assembly (12 or 14).
5. Exhaust muffler hanger bracket bolts/screws (41). 6. Lower vehicle.
 EXHAUST SYSTEM 6F-11

A UNDERBODY
B 5.7L LT1 ENGINE
C 3.4L L32 ENGINE
15 MUFFLER ASSEMBLY, EXHAUST
16 HANGER ASSEMBLY, EXHAUST MUFFLER
20 MUFFLER ASSEMBLY, EXHAUST
41 BOLT/SCREW, EXHAUST MUFFLER HANGER BRACKET,
15N•m (11 LB. FT.)
42 BOLT/SCREW, EXHAUST MUFFLER HANGER BRACKET,
15N•m (11 LB. FT.) c
43 BRACKET ASSEMBLY, EXHAUST MUFFLER INTERIOR
44 BOLT/SCREW, EXHAUST MUFFLER INTERIOR
HANGER, 15 N•m (11 LB.FT.) jv1EwAj
57 HANGER ASSEMBLY, EXHAUST MUFFLER
PC0012-6F-F-RP

Figure 9 - Installing Exhaust Muffler Hanger Assemblies to Underbody

CATALYTIC CONVERTER HEAT SHIELD

Figure 10
l++I Remove or Disconnect
1. Catalytic converter assembly. Refer to "Catalytic
Converter Assembly" under "On-Vehicle Service"
in this section.
2. Catalytic converter heat shield bolts/screws (46).
EXHAUST HEAT SHIELD
3. Catalytic converter heat shield (45).
l©..I Tighten
• Catalytic converter heat shield bolts/screws
(46) to 2.0 N•m (18 lb. in.).
3. Catalytic converter assembly. Refer to "Catalytic
Converter Assembly" under "On-Vehicle Service"
in this section.

l++I Install or Connect Figure 10

NOTICE: See "Notice" on page 6F-l of this sec-
tion.
l++I Remove or Disconnect
1. Exhaust crossover pipe assembly (3.4L L32 engine).
1. Catalytic converter heat shield (45). Refer to "Exhaust Crossover Pipe Assembly" under
2. Catalytic converter heat shield bolts/screws (46). "On-Vehicle Service" in this section.
6F·12 EXHAUST SYSTEM

47

48

45 SHIELD, CATALYTIC CONVERTER HEAT

46 BOLT/SCREW, CATALYTIC CONVERTER HEAT SHIELD,
2.0 N•m (18 LB. IN.)
~ · 46

47 SHIELD, EXHAUST HEAT

48 BOLT/SCREW, EXHAUST HEAT SHIELD, 2.0 N•m
(18 LB. IN.) PC0014-6f·f·RP

Figure 1O- Catalytic Converter and Exhaust Heat Shields

2. Catalytic converter assembly (5.7L LTl engine).
Refer to "Catalytic Converter Assembly" under
"On-Vehicle Service" in this section.
3. Exhaust heat shield bolt/screw (48).
4. Exhaust heat shield (47).
l++I Install or Connect
NOTICE: See "Notice" on page 6F-1 of this sec-
tion.
1. Exhaust heat shield (47).
2. Exhaust heat shield bolt/screw (48).
EXHAUST PIPE HEAT SHIELD ASSEMBLY
AND EXHAUST MUFFLER HEAT SHIELD
Figure 11
l++I Remove or Disconnect
1. Exhaust muffler assembly. Refer to "Exhaust Muf-
fler Assembly" under "On-Vehicle Service" in this
section.
2. Exhaust pipe assembly. Refer to "Exhaust Pipe
Assembly" in this section.
3. Exhaust pipe heat shield bolts/screws (50).

l~I Tighten 4. Exhaust pipe heat shield assembly (49).

5. Exhaust muffler heat shield bolts/screws (51).
• Exhaust heat shield bolt/screw (48) to 2.0 N•m
(18 lb. in.). 6. Exhaust muffler heat shield (52).

3. Catalytic converter assembly (5.7L LTl engine).

Refer to "Catalytic Converter Assembly" under
l++I Install or Connect
"On-Vehicle Service" in this section. NOTICE: See "Notice" on page 6F-1 of this sec-
tion.
4. Exhaust crossover pipe assembly (3.4L L32 engine).
1. Exhaust muffler heat shield (52).
Refer to "Exhaust Crossover Pipe Assembly" under
"On-Vehicle Service" in this section. 2. Exhaust muffler heat shield bolts/screws (51).
 EXHAUST SYSTEM 6F-13

Assembly" in this section.

l~I Tighten 6. Exhaust muffler assembly. Refer to "Exhaust Muf-
fler Assembly" under "On-Vehicle Service" in this
• Exhaust muffler heat shield bolts/screws (51)
to 2.0 N•m (18 lb. in.). section.

3. Exhaust pipe heat shield assembly (49). EXHAUST SYSTEM CLEARANCE

4. Exhaust pipe heat shield bolts/screws (50). DIMENSIONS

l~I Tighten
Figures 12 and 13
All checking dimensions are to be made on a cold
• Exhaust pipe heat shield bolts/screws (50) to exhaust system.
2.0 N•m (18 lb. in.).
If dimensions cannot be met, it indicates a quality
5. Exhaust pipe assembly. Refer to "Exhaust Pipe deficiency in a component part that must be corrected.

!VIEWA I
A UNDERBODY
B EXTERIOR RAIL COMPARTMENT
C BRACKET
49 SHIELD ASSEMBLY, EXHAUST PIPE HEAT
50 BOLT/SCREW, EXHAUST PIPE HEAT SHIELD,
2.0 N•m (18 LB. IN.)
51 BOLT/SCREW, EXHAUST MUFFLER HEAT SHIELD,
2.0 N•m (18 LB. IN.)
52 SHIELD, EXHAUST MUFFLER HEAT
PC0015·6f.F·RP

Figure 11 - Exhaust Pipe Heat Shield Assembly and Exhaust Muffler Heat Shield
SF-14 EXHAUST SYSTEM

18mm(0.71~
7
53

)J ~: to.~·,
16 mm (0.63")
~12
!VIEWG!
ma<
B IVIEW A I 12 mm (0.47") min.
27 mm (1.06") max.
22 mm (0.87") min.
A

·~~"
--~>v
25 mm (0.98") min.

!VIEWB I
18 mm (0.71") max.
13 mm (0.51") min.
22 mm (0.87") max.
18.5 mm (0.73") min.
I VIEWJ!

18 mm (0.71")
, 22 mm (0.87") max.
17 mm (0.67") min. A

~
~t4 19 mm (0.75") max.
mm (0.55") min.

A E 12 7
!v1EwK!
jv1EWF I
A

A UNDERBODY
B FRAME BRACKET AND SCREW
C PANEL, DASH FRONT
D FRAME
E TAILPIPE
F EXTENSION, EXHAUST HEAT SHIELD
4 PIPE ASSEMBLY, EXHAUST CROSSOVER
7 CONVERTER ASSEMBLY, CATALYTIC
8 CLAMP ASSEMBLY, CATALYTIC CONVERTER,
68 N•m (50 LB. FT.)
12 PIPE ASSEMBLY, EXHAUST 15
15 MUFFLER ASSEMBLY, EXHAUST
45 SHIELD, CATALYTIC CONVERTER HEAT
53 PAN ASSEMBLY, OIL
PC0016-6F-F-RP

Figure 12 - Exhaust System Clearance Dimensions (3.4L L32 Engine)

 EXHAUST SYSTEM 6F-15

A,~It.
~
19mm(0.75")max.
14 mm (0.55") min.

!VIEWH!
12.5 mm (0.50") max.
C 7.5 mm (0.30") min.

E
,f~~ -:,._ J
29.5 mm (1.16") max.
~J__
--r

A
- ~ 2 4 . 5 mm (0.96") min. E

!:'Ji.,.
!VIEWD

45
I cS SECTION L-L

15 mm (0.60") max.
10 mm (0.40") min.
~'~ ---=---.---. 27 mm (1.07")
14-::ffDD
!VIEWA!
10- '-==""'--=-"

~FRT IVIEWE I 30.5 mm (1.20") max.

/E 25.5 mm (1.0") min.

f(,,
55

mm )052") max.
8 mm (0.32") min. SECM-M/N-N

IVIEW BI 58
21.5 mm (0.85") max.
16.5 mm (0.65") min.

29.5 mm (1.16") max.

24.5 mm (0.96") min.
26.5 mm (1.04") max.
21.5 mm (0.85") min. &J(S!::~--
29.5 mm (1.16") max.
24.5 mm (0.96") min.
26.5 mm (1.04") max.
'f 21.5 mm (0.85") min.
B

A
A UNDERBODY
B CROSSMEMBER
C TAILPIPE
D SPARE TIRE WHEEL WELL ASSEMBLY PINCH
E PIPE, EXHAUST CROSSOVER
10 CONVERTER ASSEMBLY, CATALYTIC
14 PIPE ASSEMBLY, EXHAUST
20 MUFFLER ASSEMBLY, EXHAUST
45 SHIELD, CATALYTIC CONVERTER HEAT
49 SHIELD ASSEMBLY, EXHAUST PIPE HEAT
54 PAN ASSEMBLY, OIL
55 PIPE ASSEMBLY, TRANSMISSION OIL COOLER
29.5 mm (1.16") max. 56 TRANSMISSION ASSEMBLY
24.5 mm (0.96") min. 58 SOLENOID, EXHAUST PRESSURE REGULATOR VALVE
PC0017-6F-F-RP

Figure 13- Exhaust System Clearance Dimensions (5.7L LT1 Engine)

6F-16 EXHAUST SYSTEM

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Catalytic Converter Clamp Assembly ................................... 68 N•m (50 lb. ft.)
Catalytic Converter Hanger Bolt/Screw .................................. 41 N•m (30 lb. ft.)
Catalytic Converter Heat Shield Bolt/Screw ............................. 2.0 N•m (18 lb. in.)
Exhaust Crossover Pipe Nut ........................................... 35 N•m (26 lb. ft.)
Exhaust Heat Shield Bolt/Screw ....................................... 2.0 N•m (18 lb. in.)
Exhaust Muffler Hanger Bracket Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N •m (11 lb. ft.)
Exhaust Muffler Hanger Nut ........................................... 25 N•m (18 lb. ft.)
Exhaust Muffler Heat Shield Bolt/Screw ................................ 2.0 N•m (18 lb. in.)
Exhaust Muffler Interior Hanger Bolt/Screw .............................. 15 N•m (11 lb. ft.)
Exhaust Pipe Bolt/Screw .............................................. 20 N•m (15 lb. ft.)
Exhaust Pipe Hanger Nut ............................................. 15 N•m (11 lb. ft.)
Exhaust Pipe Heat Shield Bolt/Screw ................................... 2.0 N•m (18 lb. in.)
Exhaust Tailpipe Extension Clamp Assembly ............................. 70 N•m (52 lb. ft.)
Muffler Clamp Assembly ............................................. 68 N•m (50 lb. ft.)
Rear Axle Torque Arm Bracket Nut ..................................... 41 N•m (30 lb. ft.)
Rear Axle Torque Arm Outer Bracket Bolt/Screw .......................... 27 N•m (20 lb. ft.)

SECTION 7
AUTOMATIC AND MANUAL TRANSMISSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description .......................... 7-1
Description of Section 7 ...................... 7-1
Section 7 A - Automatic Transmission
On-Vehicle Service ...................... 7-1
Section 7A-14A- HYDRA-MATIC 4L60-E
Automatic Transmission Diagnosis
(RPO M30) .......................... 7-1
Section 7A-14B - HYDRA-MATIC 4L60-E
Automatic Transmission Unit Repair
(RPO M30) .......................... 7-1
GENERAL DESCRIPTION
Section 7 contains both on-vehicle service and unit
repair, as well as diagnosis procedures for the HYDRA-
MATIC 4L60-E automatic transmission assembly, the
Borg-Warner 5-speed manual transmission assembly and
the Borg-Warner 6-speed manual transmission assembly.
DESCRIPTION OF SECTION 7
SECTION 7 A - AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
This section contains information for automatic
transmission assembly identification, automatic transmis-
sion fluid level checking procedures and specific informa-
tion for servicing some components while the automatic
transmission assembly is in the vehicle. This section also
contains procedures for removing and installing the auto-
matic transmission assembly.
SECTION 7A-14A- HYDRA-MATIC 4L60-E
AUTOMATIC TRANSMISSION DIAGNOSIS
(RPO M30)
This section contains information to assist in diag-
nosing automatic transmission operating conditions when
the unit is in the vehicle. The diagnosis covers: road test
procedures, diagnosis charts, fluid flow diagrams, electri-
cal wiring diagrams, automatic transmission oil passage
identification and torque converter clutch diagnosis.
AUTOMATIC AND MANUAL TRANSMISSION 7-1
Section 7B - Manual Transmission On-Vehicle
Service (RPO M49 and MM6) .............. 7-1
Section 7B-6B - Borg-Warner (T5) 5-Speed
Manual Transmission Unit Repair
(RPO M49) .......................... 7-1
Section 7B-10B - Borg-Warner (T56) 6-Speed
Manual Transmission Unit Repair
(RPO MM6) .......................... 7-2
Section 7C - Clutch ........................ 7-2
SECTION 7A-14B - HYDRA-MATIC 4L60-E
AUTOMATIC TRANSMISSION UNIT REPAIR
(RPO M30)
This section contains the disassembly, inspection,
overhaul and assembly procedures for the mechanical
components on the automatic transmission. It also
includes information on gaging certain components,
proper use of special tools, and torque specifications
required for assembly.
SECTION 78 - MANUAL TRANSMISSION
ON-VEHICLE SERVICE (RPO M49 AND MM6)
This section contains information on the Borg-
Warner 5-speed (RPO M49) manual transmission and
Borg-Warner 6-speed (RPO MM6) manual transmission.
It includes information on transmission identification,
fluid level checking procedures and specifics on servicing
some components while the transmission is in the vehicle.
This section also contains procedures for the removal and
installation of the transmission from the vehicle.
SECTION 78-68 - BORG-WARNER (TS)
5-SPEED MANUAL TRANSMISSION UNIT
REPAIR (RPO M49)
This section covers the disassembly, inspection,
overhaul and assembly procedures for the Borg-Warner
5-speed manual transmission. Also included is informa-
tion on the gaging of certain components, proper use of
special tools, and torque specifications required for
assembly.
7-2 AUTOMATIC AND MANUAL TRANSMISSION
SECTION 78-1 OB - BORG-WARNER (T56)
6-SPEED MANUAL TRANSMISSION UNIT
REPAIR (RPO MM6)
This section covers the disassembly, inspection,
overhaul and assembly procedures for the Borg-Warner
6-speed manual transmission. Also included is informa-
tion on the gaging of certain components, proper use of
special tools, and torque specifications required for
assembly.
SECTION 7C - CLUTCH
This section contains clutch assembly diagnosis, on-
vehicle service of the hydraulic system, pressure plate/
clutch disc removal and installation procedures, torque
specifications and special tools required.
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·1

SECTION 7A

AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SlR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

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

NOTICE: The assembly of some components will require the use of an assembly lube. It is recommended that
Transjel ™ or petroleum jelly be used during assembly. Grease other than the recommended assembly lube will
change transmission fluid characteristics and cause undesirable shift conditions and/or filter clogging.

CONTENTS
Generallnformation .. , ..................... 7A-2
Transmission Assembly Identification
Information .......................... 7 A-2
Transmission Assembly Definitions ......... 7 A-2
Throttle Positions ...................... 7 A-2
Shift Conditions ....................... 7A-2
Noise Conditions ...................... 7 A-3
Preliminary Checking Procedure ............ 7 A-3
Line Pressure Check . . . Refer to Section 7 A-1 SA
Noise and Vibration Analysis .............. 7 A-3
Transmission Fluid Checking and Filling
Procedures ........................... 7 A-3
General Service Procedures .................. 7 A-4
No Air Tool Recommendation .............. 7 A-4
Parts Cleaning, Inspection and
Replacement .......................... 7 A-4
Flywheel Assembly/Torque Converter
Clutch Vibration Test Procedure . . . . . . . . . . 7 A-6
Fluid Leak Diagnosis ..................... 7A-6
Methods for Locating Leak .............. 7 A-6
Repairing the Leak ..................... 7 A-6
Possible Points of Fluid Leaks ............ 7 A-8
Transmission Case Porosity Repair . . . . . . . . 7 A-8
Torque Converter Clutch Electrical Controls .. 7 A-8
Torque Converter Clutch Diagnosis .......... 7 A-9
On-Vehicle Service ........................ 7 A-9
Automatic Transmission Range Selector
Lever Cable Assembly .................. 7 A-9
Automatic Transmission Control Assembly .. 7 A-10
Automatic Transmission Park Lock
Cable Assembly ...................... 7A-10
Brake Transmission Shift Interlock
System Diagnosis ....... Refer to Section SA-138
Automatic Transmission Control
Lever Solenoid ......................... 7 A-12
Park/Neutral Position Switch Assembly 7A-12
Park/Neutral Position Switch Assembly
Adjustment Using Old Switch
Assembly ....................... 7A-12
Park/Neutral Position Switch Assembly
Adjustment Using New Switch
Assembly ....................... 7A-13
Changing Transmission Fluid and Automatic
Transmission Oil Filter Assembly . . . . . . . . 7 A-13
Automatic Transmission Oil Cooler Upper
Pipe and Upper and Lower Hose
Assemblies ........................ 7A-14
Oil Cooler Flushing Procedure ............ 7A-15
Serviceable Components ................... 7A-16
Transmission Fluid Filler Tube Assembly .... 7A-16
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . . 7 A-17
Automatic Transmission Case Extension .... 7A-18
Accumulator Assembly .................. 7A-18
2-4 Band Servo Assembly ................ 7A-19
Transmission Converter Cover . . . . . . . . . . . . 7 A-20
Pressure Regulator Valve ................. 7A-20
Control Valve Body and Pressure Switch .... 7A-21
Control and Shift Solenoids . . . . . . . . . . . . . . . 7 A-22
TCC Solenoid and Wiring Harness
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 7 A-22
Electrical Connector and Seal ............. 7 A-25
Case Extension Oil Seal Assembly . . . . . . . . . 7 A-25
Automatic Transmission Assembly Removal
and Installation ....................... 7 A-25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A-27
Fastener Tightening Specifications . . . . . . . . . 7 A-27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A-28
7A-2 AUTOMATIC TRANSMISSION.ON-VEHICLE SERVICE
GENERAL INFORMATION
TRANSMISSION ASSEMBLY
IDENTIFICATION INFORMATION
Shift Conditions
Figures 1 and 2
The HYDRA-MATIC 4L60-E transmission has the
identification information stamped into the case pan rail.
The location of this information is shown in Figure 1. This
information will assist in the servicing and determination
of replacement parts when ordered through a GM parts
catalog.
Additional transmission identification is provided
on the "Service Parts Identification" label shown in Fig-
ure 2. This label contains information on the Regular Pro-
duction Options (RPO) as well as standard and mandatory
options. This label is affixed to the inside of each vehicle
at the assembly plant. Refer to SECTION OA for addi-
tional information.
TRANSMISSION ASSEMBLY DEFINITIONS
The following definitions are provided to establish a
common language and assist the user in describing trans-
mission assembly related conditions. Some of these terms
or conditions are used in the transmission assembly diag-
nosis section of this service manual.
Throttle Positions
Minimum Throttle - least amount of throttle open-
ing required for an upshift.
Light Throttle - approximately 1/4 of accelerator
pedal travel.
Medium Throttle - approximately 1/2 of accelera-
tor pedal travel.
Heavy Throttle - approximately 3/4 of accelerator
pedal travel.
Wide Open Throttle (WOT) - full travel of accel-
erator pedal.
Full Throttle Detent Downshift - quick applica-
tion of accelerator pedal to its full travel, forcing a
downshift.
Zero Throttle Coastdown - full release of acceler-
ator pedal while vehicle is in motion in drive range.
IDENTIFICATION INFORMATION
Figure 1 - Automatic Transmission Assembly Identification Information
Engine Braking- condition where engine is used to
slow vehicle by manually downshifting during zero
throttle coastdown.
Bump- sudden and forceful application of clutch or
band.
Chuggle - bucking or jerking condition that may be
engine related. May be most noticeable when the
torque converter clutch is engaged. Similar to the
feel of towing a trailer.
Delayed - condition where shift is expected but
does not occur for a period of time. Examples of this
condition could be described as clutch or band
engagement that does not occur as quickly as
expected during part throttle or wide open throttle
application of accelerator, or when manually down-
shifting to lower range. Also defined as "late" or
"extended."
Double Bump - two sudden and forceful applica-
tions of clutch or band. Also defined as "double
feel."
Early - condition where shift occurs before vehicle
has reached proper speed and tends to labor engine
after upshift.
End Bump - firmer feel at end of shift as compared
to feel at start of shift. Also defined as "end feel" or
"slip bump."
Firm - noticeable quick application of clutch or
band that is considered normal with medium to
heavy throttle shift. Should not be confused with
"harsh" or "rough."
Flare - quick increase in engine RPM accompanied
with momentary loss of torque. This most generally
occurs during a shift. Also defined as "slipping."
Harsh - more noticeable application of clutch or
band as compared to "firm." This condition is con-
sidered undesirable at any throttle position. Also
defined as "rough."
Hunting - repeating quick series of upshifts and
downshifts causing noticeable change in engine
RPM. An example could be described as a 4-3-4
shift pattern. Also defined as "busyness."
JULIAN DATE
(OR DAY OF THE YEAR)
SHIFT BUILT
A & B • FIRST SHIFT
C & H • SECOND SHIFT
RC0009-7 A-F-RP
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·3

• Manual linkage adjustment.

M-1NDI CATES TRANSMISSION
TYPE IN OPTION LIST. (SPECIFIC MX- DESIGNATES • Internal fluid leaks. Refer to SECTION 7A-15A.
MODEL CODE IS FOUND ON THE rUTOMATIC TRANSMISSION
TRANSMISSION NAMEPLATE) ASSEMBLY • Electrical system. Refer to SECTION 6D and SEC-
M30-DESIGNATES HYDRA-MATIC 4L60-E MXO - DESIGNATES 4 SPEED TION 8A.
• Transmission assembly or other mechanical compo-
SERVICE PARTS IDENTIFICATION DO NOT REMOVE nent. Refer to SECTION 7 A-l 5A.
.......
1 G3 A R 4 7 Y X E 5 1 0 aoo1 NOISE AND VIBRATION ANALYSIS
C90 C95 DF3 D3C 033 D 8 E Z E D FFL F40 GG 1 GW9 660 GU2 689 A noise or vibration noticeable when the vehicle is
JAl JA4 K05 K22 K99 LT1jMJ01MxolNA5 NBl NKl NK2 N33 N67 GJW in motion, may not be caused by the transmission assem-
T87 UJ3 U23 U35 voe VlO WC3 WG2 YT9 Y56 Oil SSC 428 421 420 bly.
· 42T 409 7SB BWT 9WT 11 A BOA If a noise or vibration is noticeable in "PARK" and
"NEUTRAL" with engine at idle, but is less noticeable as
PRINTED IN U.S.A. PART NO. 14065987 RPM increases, the cause may be poor engine perfor-
mance.

Figure 2 - Service Parts Identification Label

RC0001-7A-F-RP
!L'l'! Inspect
• Tire and wheel assemblies for:
Initial Feel - distinct firmer feel at start of shift as
compared to finish of shift. - Uneven wear.
Late - shift that occurs when engine is at higher than - Imbalance.
normal RPM for given amount of throttle. - Mixed sizes.
Shudder - repeating jerking sensation similar to - Mixed radial and bias ply. Refer to SECTION
"chuggle" but more severe and rapid in nature. This 3E.
condition may be most noticeable during certain • Suspension components for:
ranges of vehicle speed. May also be used to define
the condition after torque converter clutch engage- - Alignment and wear.
ment. - Loose fasteners. Refer to SECTION 3C.
Slipping - noticeable increase in engine RPM with- • Engine and transmission assembly mounts for:
out vehicle speed increase. Slip usually occurs dur-
- Damage.
ing or after initial clutch or band engagement.
- Loose bolts/screws.
Soft - slow, almost unnoticeable clutch application
with very little shift feel. • Transmission case mounting holes for:
Surge- repeating engine related feeling of accelera- - Missing bolts/screws, nuts, studs.
tion and deceleration that is less intense than - Stripped threads.
"chuggle."
- Cracks.
Tie-Up- condition where two opposing clutches are
attempting to apply at the same time causing the • Flywheel assembly for:
engine to labor with noticeable loss of engine RPM. - Missing or loose bolts/screws.
- Cracks.
Noise Conditions - Imbalance. Refer to SECTION 6Al.
Gear Noise - whine, most noticeable in first gear • Torque converter clutch for:
and reverse that is related to vehicle speed. A gear
noise condition may become less noticeable or go - Missing or loose bolts/screws or lugs.
away after an upshift. - Missing or loose balance weights.
Pump Noise - high-pitched whine increasing in - Imbalance.
intensity with engine RPM. This condition may also
be noticeable in "PARK" and "NEUTRAL" oper- TRANSMISSION FLUID CHECKING AND
ating ranges with the vehicle stationary. FILLING PROCEDURES
PRELIMINARY CHECKING PROCEDURE Figure 3
Transmission assembly performance may be Checking fluid level, color and condition at regular
influenced by one or more of the following items. These intervals will provide early diagnosis information about
items should be checked and corrected if necessary, the transmission. This information may then be used to
before attempting transmission assembly diagnosis. correct a condition that, if not detected early, could result
• High or low fluid level. in major transmission repair.
• Engine performance. Refer to SECTION 6 and Refer to SECTION OB for maintenance information
SECTION 6E. and servicing intervals.
7A-4 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
[TI Important
• When new, automatic transm1ss1on fluid
should be red. The red dye is added so the
assembly plant can identify it as transmission
fluid and distinguish it from engine oil or anti-
freeze. The red dye, which is not an indicator
of fluid quality, is not permanent. As the
vehicle is driven the transmission fluid will
begin to look darker. The color may eventually
appear light brown.
• Wait at least 30 minutes before checking the trans-
mission fluid level if you have been driving:
- When outside temperatures are above 32°C
(90°F).
- At high speed for greater than 15 minutes.
- In heavy traffic during hot weather.
- While pulling a trailer.
• To get the right reading, the fluid should be at nor-
mal operating temperature, which is 80°C-93°C
(180°F to 200°F).
• Hot check:
- Get the vehicle warmed up by driving about 24
km (15 miles), when outside temperatures are
above 10°C (50°F). If it's colder than 10°C
(50°F), you may have to drive longer.
• Cold check:
A cold check can be made when the transmis-
sion temperature is between 24-29°C
(75-85°F). Let the engine run at slow idle for 5
minutes if the outside temperature is 10°C
(50°F) or more. If it's colder than 10°C
(50°F), you may have to idle the engine longer.
• Fluid check procedure hot or cold:
A. Park the vehicle on a level surface.
B. Place the shift lever "PARK" with the parking
brake applied.
C. With your foot on the brake pedal, mo.ve the
shift lever through each gear range, pausmg for
about 3 seconds in each range. Then, position
the shift lever in "PARK."
D. Let the engine idle for 3 minutes or more.
E. Then follow these steps to check the fluid
level:
a. Pull out the dipstick and wipe it with a
clean rag or paper towel.
b. Push it back in all the way, wait 3 seconds
and then pull it back out again.
F. Check both sides of the dipstick, and read the
lower level. The fluid level must be in the
"COLD" area for a cold check or in the
"HOT" area or cross-hatched area for a hot
check.
G. If the fluid level is where it should be, push the
dipstick back in all the way.
NOTICE: Do not overfill. Overfilling will cause
foaming, Joss of fluid and possible damage to the
transmission.
H. If the fluid level is low, add only enough DEX-
RON IIE to bring the fluid level up to the
"COLD" area for a cold check or the "HOT"
area for a hot check. It doesn't take much fluid,
generally Jess than a pint. DO NOT OVER-
FILL.
I. After adding fluid, recheck the fluid level as
described above. When the correct fluid level
is obtained, push the dipstick back in all the
way.
• Fluid color.
- Should be red when new.
GENERAL SERVICE PROCEDURES
NO AIR TOOL RECOMMENDATION
NOTICE: It is not recommended to use air powered
tools to disassemble or assemble transmission
assemblies. Improper bolt torques can contribute to
transmission assembly repair conditions, and this
information vital to diagnosis can only be detected
when using hand tools.
PARTS CLEANING, INSPECTION AND
REPLACEMENT
• Use appropriate safety equipment such as:
- Safety glasses.
- Safety shoes.
- Gloves.
• Keep work areas and tools clean.
• Clean transmission assembly exterior before remov-
ing parts.
• Do not use wipe cloths or rags.
• Do not use solvents on:
- Rubber seals.
- Plastic(feflon® thrust washers or spacers.
• Blow out all passages with compressed air.
• Clean out small passages with fine wire.
• Handle parts carefully to prevent damage.
NOTICE: The assembly of some components will
require use of an assembly lube. It is recommended
that J 36850 Transjel TM, or equivalent, be used dur-
ing assembly. Do not use anr typ~ of gre~se to retain
parts during assembly of this umt. Lubncants other
than the recommended assembly lube will change
fluid characteristics and cause undesirable shift
conditions and/or oil filter clogging.
• When installing bolts/screws or studs into alumi-
num, always dip the threads in Transjel TM, or equiva-
lent.
• Recondition damaged or stripped aluminum threads
with thread inserts.
• Replace all gaskets and 0-ring seals.
- Do not use gasket cement or sealers.
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A-5

HVDRA·MATIC 4L60-E

CHECK IN PARK, ENGINE IDLING, VEHICLE LEVEL.

TRANS HOT MUST BE IN CROSSHATCH.
DO NOT OVERFILL.
DEXRON*-IIE FLUID ONLY.

r CHECK AUTOMATIC I
I TRANSMISSION FLUID COLOR I

RED
I NON TRANSPARENT
PINK
LT. BROWN
I

I
I
I
CHECK AUTOMATIC
TRANSMISSION FLUID LEVEL
I

r
[

l rl r
I
'
REPLACE COOLER NOTICE: AUTOMATIC
TRANSMISSION
FLUID MAY TURN. DARK
WITH NORMAL USE
AND DOES NOT ALWAYS
INDICATE CONTAMINATION
OR OXIDATION
HIGH
l~ LOW FOAM

I ADD AUTOMATIC AUTOMATIC CONTAMINANTS DRAIN AUTOMATIC

REMOVE EXCESS
AUTOMATIC TRANSMISSION TRANSMISSION IN AUTOMATIC TRANSMISSION FLUID TO
TRANSMISSION FLUID TO FLUID LEVEL TRANSMISSION DETERMINE IF THERE IS
FLUID OST AIN PROPER HIGH FLUID CONTAMINATION
LEVEL

CHECK FOR EXTERNAL DRAIN AUTOMATIC NOTICE: A VERY SMALL

LEAKS (REFER TO
"AUTOMATIC TRANSMISSION
FLUID LEAK DIAGNOSIS"
TRANSMISSION FLUID TO
DETERMINE SOURCE
OF CONTAMINATION
- AMOUNTOF MATERIAL
IN THE BOTTOM PAN IS
A NORMAL CONDITION

CORRECT LEAK
CONDITION
l REMOVE EXCESS
AUTOMATIC
TRANSMISSION
FLUID
CHANGE AUTOMATIC
TRANSMISSION FLUID
AND FILTER

AUTOMATIC TRANSMISSION
LARGE PIECES OF
ASSEMBLY OVERHAUL
METAL OR OTHER
REQUIRED (REFER
MATERIAL IN THE
TO "UNIT REPAIR
BOTTOM PAN
SECTION")

ADD NEW AUTOMATIC

TRANSMISSION FLUID AUTOMATIC TRANSMISSION
ASSEMBLY OVERHAUL
REQUIRED (REFER TO
"UNIT REPAIR SECTION")

CHECK AUTOMATIC
TRANSMISSION FLUID
• LEVEL I
ADI;) NEW AUTOMATIC
TRANSMISSION FLUID

I
I
PERFORM ROAD TEST CHECK AUTOMATIC
(REFER TO AUTOMATIC TRANSMISSION FLUID
TRANSMISSION ASSEMBLY I LEVEL
DIAGNOSIS SECTION)

RCOOOB-7 A·F·RP

Figure 3 - Checking Automatic Transmission Fluid Color, Level and Condition

7A-6 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

• Replace Teflon® and rubber lip seals only when nec-

essary and install using the appropriate seal installer. !©.I Tighten
!L'l'I Inspect • Flywheel bolts/screws to 63 N•m (46 lb. ft.).
2. Transmission converter cover bolts/screws.
• Manual linkage for:
- Bent or broken links and rods. !©.! Tighten
• All seals, gaskets, 0-ring seals and mating surfaces • Transmission converter cover bolts/screws to
for: 10 N•m (89 lb. in.).
- Nicks. 3. Lower vehicle.
- Cuts. 4. Start engine and check for vibration.
- Damage. • If vibration still exists repeat this procedure
• Snap rings for: until best possible balance is obtained.
- Expansion or compression. FLUID LEAK DIAGNOSIS
- Distortion.
- Nicks. Figure 4
The cause of most external leaks generally can be
- Proper ring-to-groove fit.
located and repaired with the transmission assembly in the
• Bearings and thrust surfaces for: vehicle.
- Wear.
Methods for Locating Leak
- Scoring.
- Pitting. General Method
1. Verify leak is transmission fluid.
FLYWHEEL ASSEMBLY/TORQUE 2. Thoroughly clean suspected leak area.
CONVERTER CLUTCH VIBRATION TEST 3. Operate vehicle for about 24 km (15 miles) or until
PROCEDURE normal operating temperatures are reached.
NOTICE: Some engine/transmission assembly 4. Park vehicle over clean paper or cardboard.
combinations cannot be balanced in this manner due
to limited clearances between the torque converter 5. Shut off engine and look for fluid spots on paper.
clutch bolts/screws and the engine. Be sure bolts/ 6. Make necessary repairs.
screws do not bottom out in lug nuts or the transmis-
sion converter cover could be dented and cause Powder Method
internal damage. 1. Thoroughly clean suspected leak area with solvent.
2. Apply aerosol type powder (foot powder) to sus-
!+,.I Remove or Disconnect pected leak area.
I. Start engine. 3. Operate vehicle for about 24 km (15 miles) or until
2. With engine at idle speed and transmission assembly normal operating temperatures are reached.
in "PARK" or "NEUTRAL," observe vibration. 4. Shut off engine.
3. Shut off engine. 5. Inspect suspected leak area and trace leak path
through powder to find source.
4. Raise and suitably support vehicle. Refer to SEC-
TION OA. 6. Make necessary repairs.
5. Transmission converter cover bolts/screws. Dye and Black Light Method
6. Flywheel bolts/screws. A fluid dye and black light kit is available from vari-
• Discard flywheel bolts/screws. ous tool manufacturers.
7. Rotate torque converter clutch 120 degrees (1/3 1. Follow manufacturer's recommendations for
turn). amount of dye to use.
2. Detect leak with black light.
!-++I Install or Connect 3. Make necessary repairs.
NOTICE: See "Notice" on page 7 A-1 of this sec-
tion. Repairing the Leak
1. Flywheel bolts/screws. Once the leak has been pinpointed and traced back to
its source, the cause of the leak must be determined for it
• Hand start flywheel bolts/screws. to be properly repaired. For example, if a gasket is
- Use new flywheel bolts/screws with replaced, but the sealing flange is bent, the new gasket
retaining compound removed from first will not repair the leak. The bent flange also must be
three threads. repaired.
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A-7

A BOTIOM PAN GASKET F OIL PUMP SEAL ASSEMBLY K MANUALSHAFTSEAL

B CASE G OIL PUMP TO CASE SEAL L SPEED SENSOR SEAL
C COOLER CONNECTORS H CONVERTER M EXTENSION TO CASE SEAL
D SERVO COVER SEAL I VENT N EXTENSION OIL SEAL ASSEMBLY
E OIL FILL TUBE SEAL J ELECTRICAL CONNECTOR SEAL O LINE PRESSURE PLUG

PH0029·4L60-E

Figure 4 - Automatic Transmission Fluid Leak Points

 7A-8 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
The following conditions may cause a leak. Before
attempting to repair a leak, these conditions should be
checked and corrected if necessary.
Gaskets
!l•l 1nspect
• Fluid level/pressure too high.
• Plugged vent or drain-back holes.
• Improperly torqued fasteners, dirty or damaged
threads.
• Warped flanges or sealing surface.
• Scratches, burrs or other damage to sealing surface.
• Damaged or worn gasket.
• Cracking or porosity of component.
• Improper sealant used, where applicable.
• Incorrect gasket.
Seals
!l•l 1nspect
• Fluid level/pressure too high.
• Plugged vent or drain-back holes.
• Damaged seal bore.
• Damaged or worn seal.
• Improper installation.
• Cracks in component.
• Scratched, nicked or damaged, manual or output
shaft surface.
• Loose or worn bearing causing excess seal wear.
Possible Points of Fluid Leaks
Oil Pan
!L'S'! Inspect
• Incorrectly tightened oil pan bolts/screws.
• Improperly installed or damaged oil pan gasket.
• Damaged oil pan.
• Incorrect oil pan gasket.
Oil Case Leak
!l•l 1nspect
• Damaged or missing transmission filler tube seal.
• Mis located filler tube bracket.
• Damaged vehicle speed sensor seal.
• Damaged manual shaft seal.
• Loose or damaged oil cooler connector fittings.
• Worn or damaged propeller shaft oil seal.
• Loose parking pawl shaft cup plug, if equipped.
• Loose line pressure pipe plug.
• Porous casting.
Leak at Torque Converter End
!l'l'! Inspect
• Torque converter seal damaged.
- Torque converter seal lip cut. Check torque
converter hub for damage.
- Bushing moved forward and damaged.
- Garter spring missing from seal.
• Torque converter leak in weld area.
• Porous casting of transmission case or oil pump.
Leak at Vent Pipe of Fluid Filler Tube Assembly
!l'l'I Inspect
• Over-filled system.
• Water or coolant in fluid. Fluid will appear milky.
• Transmission case porous.
• Incorrect fluid level indicator assembly.
• Plugged vent.
•
•
Plugged drain-back holes.
Mispositioned oil pump-to-case gasket, if equipped.
Transmission Case Porosity Repair
1. Clean leak area with solvent and air dry.
CAUTION: Epoxy cement may cause
skin irritations and eye damage. Read
and follow all information on container
label as provided by manufacturer.
2. Mix sufficient amount of epoxy cement, GM PIN
1052533, or equivalent, following manufacturers'
recommendations.
3. While transmission case is hot, apply epoxy cement
with clean, dry soldering acid brush.
4. Allow epoxy cement to cure for three hours before
starting engine.
5. Repeat fluid leak diagnosis procedures to determine
if leak is fixed.
TORQUE CONVERTER CLUTCH
ELECTRICAL CONTROLS
The torque converter clutch (TCC) system uses con-
trols that are both internal and external to the transmission
assembly. For internal control components of the TCC
system, refer to SECTION 7A-15A for wiring diagrams
and switch locations.
The external control components of the TCC system
include:
Cruise Control Release Switch Assembly - To
avoid stalling the engine when braking, the TCC is
released any time the brake pedal assembly is
applied.
Powcrtrain Control Module (PCM) - Receives
input signals and grounds TCC solenoid to apply
clutch when proper operating conditions are met.
Throttle Position Sensor - Sends throttle position
information to PCM.
Manifold Absolute Pressure (MAP) Sensor -
Sends engine vacuum (load) information to PCM.
\ _________________A_UT_O_M_AT_IC_T_R_A_N_SM_I_SS_IO_N_O_N_-V_E_H_IC_L_E_SE_R_V_IC_E_7_A_·9

Vehicle Speed Sensor (VSS) - Sends vehicle speed 6. Front floor console trim plate assembly. Refer to
information to PCM. SECTION 8C.
\
\ Engine Coolant Temperature Sensor - Sends 7. Cable assembly (806) from control assembly (805).
\ engine coolant temperature information to PCM. 8. Grommet on cable assembly (806) from base of con-
I
\
trol assembly (805), pulling cable assembly (806)
TORQUE CONVERTER CLUTCH DIAGNOSIS through hole in front compartment floor pan assem-
To properly diagnose the torque converter clutch bly.
(TCC) system, perform all electrical testing first and then
hydraulic testing. Refer to SECTION 6E3 and SECTION
7A-1 SA for additional TCC information.
!++! Install or Connect
NOTICE: See "Notice" on page 7A-1 of this sec-
tion.
ON-VEHICLE SERVICE
1. Grommet on cable assembly (806) to base of control
AUTOMATIC TRANSMISSION RANGE assembly (805) by feeding cable assembly (806)
SELECTOR LEVER CABLE ASSEMBLY through hole in front compartment floor pan assem-
bly.
Figures 2. Cable assembly (806) to control assembly (805).

!++! Remove or Disconnect 3. Front floor console trim plate assembly. Refer to
SECTION 8C.
CAUTION: Refer to "Caution" under 4. Place control assembly (805) in "NEUTRAL" posi-
"Disconnecting the Battery Negative tion.
Cable Assembly" in SECTION OA.
I. Battery negative cable assembly. [I] Important
2. Raise and suitably support vehicle. Refer to SEC- • Control assembly must remain in "NEU-
TION OA. TRAL" position until cable assembly installa-
3. Cable assembly (806) from bracket (800). tion is completed.
4. Cable assembly (806) from lever assembly (809). 5. Raise and suitably support vehicle. Refer to SEC-
S. Lower vehicle. TION OA.

A GROMMET 808

n
800 BRACKET, AUTOMATIC TRANSMISSION RANGE
SELECTOR LEVER CABLE
803 NUT, AUTOMATIC TRANSMISSION RANGE SELECTOR
LEVER, 20 N•m (15 LB. FT.)
805 CONTROL ASSEMBLY, AUTOMATIC TRANSMISSION
806 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR LEVER
808 BOLT/SCREW, AUTOMATIC TRANSMISSION CONTROL,
4.5 N•m (40 LB. IN.I
809 LEVER ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR

RC0003-7A-F·RP
7A-10 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
6. Cable assembly (806) to bracket (800) with adjust-
ment button unlocked.
7. Place lever assembly (809) in "NEUTRAL" posi-
tion by rotating lever assembly counterclockwise
from "PARK" through "REVERSE" and into
"NEUTRAL."
8. Cable assembly (806) to lever assembly (809).
9. Lock adjustment button on cable assembly (806) to
bracket (800) by turning counterclockwise.
I 0. Lower vehicle.
11. Battery negative cable assembly.
AUTOMATIC TRANSMISSION CONTROL
ASSEMBLY
Figures 5 and 6
!+-+I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Automatic transmission range selector lever cable
assembly. Refer to "Automatic Transmission Range
Selector Lever Cable Assembly" in this section.
3. Park/neutral position switch assembly. Refer to
"Park/Neutral Position Switch Assembly" in this
section.
4. Bolts/screws (808).
5. Control assembly (805).
!++I Install or Connect
NOTICE: See "Notice" on page 7A-l of this sec-
tion.
1. Control assembly (805).
2. Bolts/screws (808).
!~I Tighten
• Bolts/screws (808) to 4.5 N •m (40 lb. in.).
3. Park/neutral position switch assembly. Refer to
"Park/Neutral Position Switch Assembly" in this
section.
4. Automatic transmission range selector lever cable
assembly. Refer to "Automatic Transmission Range
Selector Lever Cable Assembly" in this section.
5. Battery negative cable assembly.
AUTOMATIC TRANSMISSION PARK LOCK
CABLE ASSEMBLY
Figure 7
!++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
806
805 CONTROL ASSEMBLY, AUTOMATIC TRANSMISSION
806 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR LEVER
808 BOLT/SCREW, AUTOMATIC TRANSMISSION CONTROL,
4.5 N•m (40 LB. IN.)
810 KNOB/HANDLE, AUTOMATIC TRANSMISSION
CONTROL LEVER
811 RETAINER, AUTOMATIC TRANSMISSION CONTROL
LEVER HANDLE
PCOOCM-7A-F-RP
Figure 6 - Automatic Transmission Control Assembly
(Typical)
1. Battery negative cable assembly.
CAUTION: Refer to "Caution" on page
7A-1 of this section.
2. Disable the SIR system. Refer to SECTION 9J.
3. Place automatic transmission control assembly in
"PARK."
4. Turn ignition key to "RUN" position.
• Do not proceed to next step with ignition key
in any other position.
5. Left-hand instrument panel sound insulator assem-
bly, instrument panel driver knee bolster assembly,
and instrument panel driver knee bolster deflector.
Refer to SECTION 8C.
6. Front floor console assembly. Refer to SECTION
SC.
7. Nut (814).
8. Clip (813).
9. Cable assembly (812) from bracket.
10. Move button (815) to "UP" position.
11. Unsnap cable terminal from park lock lever pin.
12. Lower steering column assembly. Refer to SEC-
TION 3F.
13. Unsnap cable assembly (812) from steering column
assembly (816).

812
A SPRING, AUTOMATIC TRANSMISSION PARK LOCK
CABLE
B BRACKET, AUTOMATIC TRANSMISSION PARK LOCK
CABLE
812 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION PARK
LOCK
813 CLIP, AUTOMATIC TRANSMISSION PARK LOCK CABLE
814 NUT, AUTOMATIC TRANSMISSION PARK LOCK CABLE
815 BUTION, AUTOMATIC TRANSMISSION PARK LOCK
CABLE LOCK
816 COLUMN ASSEMBLY, STEERING
Figure 7 - Automatic Transmission Park Lock Cable Assembly (Typical)
!++I Install or Connect
1. Make sure ignition key is in "RUN" position and
automatic transmission control assembly is in
"PARK."
• Do not proceed to next step with ignition key
in any other position.
2. Snap cable terminal to park lock lever pin.
3. Push cable connector forward to remove slack.
4. With no load applied to connector, press button
(815) down.
5. Cable assembly (812) to bracket.
A. Push bracket housing against adjusting spring.
B. Drop cable assembly (812) through slot in
bracket and seat housing to automatic trans-
mission control assembly.
6. Push button (815) down.
7. Snap cable assembly (812) into steering column
assembly (816).
8. Raise steering column assembly. Refer to SECTION
3F.
9. Clip (813).
10. Nut (814).
11. Front floor console assembly. Refer to SECTION
SC.
12. Left-hand instrument panel sound insulator assem-
bly, instrument panel driver knee bolster assembly,
AUTOMATIC TRANSMISSION ONNEHICLE SERVICE 7A·11
PC0005-7A-F-RP
and instrument panel driver knee bolster deflector.
Refer to SECTION SC.
13. Turn ignition key to "OFF" position.
14. Battery negative cable assembly.
15. Enable the SIR system. Refer to SECTION 9J.
!L'S'! Inspect
• Functional operation.
A. With automatic transmission control assembly
in "PARK" and the ignition key in "LOCK"
position, make sure control assembly cannot
be moved to different position. Ignition key
should be removable from steering column
assembly.
B. With ignition key in "RUN" and automatic
transmission control assembly in "NEU-
TRAL," make sure key cannot be turned to
"LOCK."
C. If above conditions are met, system is properly
adjusted. Proceed to step E.
D. If above conditions are not met, put button
(815) back to "UP" position, and readjust as
above. Then push button (815) down and
recheck operation.
E. If key cannot be removed in "PARK" position,
move button (815) to "UP" position and move
cable connector nose rearward until ignition
key can be removed.
F. Snap button (815) down.
7A-12 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

G. Reinstall cable assembly (812) into clip (813)

to ensure correct routing.

AUTOMATIC TRANSMISSION CONTROL

LEVER SOLENOID
The automatic transmission control lever solenoid is
part of the brake transmission shift interlock system
(BTSI). The solenoid prevents the operator from shifting
the automatic transmission control assembly out of
"PARK" unless the brake pedal is depressed.

Figure 8

1+-+I Remove or Disconnect

CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in section OA.
1. Battery negative cable assembly.
2. Front floor console trim plate assembly. Refer to
SECTION 8C.
3. Wiring harness electrical connector from automatic
transmission control lever solenoid (804).
4. Automatic transmission control lever solenoid (804)
by unsnapping retainers.

l-++I Install or Connect

!VIEWA!
I. Automatic transmission control lever solenoid (804)
by snapping retainers into place. A CONNECTOR, ELECTRICAL
B RETAINER, PLASTIC
2. Wiring harness electrical connector to automatic C STUD
transmission control lever solenoid (804). 804 SOLENOID, AUTOMATIC TRANSMISSION CONTROL
LEVER
3. Front floor console trim plate assembly. Refer to 805 CONTROL ASSEMBLY, AUTOMATIC TRANSMISSION
SECTION 8C.
4. Battery negative cable assembly. PC0006-7A·F-RP

Figure 8 - Automatic Transmission Control Lever Solenoid

(Typical)
PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
The park/neutral position switch assembly prevents
starter motor operation when the automatic transmission Park/Neutral Position Switch Assembly
control assembly is in any gear by breaking the starter Adjustment Using Old Switch Assembly
motor circuit. When the automatic transmission control
assembly is in reverse (engine running), the park/neutral
position switch completes the backup lamp circuit, light-
l++I Install or Connect
NOTICE: See "Notice" on page 7A-1 of this sec-
ing the backup lamps. tion.
1. Place automatic transmission control assembly
Figure 9 (805) in "NEUTRAL."
!++I Remove or Disconnect 2. Tang (818) on switch assembly (817) into slot on
automatic transmission control assembly (805).
CAUTION: Refer to "Caution" under 3. Bolts/screws (819) to automatic transmission case,
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA. loosely.
4. Insert 2.34 mm (3/32-inch) gage pin into service
I. Battery negative cable assembly. adjustment hole, and rotate switch assembly (817)
2. Front floor console assembly. Refer to SECTION until gage pin drops to 15 mm (19/32-inch) depth.
8C.
3. Bolts/screws (819). l~I Tighten
4. Switch assembly (817). • Bolts/screws (819) to 2.2 N•m (19 lb. in.).

818
A NEUTRAL NOTCH
B PARK NOTCH
C TANG SLOT
D PIN, GAGE
805 CONTROL ASSEMBLY, AUTOMATIC TRANSMISSION
817 SWITCH ASSEMBLY, PARK/NEUTRAL POSITION
818 TANG, PARK/NEUTRAL POSITION SWITCH CARRIER
819 BOLT/SCREW, PARK/NEUTRAL POSITION SWITCH,
2.2 N•m (19 LB. IN.)
825 DETENT PLATE, PARK/NEUTRAL POSITION SWITCH
PC0007·7A·F·RP
Figure 9 - Park/Neutral Position Switch Assembly
5. Front floor console assembly. Refer to SECTION
8C.
6. Battery negative cable assembly.
rn Important
• After park/neutral position switch assembly adjust-
ment, verify engine will only start with ignition key
in "PARK" or "NEUTRAL." If engine will start
with ignition key in any other position, readjust
park/neutral position switch assembly.
Park/Neutral Position Switch Assembly
Adjustment Using New Switch Assembly
!++I Install or Connect
1. Place automatic transmission control assembly
(805) in "NEUTRAL."
2. Tang (818) on switch assembly (817) into slot on
automatic transmission control assembly (805).
3. Bolts/screws (819) to automatic transmission case.
!~I Tighten
• Bolts/screws (819) to 2.2 N•m (19 lb. in.).
[I) Important
• If park/neutral position switch bolt/screw holes
will not align with automatic transmission con-
trol assembly, verify automatic transmission
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·13
control assembly is in "NEUTRAL" position.
Do not rotate park/neutral position switch
assembly. If switch assembly has been rotated
and the pin is broken, the switch assembly can
be adjusted using the procedure under "Park/
Neutral Position Switch Assembly Adjustment
Using Old Switch Assembly" in this section.
4. Front floor console assembly. Refer to SECTION
8C.
5. Battery negative cable assembly.
CHANGING TRANSMISSION FLUID AND
AUTOMATIC TRANSMISSION OIL FILTER
ASSEMBLY
Figures 3, 1O and 11
!+..I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Place drain pan under oil pan (73).
3. Bolts/screws (74) from front and sides only.
4. Loosen rear bolts/screws (74) approximately four
turns.
NOTICE: When removing automatic transmission
oil pan bolts/screws, use caution in order not to dam-
age the automatic transmission case or automatic
transmission oil pan sealing surfaces.
5. Lightly tap oil pan (73) with rubber mallet or pry to
allow fluid to drain.
IL'i'l tnspect
• Fluid color and condition. Refer to Figure 3.
• Filter. Open filter by prying the metal crimping
away from the top of the filter (black) and pull-
ing apart. The filter may contain evidence for
root cause diagnosis.
- Clutch material.
- Bronze slivers indicating bushing wear.
- Steel particles.
6. Remaining bolts/screws (74), oil pan (73) and gasket
(72).
7. Filter assembly (71) and seal (70).
• Seal (70) may be stuck in automatic transmis-
sion case.
!S,I Clean
• Automatic transm1ss1on case and gasket surfaces
with solvent, and air dry. All traces of gasket mate-
rial must be removed.
!++I Install or Connect
NOTICE: See "Notice" on page 7A-l of this sec-
tion.
1. Coat new seal (70) with small amount of Transjel ™,
or equivalent.
2. New seal (70) to filter assembly (71).
7A·14 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
70
70 SEAL, AUTO MA TIC TRANSMISSION OIL FILTER (0-RING)
71 FILTER ASSEMBLY, AUTOMATIC TRANSMISSION OIL
72 GASKET, AUTO MA TIC. TRANSMISSION OIL PAN
73 PAN, AUTOMATIC TRANSMISSION OIL
74 BOLT/SCREW, AUTOMATIC TRANSMISSION OIL PAN,
16 N•m (12 LB. FT.)
93 MAGNET, AUTOMATIC TRANSMISSION OIL PAN
PC6010-7 A-0-RP
Figure 1O - Automatic Transmission Oil Pan and Automatic
Transmission Oil Filter Assembly
A AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW
AND CONICAL WASHER ASSEMBLY IS REUSABLE
B AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW
AND CONICAL WASHER ASSEMBLY IS NOT REUSABLE
PC6011-7A-D-RP
Figure 11 -Automatic Transmission on Pan BolVScrew and
Conical Washer Assembly
3. Filter assembly (71) and seal (70) into automatic
transmission case.
4. New gasket (72), oil pan (73) and bolts/screws (74 ).
NOTICE: Automatic transmission oil pan bolt/
screw and washer assembly must not be reused if
conical washer is reversed. Failure to replace the
bolt/screw and washer may result in improper fas-
tening of system components.
,~.J Tighten
• Bolts/screws (74) to 16 N•m (12 lb. ft.).
5. Lower vehicle.
NOTICE: Do not overfill. Overfilling will cause
foaming, loss of fluid and possible damage to the
transmission.
6. Fill automatic transmission fluid to proper level.
7. Check "COLD" fluid level reading for initial fill
only. Refer to "Transmission Fluid Checking Proce-
dures" in this section.
• Do not overfill.
!L-.,! Inspect
• Gasket (72) for leaks.
AUTOMATIC TRANSMISSION OIL COOLER
UPPER PIPE AND UPPER AND LOWER
HOSE ASSEMBLIES
Figure 12
If replacement of automatic transmission oil cooler
pipe and hose assemblies is required, use only double-
wrapped and brazed steel tubing meeting GM specifica-
tion 123 Mor equivalent. Tubing should be double flared.
NOTICE: Allow sufficient clearance to transmis-
sion oil cooler pipe and hose assemblies to prevent
damage or wear which may cause fluid loss.
j++I Remove or Disconnect
1. Fitting on radiator end of oil cooler upper hose
assembly (860).
2. Fitting on radiator end of oil cooler lower hose
assembly (857).
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. Propeller shaft assembly. Refer to SECTION 4A.
5. Rear axle torque arm assembly. Refer to SECTION
3D.
6. Catalytic converter hanger assembly. Refer to SEC-
TION 6F.
7. Support automatic transmission assembly with a
transmission stand.
8. Transmission support member assembly. Refer to
SECTION 10-3.
9. Lower the transmission stand slightly, to allow
access to oil cooler fittings at the transmission
assembly.
10. Fitting on transmission assembly end of upper pipe
assembly (856).
11. Fitting on transmission assembly end of lower hose
assembly (857).
12. Upper pipe assembly (856) and lower hose assembly
(857) from engine clip (858) and pipe clip (859).
!++I Install or Connect
NOTICE: See "NOTICE" on page 7A-1 of this
section.
I. Upper pipe assembly (856) and lower hose assembly
(857) to engine clip (858) and pipe clip (859).

2. Fitting on transmission assembly end of lower hose
assembly (857).
l~I Tighten
• Fitting on transmission assembly end of lower
hose assembly (857) to 27 N•m (20 lb. ft.).
3. Fitting on transmission assembly end of upper pipe
assembly (856).
l~I Tighten
• Fitting on transmission assembly end of upper
pipe assembly (856) to 27 N•m (20 lb. ft.).
4. Raise the transmission assembly.
5. Transmission support member assembly. Refer to
SECTION 10-3.
6. Remove transmission stand.
7. Catalytic converter hanger assembly. Refer to SEC-
TION 6F.
8. Rear axle torque arm assembly. Refer to SECTION
3D.
9. Propeller shaft assembly. Refer to SECTION 4A.
10. Lower vehicle.
11. Fitting on radiator end of oil cooler lower hose
assembly (857).
856
856 PIPE ASSEMBLY, TRANSMISSION OIL COOLER UPPER
857 HOSE ASSEMBLY, TRANSMISSION OIL COOLER
LOWER
858 CLIP, ENGINE
859 CLIP, TRANSMISSION OIL COOLER PIPE
860 HOSE ASSEMBLY, TRANSMISSION OIL COOLER UPPER
861 RADIATOR ASSEMBLY
862 CLAMP, TRANSMISSION OIL COOLER UPPER HOSE
Figure 12 - Transmission Oil Cooler Pipe and Hose Assemblies
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·15
l~I Tighten
• Fitting on radiator end of oil cooler lower hose
assembly (857) to 27 N•m (20 lb. ft.).
12. Fitting on radiator end of oil cooler upper hose
assembly (860).
l~I Tighten
• Fitting on radiator end of oil cooler upper hose
assembly (860) to 27 N•m (20 lb. ft.).
OIL COOLER FLUSHING PROCEDURE
Figure 12
Tools Required:
J 35944 "Transmission" Oil Cooler and Line
Flusher
J 35944-20 Cooler Flushing Fluid
NOTICE: The automatic transmission oil cooler
flushing procedure must be performed whenever a
transmission assembly is removed for service to
remove existing oil which may be contaminated and
to prevent contamination of new oil. The flushing
procedure must be performed before installation of
the overhauled or replacement transmission assem-
bly.
NOTICE: Flushing tool is designed for use with
only J 35944-20 flushing fluid. Use of any other
856
859
857
!VIEWA!
PC0011·7A·F·RP
7A·16 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE
fluid can result in damage to the tool, automatic
transmission oil cooler components or improper
flushing of the cooler.
1. Remove fill cap on J 35944 and fill with 0.6 liters
(20 to 21 ounces) of J 35944-20.
• Do not overfill tool.
• Follow manufacturer's suggested procedures
for handling fluid.
2. Replace cap on J 35944 and pressurize to 550 to 700
kPa (80 to 100 psi).
NOTICE: Shop air supply must be equipped with a
water/oil filter and pressure should not exceed 825
kPa (120 psi). Failure to use a water/oil filter can
allow residual moisture to cause corrosion of com-
ponents. Excessive air pressure can cause damage to
components.
3. Install J 35944 to undercarriage of vehicle with hook
provided, and attach hose from flushing tool to
upper pipe assembly (856) attaching to top fitting at
transmission assembly end of oil cooler.
4. Install discharge hose to lower hose assembly (857)
attaching to bottom fitting at transmission assembly
end of oil cooler. Clip opposite end of discharge
hose to oil drain container.
5. With water valve on tool in "OFF" position, attach
water supply to J 35944.
6. Turn water supply on at faucet.
7. Flush transmission fluid by opening water valve on
tool to "ON" position for about 10 seconds.
• If water does not flow through cooler (system
is completely plugged), do not complete flush-
ing procedure. Turn water off immediately and
inspect oil cooler and pipes for restriction.
Replace cooler and/or pipes as required.
8. Turn water valve on tool to "OFF" position and clip
discharge hose to 5-gallon pail. Cover pail with shop
cloth to prevent splash.
9. Turn water valve on tool to "ON" position and
depress trigger to mix flushing fluid into water flow.
• Use bale clip to hold trigger down.
I 0. Flush oil cooler with water and fluid for· two min-
utes.
• Every 15 to 20 seconds during flushing proce-
dure, attach air supply to air valve on J 35944
and leave in place for 3 to 5 seconds to create
surging action for complete cleaning.
11. Release trigger and turn water valve on tool to
"OFF" position.
12. Disconnect discharge hose from lower hose assem-
bly (857).
13. Install hose from J 35944 to lower hose assembly
(857) attaching to bottorh fitting of oil cooler.
14. Connect discharge hose to upper pipe assembly
(856) attaching to top fitting of oil cooler.
• Reversing hoses creates back-flush.
15. Repeat steps 9 and 10.
16. Release trigger and allow water only to rinse the oil
cooler for one minute.
17. Turn water valve on tool to "OFF" position and turn
water supply off at faucet.
18. Attach air supply to air valve on J 35944 and dry
system out with dry compressed air for at least two
minutes. Be sure no moisture can be seen leaving
hose.
19. Remove J 35944 and discharge hose from oil cooler/
hoses.
20. Connect oil cooler feed hose to automatic transmis-
sion assembly.
• Feed hose is lower hose assembly (857)
attached to bottom connection at transmission
end of system.
21. Attach discharge hose to oil cooler return pipe.
• Return pipe is upper pipe assembly (856)
attached to top connection at transmission end
of system.
22. Attach opposite end of discharge hose to oil drain
container.
23. Fill automatic transmission assembly with fluid.
24. Start engine and run for 30 seconds to remove any
residual moisture from cooler.
!L"'I Inspect
A. Fluid flow through cooler feed lines during 30
second running period. Minimum of 1.8 liters
(2 quarts) of fluid should flow during this time.
B. If fluid flow is insufficient, check flow by dis-
connecting feed line at cooler and observe flow
with engine running at idle.
• Insufficient Flow: Inspect transmission
for causes.
• Sufficient Flow: Inspect cooler pipes,
hoses and fittings and repeat cooler flush-
ing procedure. If the flow through cooler
is still insufficient after second flushing
procedure, replace cooler.
25. Disconnect discharge hose.
26. Connect oil cooler return pipe to fitting.
Ge] Adjust
• Transmission fluid level.
SERVICEABLE COMPONENTS
TRANSMISSION FLUID FILLER TUBE
ASSEMBLY
Figure 13
l+-+I Remove or Disconnect
I. Indicator assembly (837).
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Bolt/screw (835) retaining tube assembly (836) to
transmission assembly (838).
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·17

4. Loosen tube assembly (836) from transmission Vehicle Speed Sensor (VSS)
assembly (838).
5. Place drain pan under transmission assembly (838). Figure 14
6. Lower vehicle.
7. Tube assembly (836) and seal (901) from vehicle by !+-t! Remove or Disconnect
pulling out from top. 1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
!-t+! Install or Connect 2. Speed sensor electrical connector.
NOTICE: See "Notice" on page 7A-l of this sec- 3. Speed sensor bolt ( 100).
tion.
4. Speed sensor (99) and 0-ring seal (42).
1. Seal (90 I) and tube assembly (836) through top of
vehicle. • Use suitable container to catch transmission
fluid.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Insert seal (901) into automatic transmission case
lot+! Install or Connect
hole. NOTICE: See "Notice on page 7 A-1 of this section.
4. Tube assembly (836) to transmission assembly 1. Speed sensor (99) with new 0-ring seal (42).
(838).
2. Speed sensor bolt ( 100).
5. Bolt/screw (835) attaching tube assembly (836) to
transmission assembly (838). I©..! Tighten
l~I Tighten • Speed sensor bolt (100) to 11 N•m (97 lb. in.).
3. Speed sensor electrical connector.
• Bolt/screw (835) to 95 N•m (70 lb. ft.) on 3.4L
L32 engines. 4. Lower vehicle.
• Bolt/screw (835) to 47 N•m (35 lb. ft.) on 5.7L NOTICE: Do not overfill. Overfilling will cause
LTl engines. foaming, loss of fluid and possible damage to the
6. Lower vehicle. transmission.
7. Indicator assembly (837). • Refill with transmission fluid as required.

~ {.:---838
~
jv1ewA I

835

A 5.7L LT1 ENGINE

B 3.4L L32 ENGINE
835 BOLT/SCREW, TRANSMISSION
836 TUBE ASSEMBLY, TRANSMISSION FLUID FILLER
837 INDICATOR ASSEMBLY, TRANSMISSION FLUID LEVEL 835 A
838
901
TRANSMISSION ASSEMBLY, AUTOMATIC
SEAL, TRANSMISSION FLUID FILLER TUBE
jv1ewe I
PC0012·7A·F·RP
Figure 13 - Transmission Fluid Filler Tube and Transmission Fluid Level Indicator Assemblies
7A·18 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

690 691

»
39

42 SEAL, 0-RING (ITSS TO CASE

EXTENSION)
99 SPEED SENSOR, INTERNAL
TRANSMISSION
100 BOLT/SCREW, SPEED SENSOR
RETAINING
RC0004-7 A-F-RP 10 CASE, AUTOMATIC TRANSMISSION
35 SEAL, AUTOMATIC TRANSMISSION CASE EXTENSION
Figure 14 - Vehicle Speed Sensor 36 EXTENSION, AUTOMATIC TRANSMISSION CASE
37 BOLT/SCREW, AUTOMATIC TRANSMISSION CASE
EXTENSION, 35 N•m (26 LB. FT.)
39 SEAL ASSEMBLY, CASE EXTENSION OIL
687 SHAFT, OUTPUT
AUTOMATIC TRANSMISSION CASE 690 SLEEVE, OUTPUT SHAFT } NOT USED ON
691 SEAL, OUTPUT SHAFT SLEEVE ALL MODELS
EXTENSION

Figure 15
RC0005-7A-F-RP
!+-+I Remove or Disconnect Figure 15 - Speedometer Drive Gear and Automatic
Transmission Case Extension
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Propeller shaft assembly. Refer to SECTION 4A.
3. Rear axle torque arm assembly. Refer to SECTION
ACCUMULATOR ASSEMBLY
30. Figure 16
4. Catalytic converter hanger assembly. Refer to SEC- Tool Required:
TION 6F.
J 25025-B Pump and Valve Body Alignment
5. Bolts/screws (37). Pin Set
6. Extension (36), with seal (35). Discard seal (35).
7. Sleeve (690) and seal (691), if necessary.
!+-+! Remove or Disconnect
I. Oil pan. Refer to "Changing Transmission Fluid and
!-++! Install or Connect Automatic Transmission Oil Filter Assembly" in
this section.
NOTICE: See "Notice" on page 7A-l of this sec-
2. Oil filter and filter seal.
tion.
3. Control valve body. Refer to "Control Valve Body
1. Sleeve (690) and seal ( 691 ), if removed. and Pressure Switch" in this section.
2. New seal (35) and extension (36). 4. Accumulator cover bolts/screws (935).
3. Bolts/screws (37). 5. 1-2 accumulator cover (934), piston (933) and
spring (932).
!~I Tighten 6. Bolts/screws (936) and spacer plate support (931 ).
• Bolts/screws (37) to 35 N•m (26 lb. ft.). 7. Spacer plate (929) and spacer plate gaskets (928 and
930).
4. Rear axle torque aim assembly. Refer to SECTION
30. 8. 3-4 accumulator spring (927), piston (926) and pin
(925).
5. Propeller shaft assembly. Refer to SECTION 4A.
6. Catalytic converter hanger assembly. Refer to SEC-
TION 6F.
!L•l1nspect
• Accumulator assembly. Refer to SECTION
7. Lower vehicle. 7A-14B.
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·19

8. 1-2 accumulator piston (933) to accumulator c~ver

(934).
• Piston legs must face toward case when
installed.
9. 1-2 accumulator spring (932) onto piston (933).
10. 1-2 accumulator cover (934) and bolts/screws (935).

!~I Tighten
• Bolts/screws (935) to 11 N•m (97 lb. in.).
11. Remove J 25025-B.
12. Control valve body. Refer to "Control Valve Body
and Pressure Switch" in this section.
13. Oil filter and filter seal.
14. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in
this section.

2-4 BAND SERVO ASSEMBLY

Figures 17 and 18

!++I Remove or Disconnect

Tool Required:
J 29714-A Servo Cover Depressor
925 PIN, ACCUMULATOR PISTON 1. Raise and suitably support vehicle. Refer to SEC-
926 PISTON, 3-4 ACCUMULATOR TION OA.
927 SPRING, 3-4 ACCUMULATOR
928 GASKET, SPACER PLATE TO CASE 2. Exhaust crossover pipe assembly and catalytic con-
929 PLATE, VALVE BODY SPACER verter hanger assembly. Refer to SECTION 6F.
930 GASKET, SPACER PLATE TO VALVE BODY
931 PLATE, SPACER PLATE SUPPORT
3. Propeller shaft assembly. Refer to SECTION 4A.
932 1-2 ACCUMULATOR 4. Rear axle torque arm assembly. Refer to SECTION
933 1-2 ACCUMULATOR 3D.
934 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR
935 BOLT/SCREW, ACCUMULATOR COVER 5. Support automatic transmission assembly with
936 BOLT/SCREW, SPACER PLATE SUPPORT transmission stand.
RC000&-7 A-F-RP 6. Transmission support. Refer to SECTION 10-3.
Figure 16 - Accumulator Assembly 7. Catalytic converter heat shield. Refer to SECTION
6F.
8. Lower automatic transmission assembly.
!++I Install or Connect 9. Two automatic transmission oil pan bolts/screws
from below servo cover ( 15).
1. 3-4 accumulator pin (925) into transmission case. 10. Install J 29714-A on automatic transmission oil pan
2. 3-4 accumulator piston (926) onto pin (925). rail.
• Piston legs must face valve body. 11. Reinstall automatic transmission oil pan bolts/
screws.
3. 3-4 accumulator piston spring (927).
12. Depress servo cover (15) and remove retaining ring
4. J 25025-B to transmission case. (13).
5. Case gasket and valve body gasket to spacer plate. 13. J 29714-A.
• Case gasket is identified by a "C." 14. Servo cover (15).
• Valve body gasket is identified by a "V." • If unable to remove by hand, use slip joint pli-
• Use J 36850 to retain gaskets to spacer plate. ers.
6. Spacer plate (929) and gaskets (928 and 930) to • 0-ring seal may remain in automatic transmis-
transmission case. sion case.
7. Spacer plate support (931) and bolts/screws (936). 15. 2-4 band servo.assembly (16).

l~I Tighten !L'l'I Inspect

• Spacer plate support bolts/screws (936) to 11 • 2-4 band servo assembly. Refer to SECTION
N•m (97 lb. in.). 7 A-l 5B for disassembly and inspection procedures.
7A·20 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

!®'I Tighten
• Automatic transmission oil pan bolts/screws to
16 N•m (12 lb. ft.).
7. Raise automatic transmission assembly.
8. Catalytic converter heat shield. Refer to SECTION
6F.
9. Transmission support. Refer to SECTION 10-3.
10. Remove tool supporting automatic transmission
assembly.
11. Rear axle torque arm assembly. Refer to SECTION
3D.
12. Propeller shaft assembly. Refer to SECTION 4A.
13. Exhaust crossover pipe assembly and catalytic con-
verter hanger assembly. Refer to SECTION 6F.
13 RING, 2-4 BAND SERVO COVER RETAINING
14. Lower vehicle.
15 COVER, 2-4 BAND SERVO
TRANSMISSION CONVERTER COVER
PC6017-7A-D-RP

Figure 17 - 2-4 Band Servo Cover

Figure 19

j++I Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Converter cover bolts/screws (840).
3. Converter cover (839) from automatic transmission
assembly (838).

!++I Install or Connect

NOTICE: See "Notice" on page 7A-1 of this
section.
1. Converter cover (839) to automatic transmission
assembly (838).
2. Converter cover bolts/screws (840).
15 COVER, 2-4 BAND SERVO
16 SERVO ASSEMBLY, 2-4 BAND !®'I Tighten
PC6018-7A-D-RP • Transmission converter cover bolts/screws
(840) to 10 N•m (89 lb. in.).
Figure 18 - 2-4 Band Servo Assembly
3. Lower vehicle.

PRESSURE REGULATOR VALVE

Figure 20
!++I Install or Connect
NOTICE: See "Notice" on page 7A-l of this j++I Remove or Disconnect
section. l. Automatic transmission oil pan. Refer to "Changing
1. 2-4 band servo assembly (16). Transmission Fluid and Automatic Transmission Oil
Filter Assembly" in this section.
2. Servo cover ( 15).
2. Compress TV (throttle valve) boost valve bushing
• Replace 0-ring seal on servo cover ( 15). and related components (223 through 218) with
3. Install J 29714-A on automatic transmission oil pan small screwdriver.
rail. 3. Retainer ring (224).
4. Depress servo cover ( 15). 4. Slowly release spring pressure.
5. Retaining ring (13). 5. Regulator valve (218).
6. Remove J 29714-A. 6. Spring (219).

840
838 TRANSMISSION ASSEMBLY, AUTOMATIC
839 COVER, TRANSMISSION CONVERTER
840 BOLT/SCREW, TRANSMISSION CONVERTER COVER,
10 N•m (89 LB. IN.)
PC0018·7A·f·RP
Figure 19 - Transmission Converter Cover
7. Reverse boost valve (220) and bushing {221 ).
8. TV boost valve (222) and bushing (223).
!L'l'! tnspect
• Pressure regulator valve assembly. Refer to SEC-
TION 7 A-1 SB for disassembly and inspection pro-
cedures.
!++! Install or Connect
1. Regulator valve (218) into pump cover bore.
2. Spring (219).
3. Reverse boost valve (220) into bushing (221).
• Small end first. Retain with Transjel TM, or
equivalent.
4. Bushing (221) with reverse boost valve (220) into
pump cover bore.
5. TV boost valve (222) into bushing (223).
• Insert long land of TV boost valve (222) into
largest hole of bushing (223). Retain with
Transjel ™, or equivalent.
6. Bushing (223) with TV boost valve (222) into pump
cover bore.
7. Compress TV boost valve bushing and related com-
ponents (223 through 218).
8. Retainer ring (224).
9. Automatic transmission oil pan. Refer to "Changing
Transmission Fluid and Automatic Transmission Oil
Filter Assembly" in this section.
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·21
217
//N~--224
217 PUMP ASSEMBLY, AUTOMATIC TRANSMISSION OIL
218 VALVE, PRESSURE REGULATOR
219 SPRING, PRESSURE REGULATOR VALVE
220 VALVE, REVERSE BOOST
221 BUSHING, REVERSE BOOST VALVE
222 VALVE, TV BOOST
223 BUSHING, TV BOOST VALVE
224 RING, TV BOOST VALVE BUSHING RETAINER
PC0019·7A·f-RP
Figure 20 - Pressure Regulator Valve Assembly
CONTROL VALVE BODY AND PRESSURE
SWITCH
Figures 10, 21, 22 and 24
!++! Remove or Disconnect
1. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" m
this section.
2. Oil filter and filter seal.
3. Electrical connectors from control valve body com-
ponents.
4. Torque converter clutch (TCC) solenoid bolts/
screws and solenoid assembly with 0-ring seal.
5. Wiring harness bolts/screws and lay wiring harness
aside.
6. Bolts/screws (942) and pressure switch assembly
(941 ).
7. Bolt/screw (939) and manual detent spring assembly
(938).
8. Remaining control valve body bolts/screws.
9. Manual valve link (705).
10. Control valve body (937).
!L•! 1nspect
• Control valve body (937). Refer to SECTION
7 A-14B for cleaning, inspection and repair of the
control valve body.
7A-22 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

!++I Install or Connect !~I Tighten

NOTICE: Install all valve body bolts/screws then • All bolts/screws in the pattern shown in Figure
torque in a spiral pattern sta11ing from the center (see 22 to 11 N•m (97 lb. in.).
Figure 22). If bolts/screws are torqued at random, 8. Oil filter and filter seal.
valve bores may be distorted and inhibit valve
operation. 9. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in
I. Control valve body (937) and manual valve link this section.
(705) to transmission case ( 10).
2. Control valve body bolts/screws. CONTROL AND SHIFT SOLENOIDS
3. Manual detent spring assembly (938) and bolt/screw
(939). Figures 10, 16 and 23
4. Pressure switch assembly (941) and bolts/screws
(942).
j++I Remove or Disconnect
5. Wiring harness and wiring harness bolts/screws. 1. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in
6. TCC solenoid, 0-ring seal and bolts/screws. this section.
7. Electrical connectors. 2. Oil filter and filter seal.
3. Accumulator cover bolts/screws (935).
4. 1-2 accumulator cover, piston and spring (934, 933
and 932).
5. Component electrical connectors.
6. Pressure control solenoid retainer bolt/screw,
retainer and solenoid.
7. Shift solenoid retainers and shift solenoids.
8. 3-2 control solenoid retainer and control solenoid.

!++I Install or Connect

1. 3-2 control solenoid and retainer.
2. Shift solenoids and retainers.
3. Pressure control solenoid, retainer and retainer bolt/
screw.
• Position pressure control solenoid with the
electrical tabs facing outboard.
4. Component electrical connectors.
5. 1-2 accumulator piston to the accumulator cover.
• Piston legs must face toward the case when
installed.
6. 1-2 accumulator spring onto piston (932 and 933).
7. 1-2 accumulator cover (934) and accumulator cover-

'\,., 942
bolts/screws (935).

!~I Tighten
• Bolts/screws (935) to 11 N•m (97 lb. in.).
8. Oil filter and filter seal.
9. Oil pan. Refer to "Changing Transmission Fluid and
10 CASE, TRANSMISSION Automatic Transmission Oil Filter Assembly" in
937 VALVE ASSEMBLY, CONTROL BODY this section.
938 SPRING ASSEMBLY, MANUAL DETENT
939 BOLT/SCREW, MANUAL DETENT SPRING TCC SOLENOID AND WIRING HARNESS
940 SOLENOID ASSEMBLY, WIRING HARNESS AND
941 SWITCH ASSEMBLY, TRANSMISSION PRESSURE REPLACEMENT
942 BOLT/SCREW, PRESSURE SWITCH ASSEMBLY
Figures 16 and 23
RC0007·7A·f-RP
Tool Required:
Figure 21 - Control Valve and Pressure Switch Assembly J 28458 Power Piston Seal Protector and Dia-
phragm Retainer Installer
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·23

A MS X 1.0 X 65.0
B M6X1.0X54.4
C M6X1.0X47.5
D M6 X 1.0 X 18.0
E M6 X 1.0 X 35.0
F MS X 1.25 X 20.0
G M6 X 1.0 X 12.0
PH0197-4L60-E

Figure 22 - Valve Body Bolts/Screws and Tightening Pattern

!+,.! Remove or Disconnect !,.+! Install or Connect

1. Exhaust system. Refer to SECTION 6F. 1. TCC solenoid with wiring harness to transmission
case.
2. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in 2. Pass-through electrical connector to transmission
this section. case.
3. Oil filter and seal. 3. TCC solenoid bolts/screws.
4. Pressure control solenoid, retainer and bolt/screw.
4. External wiring harness connector from transmis-
sion pass-through connector.
• Squeeze fore and aft flats on connector to
I~! Tighten
release locking tabs and pull connector. • TCC solenoid bolts/screws to 11 N•m (97 lb.
in.).
5. Accumulator cover bolts/screws (935).
• Pressure control solenoid bolt/screw to 11 N•m
6. 1-2 accumulator cover, piston and spring (934, 933 (97 lb. in.).
and 932). 5. Component electrical connectors.
7. Component electrical connectors. 6. 1-2 accumulator piston (933) to 1-2 accumulator
8. Pressure control solenoid retainer bolt/screw, cover (934 ).
retainer and solenoid. • Piston legs must face toward the case when
9. TCC solenoid bolts/screws. installed.
7. 1-2 accumulator spring onto piston (932)/(933).
10. Pass-through electrical connector from transmission
case. 8. 1-2 accumulator cover (934) and accumulator cover
bolts/screws (935).
• Use small end of J 28458 over top of connector
and twist to release four tabs while at the same
time pulling harness connector from the trans- I~! Tighten
mission case. • Bolts/screws to 11 N•m (97 lb. in.).
11. TCC solenoid with wiring harness from transmis- 9. Wiring harness connector to transmission pass-
sion case. through connector.
7A·24 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

PRESSURE CONTROL SOLENOID

VEHICLE SPEED SENSOR

CONVERTER CLUTCH SOLENOID

1-2 AND 2-3

SHIFT SOLENOID
3-2 CONTROL SOLENOID

PRESSURE SWITCH
ASSEMBLY

RC1016-7A-Y·RP

Figure 23 - Electronic Component Location Views

 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·25

Automatic Transmission Oil Filter Assembly" in

this section.

~ CASE EXTENSION OIL SEAL ASSEMBLY

703 709
Figure 15
Tool Required:
J 21426 Case Extension Oil Seal Installer

j++! Remove or Disconnect

1. Propeller shaft assembly. Refer to SECTION 4A.
2. Oil seal assembly (39) with screwdriver.
340
!++I Install or Connect
340 VALVE, MANUAL
1. Oil seal assembly (39). Tap into place with J 21426.
703 LEVER, MANUAL SHIFT DETENT 2. Propeller shaft assembly. Refer to SE.CTION 4A.
70~ LINK ASSEMBLY, MANUAL VALVE
709 DETENT ASSEMBLY, MANUAL SHIFT
NOTICE: Do not overfill. Overfilling will cause
foaming, loss of fluid and possible damage to the
transmission.
PC6023-7 A·D-RP

Figure 24 - Manual Shift Detent Assembly

10. Oil filter and seal.
11. Oil pan. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in
this section.
12. Exhaust system. Refer to SECTION 6F.
ELECTRICAL CONNECTOR AND SEAL
Figure23
l++I Remove or Disconnect
1. Oil pan and automatic transmission oil filter assem-
bly. Refer to "Changing Transmission Fluid and
Automatic Transmission Oil Filter Assembly" in
this section.
2. Internal and external electrical wires from electrical
connections.
3. Electrical connector and seal from automatic trans-
mission assembly.
4. Seal from electrical connector.
• Discard old seal.
IL"I Inspect
• Automatic transm1ss1on sealing surface for
damage or corrosion.
!++I Install or Ccnnect
1. New seal to electrical connector.
2. Electrical connector and new seal to automatic
transmission assembly.
3. Internal and external electrical wires to electrical
connectors.
4. Oil pan and automatic transmission oil filter assem-
bly. Refer to "Changing Transmission Fluid and
[21 Adjust
• Automatic transmission fluid level.
AUTOMATIC TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Figures 19 and 25 through 28
A pressure test should be performed before auto-
matic transmission assembly removal to aid in diagnosis.
NOTICE: Transmission oil cooler flushing must be
performed when an automatic transmission assem-
bly is removed for service. The flushing procedure
should be performed after the installation of the
overhauled or replacement assembly. Failure to
flush the system may cause damage to the system
and its components.
!++! Remove or Disconnect
Tool Required:
J 21426 Output Shaft Sleeve and Case Exten-
sion Oil Seal Installer
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Mark position of propeller shaft assembly to pinion
yoke.
4. Propeller shaft assembly. Refer to SECTION 4A.
5. Support transmission assembly (838).
6. Washer (853) and nut (852) from support (850) and
transmission assembly (838).
7. Bolts/screws (854) from support (850) and rail
assembly (846).
8. Support (850) from transmission assembly (838)
and rail assembly (846).
9. Rear axle torque arm. Refer to SECTION 3D.
7A-26 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

l 0. Catalytic converter hanger assembly. Refer to SEC-

TION 6F.
11. Bolts/screws (840) from cover (839).
12. Cover (839) from transmission assembly (838).
13. Bolts/screws (842) from converter assembly (1 ).
14. Flywheel assembly (841) from converter assembly
(1).
15. Move catalytic converter heat shield as necessary.
Refer to SECTION 6F.
16. Automatic transmission range selector lever cable
assembly. Refer to "Automatic Transmission Range
Selector Lever Cable Assembly" in this section. 1 CONVERTER ASSEMBLY, TORQUE
841 FLYWHEEL ASSEMBLY
17. Transmission oil cooler pipe assemblies from trans- 842 BOLT/SCREW, TRANSMISSION TORQUE CONVERTER,
mission oil cooler pipe clips. 63 N•m (46 LB. FT.)
18. Electrical connectors at transmission assembly PC0022-7 A·F-RP
(838).
Figure 25 - Torque Converter Assembly-to-Flywheel
19. Bolts/screws (843 or 845). Assembly
20. Transmission fluid level indicator assembly.
21. Separate transmission assembly (838) from engine
block.
22. Transmission oil cooler lines. 846

23. Lower transmission assembly (838) from vehicle.

l++I Install or Connect

NOTICE: See "Notice" on page 7 A-1 of this sec-
tion.
1. Raise transmission assembly (838) into vehicle.
2. Transmission oil cooler lines.
3. Align transmission assembly (838) to engine block.
4. Transmission fluid level indicator assembly.
5. Bolts/screws (843 or 845).

I~! Tighten I I

• Bolts/screws (843) to 47 N•m (35 lb. ft.).

• Bolts/screws (845) to 95 N•m (70 lb. ft.).
838 TRANSMISSION ASSEMBLY, AUTOMATIC
~ ...
6. Electrical connectors to transmission assembly
846 RAIL ASSEMBLY, ENGINE COMPARTMENT INNER SIDE
(838). 850 SUPPORT, TRANSMISSION
7. Transmission oil cooler pipe and hose assemblies to 852 NUT, TRANSMISSION MOUNT, 47 N•m (35 LB. FT.)
853 WASHER, TRANSMISSION MOUNT
transmission oil cooler pipe clips. 854 BOLT/SCREW, TRANSMISSION SUPPORT
8. Automatic transmission range selector lever cable
assembly. Refer to "Automatic Transmission Range PC0023-7A-F-RP
Selector Lever Cable Assembly" in this section.
Figure 26 - Automatic Transmission Assembly Mounting
9. Reposition catalytic converter heat shield. Refer to
SECTION 6F.
10. Flywheel assembly (841) to converter assembly (1 ).
11. Bolts/screws (842) to converter assembly ( 1). l~I Tighten

l~I Tighten
• Bolts/screws (840) to 10 N•m (89 lb. in.).
14. Catalytic converter hanger assembly. Refer to SEC-
• Bolts/screws (842) to 63 N•m (46 lb. ft.). TION 6F.
12. Converter cover (839) to transmission assembly 15. Rear axle torque arm. Refer to SECTION 3D.
(838). 16. Support (850) to transmission assembly (838) and
13. Bolts/screws (840) to cover (839). rail assembly (846).
 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A·27

843 845 844

844

838 TRANSMISSION ASSEMBLY, AUTOMATIC 838 TRANSMISSION ASSEMBLY, AUTOMATIC

843 BOLT/SCREW, TRANSMISSION, 47 N•m (35 LB. FT.) 844 ENGINE ASSEMBLY
844 ENGINE ASSEMBLY 845 BOLT/SCREW, TRANSMISSION, 95 N•m (70 LB. FT.)

PC0024-7A·F·RP PC0025-7A-F-RP

Figure 27 - Automatic Transmission Assembly-to-Engine Figure 28 - Automatic Transmission Assembly-to-Engine

Assembly (5.7 LT1 Engine) Assembly (3.4L L32 Engine)

17. Bolts/screws (854) to support (850) and rail assem-
bly (846).
18. Washer (853) and nut (852) to support (850) and
transmission assembly (838).
l~I Tighten
• Nut (852) to 47 N•m (35 lb. ft.).
19. Remove support from transmission assembly (838).
20. Propeller shaft assembly, using marks made during
removal. Refer to SECTION 4A.
21. Lower vehicle.
22. Battery negative cable assembly.
IW,I Clean
NOTICE: Transmission oil cooler flushing must be
performed when a transmission assembly is
removed for service. The flushing procedure should
be performed after the installation of the overhauled
or replacement assembly. Failure to flush the system
may cause damage to the system and its compo-
nents.
• Transmission oil cooler and oil cooler pipe and hose
assemblies. Refer to "Oil Cooler Flushing Proce-
dure" in this section.
[£] Adjust
• Automatic transm1ss1on shift control lever cable
assembly. Refer to "Automatic Transmission Range
Selector Lever Cable Assembly" in this section.
NOTICE: Do not overfill. Overfilling will cause
foaming, loss of fluid and possible damage to the
transmission.
• Transmission fluid level.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Accumulator Cover Bolt/Screw ........................................ 11 N •m (97 lb. in.)
Automatic Transmission Case Extension Bolt/Screw ....................... 35 N•m (26 lb. ft.)
Automatic Transmission Control Bolt/Screw ............................. 4.5 N•m (40 lb. in.)
Automatic Transmission Oil Cooler Pipe and Hose Assembly Fittings .......... 27 N•m (20 lb. ft.)
Automatic Transmission Oil Pan Bolt/Screw .............................. 16 N•m (12 lb. ft.)
Automatic Transmission Range Selector Lever Cable Bracket Bolt/Screw ....... 24 N•m (18 lb. ft.)
Automatic Transmission Range Selector Lever Nut ......................... 20 N•m (15 lb. ft.)
Control Valve Body Bolt/Screw ........................................ 11 N•m (97 lb. in.)
Flywheel Bolt/Screw ................................................. 63 N•m (46 lb. ft.)
Manual Shift Detent Bolt/Screw ........................................ 22 N•m (16 lb. ft.)
Park/Neutral Position Switch Bolt/Screw ................................ 2.2 N•m (19 lb. in.)
Pressure Control Solenoid Retainer Bolt/Screw ............................ 11 N •m (97 lb. in.)
Spacer Plate Support Bolt/Screw ....................................... 11 N•m (97 lb. in.)
7A·28 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

Special Hex Washer Head Bolt (M6X1Xl6) .............................. 11 N•m (97 lb. in.)
TCC Solenoid Valve Bolt/Screw ....................................... 11 N•m (97 lb. in.)
Transmission Bolt/Screw (3.4L L32 Engine) .............................. 95 N•m (70 lb. ft.)
Transmission Bolt/Screw (5.7L LTl Engine) .............................. 47 N•m (35 lb. ft.)
Transmission Converter Cover Bolt/Screw ............................... 10 N•m (89 lb. in.)
Transmission Mount Nut .............................................. 47 N•m (35 lb. ft.)
Transmission Torque Converter Bolt/Screw ............................... 63 N•m (46 lb. ft.)
Vehicle Speed Sensor Bolt/Screw ....................................... 11 N•m (97 lb. in.)
Vehicle Speed Sensor Retaining Bolt/Screw .............................. 10 N•m (89 lb. in.)

SPECIAL TOOLS

J 21366

12]
ffl J 36850
IT]

w J 29714-A IT] Q J 35944-20

- .. J 28458 J 21426
J 25025-B

CONVERTER HOLDING STRAP VALVE BODY ALIGNMENT PIN SET

TRANSMISSION ASSEMBLY LUBRICANT (TRANSJEL ®l POWER PISTON SEAL PROTECTOR AND DIAPHRAGM
RETAINER INSTALLER
SERVO COVER DEPRESSOR
CASE EXTENSION OIL SEAL INSTALLER
OIL COOLER AND LINE FLUSHER
COOLER FLUSHING FLUID (1 GALLON)
RC1024-7A-Y·RP
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
SECTION 7A-14A
HVDRA-MATIC 4L60-E
AUTOMATIC TRANSMISSION DIAGNOSIS
RPO M30
CONTENTS
General Information ...................................... 7A-14A- 1
How to Use This Section ........................... 7A-14A- 1
Transmission Definitions and
Abbreviations ........................................ 7A-14A- 1
Throttle Positions .................................. 7A-l 4A- 1
Shift Conditions ..................................... 7A-l 4A- 1
Noise Conditions ................................... 7A-14A- 2
Abbreviations ........................................ 7A-14A- 2
Transmission General Description ............ 7A-14A- 2
Transmission Component and System
Descriptions ........................................... 7A-14A- 3
Transmission Adapt Function ................ 7A-l 4A- 3
Electronic Component Location
Views ................................................. 7A-14A- 5
Transmission Electrical Connector ............ 7A-14A- 9
Range Reference Chart ......................... 7A-l 4A-10
Diagnosis ....................................................... 7A-14A-11
Basic Knowledge Required ....................... 7A-14A-ll
Special Tools ................................ 7A-14A-ll & 85
Functional Test Procedure ......................... 7A-14A-12
Trouble Code Actions ................................ 7A-14A-14
GENERAL INFORMATION
HOW TO USE THIS SECTION
This section provides general information on
transmissions, a detailed description of the operation
of the HYDRA-MATIC 4L60-E and procedures for
diagnosing the HYDRA-MATIC 4L60-E. When
diagnosing any condition on the HYDRA-MATIC
4L60-E, begin with the "HYDRA-MATIC 4L60-E
Functional Test Procedure" in this section. After the
cause of a condition is determined, refer to SECTION
7A-14B, "ON-VEHICLE SERVICE" for repair
procedures.
TRANSMISSION DEFINITIONS AND
ABBREVIATIONS
The following definitions and abbreviations are
provided to establish a common language for
describing transmission related conditions. These
terms are used in SECTION 7A-14B.
Throttle Positions
• Minimum Throttle - the least amount of throttle
opening required for an upshift.
7A-14A-1
Transmission Fluid Checking
Procedure ............................................... 7A-14A-16
Line Pressure Check Procedure ................. 7A-14A-l 7
Electrical/Garage Shift Test ....................... 7A-14A-18
Road Test Procedure .................................. 7A-14A-20
Torque Converter Clutch (TCC) Diagnosis .. 7A-14A-20
Torque Converter Evaluation ..................... 7A-14A-20
TCC Shudder ............................................. 7A-14A-21
Flexplate/Torque Converter Vibration
Test Procedure ....................................... 7A-14A-22
Shift Speed Chart ....................................... 7A-14A-33
Internal Wiring Harness Check .................. 7A-14A-34
Component Resistance Chart ..................... 7A-14A-36
Pressure Switch Assembly
Resistance Check ................................... 7A-14A-37
Diagnosis Charts ........................................ 7A-14A-40
Fluid Leak Diagnosis .................................... 7A-14A-50
Leak Inspection Points .......................... 7A-14A-51
Fluid Flow and Circuit Descriptions ......... 7A-14A-52
Fluid Passage Identification ....................... 7A-14A-76
• Light Throttle - approximately 1/4 of accelerator
pedal travel. (25% Throttle Position)
• Medium Throttle - ap__Qroximatel)'. 1/2 of
accelerator pedal travel. (50% Throttle Position)
• Heavy Throttle - approximately 3/4 of
accelerator pedal travel. (75% Throttle Position)
• Wide Open Throttle (WOT) - full travel of the
accelerator pedal. (100% Throttle Position)
• Full Throttle Detent Downshift - a quick apply
of the accelerator pedal to its full travel, forcing
a downshift.
• Zero Throttle Coastdown - a full release of the
accelerator pedal while the car is in motion and
in drive range.
• Engine Braking - a condition where the engine
is used to slow the car by manually downshifting
during a zero throttle coastdown.
Shift Conditions
• Bump- a sudden and forceful apply of a clutch
or band.
• Chuggle - a bucking or jerking may be most
noticeable when the converter clutch is engaged;
similar to the feel of towing a trailer.
7A-14A-2 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
• Delayed - a condition where a shift is expected
but does not occur for a period of time. Samples
of this could be described as clutch or band
engagement that does not occur as quickly as
expected during a part throttle or wide open
throttle apply of the accelerator or, when
manually downshifting to a lower range. Also
defined as "LATE" or "EXTENDED".
• Double Bump (Double Feel) - two sudden and
forceful applies of a clutch or band.
• Early - a condition where the shift occurs before
the car has reached proper speed. Tends to labor
the engine after the upshift.
• End Bump - a firmer feel at the end of a shift
as compared to the feel at the start of the shift.
Also defined as "END FEEL" or "SLIP
BUMP".
• Firm - a noticeably quick apply of a clutch or
band that is considered normal with a medium
to heavy throttle. Should not be confused with
"HARSH" or "ROUGH".
• Flare - a quick increase in engine rpm along
with a momentary loss of torque. This most
generally occurs during a shift. Also defined as
"SLIPPING".
• Harsh (Rough) - a more noticeable apply of a
clutch or band as compared with "FIRM". This
condition is considered undesirable at any
throttle position.
• Hunting - a repeating quick series of upshifts
~nd d~wnshifts that causes a noticeable change
m engme rpm. An example could be described
as a 4-3-4 shift pattern. Also defined as
"BUSYNESS".
• Initial Feel - a distinct firmer feel at the start of
a shift as compared to the finish of the shift.
• Late - a shift that occurs when the engine is at
a higher than normal rpm for a given amount
of throttle.
• Shudder - a repeating jerking condition similar
to "CHUGGLE" but more severe and rapid.
This condition may be most noticeable during
certain ranges of car speed.
• Slipping - a noticeable increase in engine rpm
without a car speed increase. A slip usually
occurs during or after initial clutch or band
apply.
• Soft - a slow, almost unnoticeable clutch or
band apply with very little shift feel.
• Surge - a repeating engine related condition of
acceleration and deceleration that is less intense
than "CHUGGLE".
• Tie-Up - a condition where two opposing
clutches and/or bands are attempting to apply
at the same time causing the engine to labor
with a noticeable loss of engine rpm.
Noise Conditions
• Planetary Gear Noise - a whine related to car
speed most noticeable in first gear or reverse.
Becomes less noticeable after an upshift.
• Pump Noise - a high pitch whine that increases
with engine rpm.
Abbreviations
• PCM - Powertrain Control Module.
• TCC - Torque Converter Clutch.
• TP Sensor - Throttle Position Sensor.
• ECT Sensor - Engine Coolant Temperature
Sensor.
• VS Sensor - Vehicle Speed Sensor.
• RWD - Rear Wheel Drive.
• 2WD - 2 Wheel Drive.
• 4WD - 4 Wheel Drive.
• PSA - Transmission Fluid Pressure Switch
Assembly.
• TTS - Transmission Temperature Sensor
TRANSMISSION GENERAL DESCRIPTION
The HYDRA-MATIC 4L60-E is a fully
automatic rear wheel drive electronically controlled
transmission. It provides four forward ranges
including overdrive, and reverse. Shift points are
controlled by the PCM via two shift solenoids. Oil
pressure is supplied by a vane type oil pump, and
regulated by the PCM with a transmission pressure
control solenoid (force motor). Shift schedules and
TCC apply rates are also controlled by the PCM and
are influenced by transmission temperature.
The transmission can be operated in any one of
the following seven modes:
P - Park position prevents the vehicle from
rolling either forward or backward. (For safety
reasons the parking brake should be used in
addition to the park position.)
R - Reverse allows the vehicle to be operated
in a rearward direction.
N - Neutral allows the engine to be started and
operated while driving the vehicle. If necessary
this position may be selected if the engine must
be restarted with the vehicle moving.
@ - Overdrive is used for all normal driving
conditions. It provides four gear ratios plus
converter clutch operation. Downshifts are
available for safe passing by depressing the
accelerator.
D - Drive position is used for city traffic and
hilly terrain. It provides three gear ranges.
Again, downshifts are available by depressing
the accelerator.
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-3

2 - Manual second is used to provide Transmission Adapt Function

acceleration, engine braking, or greater traction
from a stop. When manual second is chosen, The HYDRA-MATIC 4L60-E uses a line
the vehicle will start out and remain in second pressure control system which has the ability to adapt
gear. This range may be selected at any vehicle the system's line pressure to compensate for normal
speed. wear of clutch fiber plates, seals, springs, etc. This
"learning" feature is similar to what is used for fuel
1 - Manual Lo is used to provide maximum control (integrator/block learn).
engine braking. This range may also be selected
at any vehicle speed. The HYDRA-MATIC 4L60-E transmission only
uses the adapt function for the 1-2 upshift. The PCM
TRANSMISSION COMPONENT AND SYSTEM monitors engine speed to determine if the shift is
occurring too fast (harsh) or too slow (soft) and adjusts
DESCRIPTIONS
the pressure control solenoid to maintain the correct
The mechanical components of this unit are: shift feel. The line pressure can adapt to values ranging
• Torque converter with converter clutch from 5 psi below, to 10 psi above normal line pressure.
(TCC)
• Vane type oil pump
• Five multiple disc clutches
• 2-4 band assembly
• Two planetary gear sets
• One sprag clutch
• One roller clutch
• Control valve assembly
The electrical components of this unit are:
• Two shift solenoids
• 3-2 downshift solenoid
• Transmission pressure control solenoid
(force motor)
• Torque converter clutch solenoid and wiring
harness assembly
• Transmission fluid temperature sensor
• Fluid pressure switch assembly
• Vehicle speed sensor (2WD only)
Refer to Figure 1 for component locations. Refer
to Range Reference Chart Figure 7 for component
operation in all seven modes of transmission
operation. Refer to Figures 2-6 for detailed
descriptions of electrical components.
 ......
:p,
HYDRA-MATIC 4L60-E ...
:t....
I

CASE REVERSE INPUT CLUTCH OVERRUN FORWARD 3-4 INPUT LO AND REACTION OUTPUT
ASSEMBLY INPUT CLUTCH HOUSING CLUTCH CLUTCH CLUTCH PLANETARY REVERSE PLANETARY SHAFT
.p.
GEARSET CLUTCH GEARSET
~I
m
)>
c:
d
3::
~
.,, n
-t
cc·
c:
-, ~
CD
_.
z
Cl)
::r: 3::
-<
0
cii
Cl)
:II
)> 0
~
z
c
~
n ~
.j>,.
r
z
en 0
0 Cl)
m cii
~
Q)
:::i
en
3
cii"
en
c5·
:::i

:xJ
:i::
0
0 2-4
~ TURBINE PUMP BAND INSIDE MANUAL CONTROL VALVE PARKING LOCK PARKING SPEED
•,,..,~ SHAFT ASSEMBLY ASSEMBLY DETENT LEVER SHAFT ASSEMBLY ACTUATOR ASSEMBLY PAWL SENSOR
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-5

PRESSURE CONTROL SOLENOID

AUTOMATIC TRANSMISSION
OUTPUT SPEED SENSOR
(OR VEHICLE SPEED SENSOR)

TORQUE
CONVERTER CLUTCH SOLENOID

1-2 AND 2-3

SHIFT SOLENOIDS
3-2 CONTROL SOLENOID

TRANSMISSION FLUID PRESSURE SWITCH

ASSEMBLY

RH0003-4L60-E

Figure 2 Electronic Component Location Views

7A-14A-6 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

Torque Converter Clutch Solenoid

The torque converter clutch solenoid is a normally open exhaust
valve that is used to control torque converter clutch apply and
release.
When grounded (energized) by the PCM, the TCC solenoid stops
converter signal oil from exhausting. This causes converter signal
oil pressure to increase and shift the TCC valve to shift into the
apply position
The brake switch is an input to the PCM, and the PCM directly TCC solenoid resistance should be 20-40 ohms minimum
controls TCC apply based on the brake switch status. when measured at 20°C (68°F).
If a fault is detected in the TCC circuit, code 067 or 069 will set.

Transmission Pressure Control Solenoid

The transmission pressure control solenoid (or force motor) is an
If there is a difference between the amperage coqimanded by the
electronic pressure regulator that controls pressure based on current
PCM and the actual amperage, diagnostic trouble code 073 will set.
flow through its coil winding. The magnetic field produced by the
coil moves the solenoid's internal valve which varies pressure to Unlike the pressure control solenoid on the HYDRA-MATIC 4L80-
the pressure regulator valve. E, the 4L60-E pressure control solenoid does not pulse every 10
seconds for a cleaning cycle.
The PCM controls the pressure control solenoid by commanding
current between O and 1.1 amps. This changes the duty cycle of Force High Force Low Line Pressure
the solenoid, which can range between O % and 60 %. 1.1 amps
corresponds to minimum line pressure, and O amps is maximum
+ 0% Duty Cycle OAmps Maximum
line pressure (if solenoid loses power, transmission will still have
+ 60% Duty Cycle 1.1 Amps@ 4-5 V Minimum
maximum line pressure).
Line pressure values are calculated by the PCM using inputs such
as the throttle position sensor. Transmission Pressure Control Solenoid resistance should
The pressure control solenoid takes the place of the throttle valve measure 3.5 - 8 ohm when measured at 20°C (68°F).
that was used on past model transmissions.

1-2 and 2-3 Shift Solenoids

The 1-2 and 2-3 shift solenoids (also called A and B solenoids) are
identical solenoid devices that control the movement of the 1-2 and
2-3 shift valves (the 3-4 shift valve is not directly controlled by a
shift solenoid). The solenoids are normally open exhaust valves
that work in four combinations to shift the transmission into different
gears (see chart).
The PCM energizes each solenoid by grounding it through an
internal quad driver. This sends current through the coil winding in
the solenoid and moves the internal plunger out of the exhaust
position. When 'ON', the solenoid redirects fluid to move a shift
valve.
PCM controlled shift solenoids eliminate the need for TV and
governor pressures to control shift valve operation.
Note: The manual valve can hydraulically override the shift
solenoids. Only in 04 are the shift solenoid states totally
determining what gear the transmission is in. In the other manual
valve positions, the transmission shifts hydraulically and the shift
solenoid states 'catch up' when throttle position and vehicle speed
fall into the correct ranges.
Diagnostic trouble codes 081 and 082 indicate shift solenoid circuit
voltage faults.
Shift solenoid resistance should measure 20-40 ohms
minimum when measured at 20°C (68°F). Shift solenoid
current flow should not exceed 0.75 amps. The shift
solenoid should energize at a voltage of 7.5 volts or more
(measured across the terminals). The shift solenoid should
de-energize when voltage is one volt or less.
If both solenoids lose power, third gear only will result.

RH0004-4L60-E

Figure 3 Electronic Component Descriptions

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-7

Transmission Fluid Pressure~-·

Switch Assembly ·- -seven
-- ------------
valid combination and two invalid combinations
The transmission fluid pressure switch assembly (PSA) is a set of are available from the TPS: Valid combinations for
five pressure switches on the valve body that sense whether fluid Circuits A, B and C are shown below. Invalid
pressure is present in five different valve body passages. The combinations are A=OV, B=OV AND C=OV; OR A=OV,
combination of which switches are open and closed is used by the B=12V AND C=OV.
PCM to determine actual manual valve position. The PSA assembly
however cannot distinguish between Park and Neutral because the OIL PRESSURE VALID TPS COMBINATION
RANGE
monitored valve body pressures are identical in both cases. INDICATOR CHART

The switches are wired to provide three signal lines that are PARK
"A" ·s· ·c·
monitored by the PCM. These inputs are used to help control line PARK 12 0 12
REVERSE REVERSE 0 0 12
pressure, torque converter clutch apply and shift solenoid operation.
Voltage at each of the signal lines will be either zero or twelve NEUTRAL NEUTRAL 12 0 12
volts. 04 12 0 0
04
03 12 12 0
To monitor PSA assembly operation, the PCM compares the actual 03 D2 12 12 12
voltage combination of the switches to a PSA combination chart D2 D1 0 12 12
stored in the its memory. If the PCM sees one of two 'illegal' ILLEGAL 0 12 0
D1
voltage combinations (see chart) a code 028 will result. ILLEGAL 0 0 0
PSA assembly signal voltage can be measured from each pin to • OIL PRESSURE PRESENT EXPECTED VOLTAGE READINGS
ground, and compared to the combination chart. On the transmission
wiring harness, pin N is 'range signal A', pin R is 'range signal B',
and pin P is 'range signal C'. With the wiring harness connected
and engine running, a voltage measurement of these three lines will
indicate a 'high' reading (near 12 volts) when a circuit is open, and
a low (zero volts) when the circuit is switched to ground.
The transmission temperature sensor is part of the transmission
fluid pressure switch assembly.

SWITCH LOGIC

Vehicle Speed Sensor

The vehicle speed sensor (or transmission output speed sensor) is
used to control shift points and calculate TCC slip.
The speed sensor contains a coil that gives off a continuous magnetic
field. A rotor rotates past the sensor, and the rotor teeth break the
magnetic field. Each break in the field sends a pulse to the VSSB
(Vehicle Speed Sensor Buffer). The VSSB sends two signals to the
PCM, the first is a 2002 pulse per mile (PPM) signal used by the
engine. The second is the transmission/transfer case 40 pulse per
revolution (PPR) signal used to control the transmission.
In two wheel drive (2WD) applications, the vehicle speed sensor is
located on the transmission extension housing.
Sensor resistance should be 1260-1540 ohms when
measured at 20°C (68°F). Output voltage will vary with
speed from a minimum of 0.5 Volts AC at 100 RPM, to
more than 100 Volts AC at 8000 RPM.
Four wheel drive (4WD) applications use a vehicle speed sensor
located on the transfer case.
In 2WD or 4WD Hi, trans output speed= transfer case speed
In 4WD Lo, trans output speed =transfer case speed x constant
Codes 024 or 072 will set if a fault exists in the vehicle speed
sensor circuit 40 PPR line.

3-2 Control Solenoid

The 3-2 control solenoid is a pulse width modulated solenoid used
to improve the 3-2 downshift. The solenoid regulates the release of
the 3-4 clutch and 2-4 band apply.
The solenoid uses duty cycle to regulate pressures that smoothly
release the clutch and apply the band. Duty cycle is normally about
0% in first gear, 90% in all other drive gears and drops during the
3-2 downshift. Throttle position, vehicle speed and the commanded
gear are used to determine duty cycle.
3-2 Control solenoid resistance should be a minimum of
9~14 ohms at 20°C (68°F). It is operated using pulse width
modulation at a frequency of 50 Hz.
If a voltage fault is detected in the 3-2 control solenoid circuit,
diagnostic trouble code 066 will set.
PH0005-4L60-E-R1

Figure 4 Electronic Component Descriptions

7A-14A-8 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

Transmission Fluid Temperature TRANSMISSION SENSOR - TEMPERATURE TO

Sensor RESISTANCE TO VOLTAGE (approximate)

The transmission fluid temperature sensor is part of the transmission °C Of RESISTANCE VOLTS
fluid pressure switch assembly and is used to help control torque -40 -40 100544 5
converter clutch apply and shift quality.
-28 -21 52426 4.78
The temperature sensor is a resistor (thermister) which changes -16 10 18580 4.18
value based on temperature. At low temperatures the resistance is
high, and at high temperatures the resistance is low. -4 23 12300 3.84
0 32 9379 3.45
The PCM sends a 5 volt signal to the temperature sensor and
measures the voltage drop in the circuit. This means you will 7 40 7270 3.20
measure a high voltage when the transmission is cold, and a low 19 68 3520 2.56
voltage when the transmission is hot.
31 86 2232 1.80
If the temperature sensor circuit has a fault, code 058 or 059 will 43 110 1200 1.10
set. Code 079 will set if the transmission is operating at a high
temperature for a period of time. 55 131 858 3.25
67 145 675 2.88
79 176 333 2.24
91 194 241 1.70
103 213 154 1.28
115 239 115 .96
127 260 79 .64
139 284 60 .32
151 302 47 .00

TRANSMISSION SENSOR RESISTANCE VS. TEMPERATURE

110
100
'iii'
E 90
\
-g 80 \
~ 70 \
cB 60
\
! 50
\
"iii 40
a: \
0 30
~ 20 \
GI
U)
10
0
"....... ~

-
-50 -30 -10 10 30 50 70 90 110 130 150
Temperature °C

RH0006-4L60-E

Figure 5 Electronic Component Descriptions

 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-9

TRANSMISSION ELECTRICAL CONNECTOR

The transmission electrical connector is a very important part of the

HYDRA-MATIC 4L60-E operating system. Anything that interferes
with the electrical connection can cause the transmission to set
Diagnostic Trouble Codes and/or operate incorrectly.

The following items can affect the electrical connection:

- Bent pins in the connector from rough handling during connection
and disconnection
- Wires backing away from the pins or coming uncrimped (in
either the transmission or vehicle wiring harness)
- Dirt contamination entering the connector when it is unconnected
- Pins in the connector backing out of the connector or pushed out
during connection
- Excessive transmission fluid leaking into the connector, wicking
up into the vehicle wiring harness and degrading the wire
insulation *
- Water/moisture intrusion in the connector
- Low pin retention from excessive connection and disconnection
of the wiring harness
SQUEEZE
- Pin corrosion from contamination HERE
* The presence of transmission fluid in the transmission connector is
not harmful in itself. The fluid only affects the vehicle harness
wiring insulation if the fluid wicks up that far.

Points to remember when working with the transmission electrical

connector:
- To remove the connector, squeeze the two tabs towards each
other and pull straight up (See illustration).
- Carefully limit twisting or wiggling the connector during removal.
This can bend pins.
- DO NOT pry the connector off with a screwdriver or other tool.
- To install the connector, first orient the pins by lining up the
arrows on each half of the connector. Push the connector straight
down into the transmission without twisting or angling the mating
parts.
- The connector should click into place with a positive feel and/or
noise.
- Whenever the transmission pass-thru connector is disconnected
from the vehicle harness and the engine is running, multiple
Diagnostic Trouble Codes will set. Be sure to clear these codes
after re-connecting the pass-thru connector.
DTC's 59, 67 and 82 will set with key on, engine off.
DTC's 59, 66, 67, 73 and 82 will set with key on, engine on.

PH0220-4L60-E

Figure 6 Transmission Electrical Connector

7A-14A-10 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS

4L60-E

SHIFT SOLENOID REVERSE FORWARD

RANGE 2-4 OVERRUN FORWARD SPRAG CL. 3-4 LO/ROLLER LO/REV.
GEAR INPUT
BAND CLUTCH CLUTCH CLUTCH ASSEMBLY CLUTCH CLUTCH CLUTCH
1-2 2-3
PARK ON* ON* APPLIED
REVERSE ON* ON* APPLIED APPLIED
NEUTRAL ON* ON*
1st ON ON APPLIED HOLDING HOLDING
2nd OFF ON APPLIED APPLIED HOLDING
@) 3rd OFF OFF APPLIED HOLDING APPLIED
4th ON OFF APPLIED APPLIED APPLIED
1st 'ON ON APPLIED HOLDING HOLDING
D 2nd OFF ON APPLIED APPLIED HOLDING
3rd OFF OFF APPLIED APPLIED HOLDING APPLIED
1st** ON ON APPLIED APPLIED HOLDING HOLDING
2
2nd OFF ON APPLIED APPLIED APPLIED HOLDING
1st ON ON APPLIED APPLIED HOLDING HOLDING APPLIED
1
2nd*** OFF ON APPLIED APPLIED APPLIED HOLDING

* SHIFT SOLENOID STATE IS A FUNCTION OF VEHICLE SPEED AND MAY CHANGE IF VEHICLE SPEED INCREASES SUFFICIENTLY
IN PARK, REVERSE OR NEUTRAL. HOWEVER, THIS DOES NOT AFFECT TRANSMISSION OPERATION.
** MANUAL SECOND - FIRST GEAR IS ELECTRONICALLY PREVENTED UNDER NORMAL OPERATING CONDITIONS.
*** MANUAL FIRST - SECOND GEAR IS ONLY AVAILABLE ABOVE APPROXIMATELY 48 TO 56 KM/H (30 TO 35 MPH).
PH0002-4L60-E-R 1

Figure 7 Range Reference Chart

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
DIAGNOSIS
NOTICE: If a wire is probed with a sharp
instrument and not properly sealed afterward, the
wire will corrode and an open circuit will result.
Diagnostic test probes are now available that
allow you to probe individual wires without leaving
the wire open to the environment. These probe devices
are inexpensive and easy to install, and they
permanently seal the wire from corrosion.
BASIC KNOWLEDGE REQUIRED (Refer to 6E)
You must be familiar with some basic electronics
to use this section of the Service Manual. They will
help you to follow diagnostic procedures.
NOTICE: Lack of basic knowledge of this
powertrain when performing diagnostic pro-
cedures could result in incorrect diagnostic
performance or damage to powertrain com-
ponents. Do not, under any circumstances, attempt
to diagnose a powertrain problem without this
basic knowledge.
7A-14A-11
Special Tools
You should be able to use a Digital Volt Meter
(DVM), a circuit tester, jumper wires or leads and a
line pressure gage set. The functional test procedures
given in Figures 8 and 9 are designed to verify the
correct operation of electronic components in the
transmission. This will eliminate the unnecessary
removal of transmission components.
QUICK CHECK PROCEDURE
When diagnosing any HYDRA-MATIC
4L60-E related condition, always begin with the
functional test procedure in this section. The
functional test procedure will indicate the proper path
of diagnosing the transmission by describing the basic
checks and then referencing the locations of specific
checks. Refer to Figures 8 and 9.
TRANSMISSION FLUID CHECKING PROCEDURE
Whenever checking HYDRA-MATIC 4L60-E
transmission fluid refer to Figure 12.
7A-14A-12 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

4L60-E TRANSMISSION
FUNCTIONAL TEST (1 of 2)

PERFORM OBD (ON BOARD DIAGNOSTICS)

SYSTEM CHECK

I
OK I NOT OK I
I

PERFORM 4L60-E TRANSMISSION DIAGNOSE AND REPAIR ALL OTC

FLUID CHECKING PROCEDURE (DIAGNOSTIC TROUBLE CODES)
FIGURE 12

I
OK I NOT OK I
I

VERIFY CUSTOMER COMPLAINT

CORRECT AS NECESSARY
I
• REFER TO ELECTRICAUGARAGE SHIFT TEST IN
THIS SECTION
• REFER TO ROAD TEST PROCEDURE IN THIS
SECTION

HARSH I SOFT SHIFT POOR TCC

CONDITION PERFORMANCE CONDITION

PERFORM TRANSMISSION REFER TO TORQUE REFER TO TCC

LINE PRESSURE CHECK CONVERTER EVALUATION DIAGNOSIS IN THIS
PROCEDURE IN THIS SECTION SECTION
WIRINy CONCERNS:
INSPECT TRANSMISSION
WIRING CONNECTORS

NEXT
REFER TO DIAGNOSIS PAGE
CHARTS FOR
SYMPTOMS AND
POSSIBLE CAUSES

RH0011-4L60-E

Figure 8 Transmission Functional Test (1 of 2)

 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-13

~
4L60-E TRANSMISSION
FUNCTIONAL TEST (2 of 2)

T
DELAYED OR NO VIBRATION FLUID LEAK
ENGAGEMENT INTO OR NOISE
DRIVE OR REVERSE

PERFORM TRANSMISSION REFER TO FLEXPLATE I REFER TO FLUID LEAK

LINE PRESSURE CHECK TORQUE CONVERTER DIAGNOSIS AND
PROCEDURE VIBRATION TEST REPAIR PROCEDURE
PROCEDURE IN THIS
SECTION
OTHER
TRANSMISSION
CONDITIONS

REFER TO DIAGNOSIS
CHARTS FOR
SYMPTOMS AND
POSSIBLE CAUSES
RH0012-4L60-E

Figure 9 Transmission Functional Test (2 of 2)

7A·14A·14 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

DIAGNOSTIC TROUBLE CODES AND DEFAULT ACTIONS

Refer to Section 6E3 to Diagnose Trouble Codes.
TROUBLE CODE CODE PARAMETERS DEFAULT ACTION

14 Engine coolant temp over 151 °C • TCC apply cold.

Engine Coolant Temp
Sensor Circuit (High)
15
Engine Coolant Temp
Sensor Circuit (Low)
21
Throttle Position Sensor Circuit
(High)
22
Throttle Position Sensor Circuit
(Low)
24
Vehicle Speed Sensor Signal Low
(306°F) for 1/2 second.
Engine coolant temp less than -40°C • TCC apply cold .
(-40°F) for 1/2 second.
TP voltage greater than • NoTCC .
4.88 volts for four seconds. • Fixed shift points.
• Harsh shifts .
• Maximum line pressure .
• No fourth gear in hot mode .
· With engine running, TP voltage • NoTCC .
less than .06 volts for four seconds. • Fixed shift points .
(Diesel is less than .16 volts.)
..
• Harsh shifts .
Maximum line pressure .
No fourth gear in hot mode .
In Drive or Reverse with engine speed • Maximum line pressure .
greater than 3000 rpm, output speed • Second gear only.
is less than 250 rpm for three seconds.
(MAP is 100-255 kPa, TP is 10-100%)

28
PCM detects one of two "invalid" • NoTCC .
Fluid Pressure Switch Assembly Fault
combinations of PSM signals for • Harsh shifts .
five seconds. • No fourth gear in hot mode.
• No 2nd gear in 02 .
With brake on, vehicle speed is • NoTCC.
37 5-20 mph for six seconds, then • No fourth gear in hot mode .
Brake Switch Stuck "ON" vehicle speed is >20 mph for six
seconds. After vehicle speed is < 5 mph.
This must happen seven times.
With brake off, vehicle speed is • NoTCC .
38 (I) >20 mph for six seconds, then vehicle • No fourth gear in hot mode.
Brake Switch Stuck "OFF" speed is 5-20 mph for six seconds.
After vehicle speed is < 5 mph.
This must happen seven times.

53
System Voltage High
58
Transmission Fluid
Temp Sensor Circuit (High)
59
Transmission Fluid
Temp Sensor Circuit (Low)
Generator voltage is greater than
19.5 volts for two seconds. .•No TCC.
Maximum line pressure .
• Third gear only.
Transmission fluid temperature is • No default action .
greater than 151 °C (306°F) for
one second.
Transmission fluid temperature is • No default action .
below -40°C (-40°F) for
one second.

(I) Not used on 3.4L F-Cars.

RH0026-4L60-E-C

Figure 10 Trouble Chart Diagnosis Chart A

 4l60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-15

DIAGNOSTIC TROUBLE CODES AND DEFAULT ACTIONS

Refer to Section 6E3 to Diagnose Trouble Codes.

TROUBLE CODE CODE PARAMETERS DEFAULT ACTION

Two successive speed readings have a • Maximum line pressure .

72 difference of more then 1000 RPM.
Vehicle Speed Sensor Loss (Difference must be more than
1500 RPM in P and N.)
73 (]) Pressure control solenoid return amper-
Pressure Control Solenoid Current age varies more than .16 amp from
93 (2) commanded amperage for one second.
• Soft landing second gear only.
• NoTCC.
• Harsh shifts .
• Maximum line pressure.

74 (I) ASR active for five seconds. • Inhibit TCC operation .

• Inhibit 4th gear, if not in Hot
TCS/ ASR Circuit Low mode.
75 (I) System voltage is less than 7 .3 V at • NoTCC.
System Voltage Low low temps and less than 11.7 Vat high • Maximum line pressure.
96 (2) temps for four seconds. • Third gear only.
79 Transmission temp is higher than
Transmission Fluid Overtemp 146°C (302°F) for 30 minutes.
Slip > 100 RPM, TCC Mode = Locked, • Inhibit TCC Operation .
80 Gear = 2, 3, or 4; Gear selector in D3 • Maximum line pressure .
Trans Component Slipping or D4, No code 28; 0 < TPS < 3.5% • Inhibit 4th gear if not in Hot
Transmission temp is between 60-100°C. mode.
This must happen for at least 10 seconds.
2-3 Shift Solenoid is commanded "ON" • NoTCC .
by PCM but circuit voltage is high for • Maximum line pressure .
81 (I) two seconds .
Second or third gear only.
2-3 Shift Solenoid OR
Circuit Fault 2-3 Shift Solenoid is commanded "OFF"
by PCM but circuit voltage is low for
two seconds.
1-2 Shift Solenoid is commanded "ON" • Maximum line pressure .
by PCM but circuit voltage is high for • Second or third gear only
82 (I) two seconds OR
1-2 Shift Solenoid OR • First and fourth gears only.
Circuit Fault 1-2 Shift Solenoid is commanded "OFF"
by PCM but circuit voltage is low for
two seconds.
84 At high duty cycle, the circuit voltage • Third gear only.
3-2.Control Solenoid high -OR- at low duty cycle the circuit • Soft landing to 3rd gear.
Circuit Fault 0) voltage is low for four seconds.
With gear selector in a drive range, • TCC "ON" in all gears .
85 (I) transmission in 2nd, 3rd or 4th, • Early shifts.
TCC Stuck "ON" TP Sensor greater than 25% and TCC
90 (2) unlocked - slip is between -20 and
20RPM.
90 TCC is commanded on, but circuit is • NoTCC .
TCC Solenoid high -OR- TCC is commanded off but • No fourth gear in hot inode.
Circuit Fault (]) circuit voltage is low for two seconds.

(I) Not used on 3.4L F-Cars.

(2) Used on 3.4L F-Cars only. RH0027-4L60-E-C

Figure 11 Trouble Code Diagnosis Chart B

7A-14A-16 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

4L60-E TRANSMISSION FLUID CHECKING PROCEDURE

1. Wann the transmission to operating temperature by driving the vehicle about 15 miles (24 km). Operating temperature is
180-200°F (82-94°C).
2. Park vehicle on a level surface, place shift lever in "P" park and apply the parking brake.
3. Check fluid level on the dipstick (read the lower level).
4. If fluid level is low, DEXRON®-111 Automatic Transmissions Fluid is preferred, if unavailable DEXRON®-IIE is
acceptable, add only enough to bring the fluid level into the hot area.
* It is important to check fluid level when the transmission has reached operating temperature. The hot range is calibrated to
correspond to the correct fluid level range for fluid between 180 and 200°F (82-94°C).

(~~lc_OL~D'~~~~~----~\
~
HOT CHECK RANGE (180-200'F. 82-92'C)

•-------------1 1
CHECK FLUID COLORi--
1
I -----------

RED
INON TRANSPARENT
PINK
I I LT. BROWN I
I
I CHECK FLUID LEVEL :i-.---------- I REPLACE COOLER I NOTICE: TRANSMISSION
FLUID MAY TURN DARK
WITH NORMAL USE
AND DOES NOT ALWAYS
INDICATE CONTAMINATION
I HIGH j~ I LOW I OR OXIDATION

REMOVE ADD FLUID TO FLUID CONTAMINANTS DRAIN FLUID TO

EXCESS OBTAIN PROPER LEVEL IN DETERMINE IF
FLUID LEVEL HIGH FLUID THERE IS CONTAMINATION

-
CHECK FOR EXTERNAL DRAIN FLUID NOTICE: A VERY SMALL
LEAKS (REFER TO TO DETERMINE AMOUNT OF MATERIAL
"FLUID LEAK SOURCE OF IN THE BOTIOM PAN IS
DIAGNOSIS") CONTAMINATION A NORMAL CONDITION
REMOVE
EXCESS
FLUID CHANGE
CORRECT LEAK FLUID AND
CONDITION FILTER
TRANSMISSION
OVERHAUL (OR SRTA)
REQUIRED - LARGE PIECES OF METAL OR
(REFER TO "UNIT OTHER MATERIAL IN THE
REPAIR SECTION") BOTIOM PAN

FLUSH COOLER TRANSMISSION OVERHAUL

(OR SRTA) REQUIRED
(REFER TO "UNIT REPAIR
ADD NEWFLUID SECTION")
I
FLUSH COOLER
CHECK FLUID LEVEL
I

- PERFORM OBD SYSTEM

ADD NEW FLUID

- ---------~-.~ CHECK IF NOT ALREADY

PERFORMED

REFER TO 4L60-E TRANSMIS-

SION FUNCTIONAL TEST
~

~~
I
CHECK FLUID LEVEL

PROCEDURE
RH0008-4L60-E-R1

Figure 12 Fluid Checking Procedure

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-17

HYDRA-MATIC 4L60-E LINE PRESSURE CHECK PROCEDURE

Line pressures are calibrated for two sets of gear ranges - Drive-Park-Neutral and Reverse. This allows the transmission
line pressure to be appropriate for different pressure needs in different gear ranges:

Gear Range Line Pressure Range

Drive, Park or Neutral 55 - 189 PSI
Reverse 64 - 324 PSI

Before performing a line pressure check, verify that the pressure control solenoid is receiving the correct electrical signal
from the PCM:
1. Install a scan tool.
2. Start the engine and set parking brake.
3. Check for a stored pressure control solenoid diagnostic
trouble code, and other diagnostic trouble codes.
4. Repair vehicle if necessary.
Inspect
• Fluid level (see Section 7A)
• Manual linkage

Install or Connect
TECH 1 Scan tool
• Oil pressure gage at line pressure tap
5. Put gear selector in Park .and set the parking brake.
6. Start engine and allow it to warm up at idle.
7. Access the "PCS Control" test on the TECH 1 scan tool.
8. Increase DESIRED PCS in 0.1 Amp increments and read the corresponding line pressure on the pressure gage.
(Allow pressure to stabilize for 5 seconds after each current change.) ·
9. Compare data to the Drive-Park-Neutral line pressure chart below.

*NOTICE Total test running time should not exceed 2 minutes, or transmission damage could occur.

CAUTION Brakes must be applied at all times to prevent unexpected vehicle motion.

If pressure readings differ greatly from the line pressure chart, refer to the Diagnosis Charts contained in this section.
1

The TECH 1 scan tool is only able to control the pressure control solenoid in Park and Neutral with the vehicle stopped.
This protects the clutches from extremely high or low pressures in Drive or Reverse ranges.

Pressure Control Solenoid Current (Amp) Line Pressure (PSI)

0.02 170 - 190
0.10 165 - 185
0.20 160 - 180
0.30 155 - 175
0.40 148 - 168
0.50 140 - 160
0.60 130 - 145
0.70 110- 130
0.80 90 - 115
0.90 65 - 90
0.98 55 - 65
Pressures at 1500 RPM and 66°C (150°F). Line pressure drops as
temperature increases. PH0010-4L60-E-R 1

Figure 13 Line Pressure Check Procedure

7A-14A-18 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
LINE PRESSURE CHECK PROCEDURE
This test can be performed during the hoist or
road test. It is easier to check pressures during the
hoist test because the tubing and pressure gage can
remain outside of the vehicle, and won't be damaged
by road conditions or debris. The technician can
diagnose more quickly on the hoist since the driver
doesn't have to watch the road.
The HYDRA-MATIC 4L60-E uses a vane type
oil pump to produce hydraulic pressure, and a
transmission pressure control solenoid (force motor)
to control that pressure at the pressure regulator valve,
after it leaves the pump. The transmission pressure
control solenoid is controlled by an electrical signal
that ranges from O to 1 amp. One amp corresponds to
minimum line pressure (approx. 50 to 55 PSI not O
PSI) and O amps corresponds to a maximum line
pressure (approx. 265 to 290 PSI) in D. Refer to
Figure 13 to perform line pressure test.
ELECTRICAL/GARAGE SHIFT TEST
This preliminary test should be performed before
a hoist or road test to make sure electronic control
inputs are connected and operating. If the inputs are
not checked before operating the transmission, a
simple electrical condition could be misdiagnosed as
a major transmission condition.
A scan tool provides valuable information and
must be used on the HYDRA-MATIC 4L60-E
transmission for accurate diagnosis. Refer to Figure
15 for an example of Tech 1 information.
1. Move gear selector to "Park" (P) and set the
parking brake.
2. Connect scan tool to DLC terminal.
3. Start engine.
4. Connect power to scan tool.
5. Verify that the following signals are present:
• ENGINE SPEED
• TRANS OUTPUT SPEED
• VEHICLE SPEED
• A/B/CRNG
• PRNDL SELECT
• DESIRED PCS
• ACTUALPCS
• PCS DUTY CYCLE
• BRAKE SWITCH
• 4 WD LOW SWITCH (4WD Only)
• ENG COOLANT TEMP
• TRANS FLUID TEMP
• THROTTLEANGLE
• SYSTEM VOLTS
6. Monitor the BRAKE SWITCH signal while
tapping the brake pedal with your foot.
• The BRAKE SWITCH should be on when
the pedal is depressed, and come off when
the brake pedal is released.
7. Monitor the PRNDL SELECT signal and move
the gear selector through all the ranges.
• Verify that the PRNDL SELECT value
matches the gear range indicated on the
instrument panel or console.
• Gear selections should be immediate and
not harsh.
8. Move gear selector to neutral and monitor the
THROTTLE ANGLE signal while increasing
and decreasing engine RPM with the accelerator
pedal.
• THROTTLE ANGLE should increase with
engine RPM.
Upshift Control and Torque Converter Clutch
(TCC) Apply
The PCM calculates upshift points based
primarily on two inputs: THROTTLE ANGLE and
VEHICLE SPEED. When the PCM says a shift should
occur, an electrical signal is sent to the shift solenoids
which in tum moves the valves to perform the upshift.
The shift speed charts reference THROTTLE
ANGLE instead of "min throttle" or "wot" to make
shift speed measurement more uniform and accurate.
A scan tool should be used to monitor THROTTLE
ANGLE. Some scan tools have been programmed to
record shift point information. Check the instruction
manual to see if this test is available. Refer to Figures
16, 17 and 18 for examples of Tech 1 information.
With gear selector in D4:
1. Look at the shift speed chart contained in this
section and choose a percent throttle angle of
15 or 20. (Figure 24.)
2. Set up the scan tool to monitor THROTTLE
ANGLE and VEHICLE SPEED.
3. Accelerate to the chosen throttle angle and hold
the throttle steady.
4. As the transmission upshifts, note the shift speed
and commanded gear changes for:
• 2nd gear.
• 3rd gear.
• 4th gear.
 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS
IT] Important
• Shift speeds may vary due to slight hydraulic
delays responding to electronic controls. A
change from the original equipment tire size
also affects shift speeds.
Note when TCC applies. This should occur in
third or fourth gear. If the apply is not noticed
by an RPM drop, refer to the "Preliminary
Torque Converter Clutch Diagnosis" information
contained in this section.
The TCC should not apply unless the
transmission has reached a minimum operating
temperature of 18°C TRAN TEMP and engine
coolant temp of 60°C.
5. Repeat steps 1-4 using several different throttle
.. angles.
Part Throttle Detent Downshift
At vehicle speeds of 64 to 88 km/h (40 to 55
mph) in fourth gear, quickly increase throttle angle.
Verify that:
• TCC releases.
• Transmission downshifts to 3rd gear
immediately.
• 1-2 Shift Solenoid turns off.
Full Throttle Detent Downshift
At vehicle speeds of 64 to 88 km/h (40 to 55
~ph) in_ fourth ge~r.' quickly increase throttle angle to
its maximum pos1t10n. Refer to Figures 20, 21 and
22 for examples of Tech 1 information.
Verify that:
• TCC releases.
• Transmission downshifts to 2nd gear
immediately.
• J-2 Shift Solenoid is off, 2-3 Shift Solenoid
1s on.
Manual Downshifts
The shift solenoids do not control the initial
downshift during 4-3 and 3-2 manual downshifts. All
manual downshifts are hydraulic except the 2-1. The
solenoid states will change during, or shortly after a
manual downshift is selected. Refer to Figure 23 for
an example of Tech 1 information.
1. At vehicle speeds of 64 to 88 km/h (40 to 55
mph) in fourth gear, release the accelerator pedal
while moving the gear selector to 03. Observe
that:
7A-14A-19
•TCC releases.
•Transmission downshifts to 3rd gear
immediately.
• Engine slows vehicle down.
2. Move gear selector back to 04 and accelerate
to 64 to 72 km/h (40 to 45 mph). Release the
accelerator while moving the gear selector to
02 and observe that:
• TCC releases.
• Transmission downshifts to 2nd gear
immediately.
• Engine slows vehicle down.
3. Move gear selector back to 04 and accelerate
to 48 km/h (30 mph). Release the accelerator
pedal while moving the gear selector to O 1 and
observe that:
• TCC releases.
• Transmission downshifts to 1st gear
immediately.
• Engine slows vehicle down.
Coasting Downshifts
1. With the gear selector in 04, accelerate to 4th
gear with TCC applied.
2. Release the accelerator pedal and lightly apply
the brakes, and observe that:
• TCC releases.
• Downshifts occur at speeds shown on the
shift speed chart.
Manual Gear Range Selection
Upshifts in the manual gear ranges are controlled
by the shift solenoids. ·
Perform the following tests by accelerating at
10-15 degrees TP Sensor.
Manual Third (03)
• With vehicle stopped, move the gear
selector to 03 and accelerate to observe:
- 1-2 shift.
- 2-3 shift.
Manual Second (D2)
1. With vehicle stopped, move gear selector
to 02 and accelerate to observe:
• Transmission starts and remains in
second gear.
2. Accelerate to 40 km/h (35 mph) and
observe:
• 2-3 shift does not occur.
• TCC does not apply.
7A-14A-20 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
Manual First (Dl)
• With vehicle stopped, move gear selector
to Dl. Accelerate to 32 km/h (20 mph) and
observe:
No upshifts occur.
- TCC does not apply.
- Can upshift out of first at fuel cut-off.
Reverse (R)
• With vehicle stopped, move gear selector
to R and slowly accelerate to observe:
- 1-2 and 2-3 Shift Solenoids are on.
. Use a scan tool to see if any transmission trouble
codes have been set. Refer to "Trouble Code
Diagnosis" in this section and repair the vehicle as
directed. After repairing the vehicle, perform the hoist
test and verify that the code has not set again.
If the transmission is not performing well and
no trouble codes have been set, there may be an
intermittent condition. Check all electrical connections
for damage or a loose fit. Some scan tools have a
snapshot test which can help catch an intermittent
.condition that doesn't occur long enough to set a
code.
You may want to read "Electronic Component
Diagnosis" in this section to become familiar with
transmission conditions caused by transmission
electrical malfunctions.
If no trouble codes have been set and the
condition is suspected to be hydraulic, take the vehicle
on a road test.
ROAD TEST PROCEDURE
• Perform the road test using a scan tool.
• This test should be performed when traffic and
road conditions permit.
• Observe all traffic safety regulations.
1. Start engine.
2. Depress brake pedal.
3. Move gear selector from:
• Park to Reverse.
• Reverse to Neutral.
• Neutral to D4.
rn
•
Important
Gear selections should be immediate and
not harsh.
4. Perform the same test procedure as instructed
previously in the road test:
• Upshifts and TCC apply.
• Part Throttle Detent Downshift.
• Full Throttle Detent Downshift.
• Manual Downshifts.
• Coasting Downshifts.
• Manual Gear Range Selection.
Use a scan tool to see if any transm1ss10n
malfunction codes have been set. If so, perform
transmission functional test. (Figure 8.) After repairing
the vehicle, perform the road test and verify that no
codes have been set again.
If no codes have been set and the condition
remains, refer to the "Diagnosis Charts" contained in
this section. If the .condition is suspected to originate
in. the torque converter, refer to "Torque Converter
Clutch (TCC) Diagnosis" later in this section.
TORQUE CONVERTER CLUTCH (TCC)
DIAGNOSIS
To properly diagnose the Torque Converter
Clutch (TCC) system, perform all electrical testing
first and then the hydraulic testing.
The TCC is applied by fluid pressure which is
controlled by a solenoid located inside the Automatic
Transmission assembly. The solenoid is energized by
completing an electrical circuit through a combination
of switches and sensors. Refer to Figure 19 for an
example of Tech 1 information.
Functional Check Procedure
ll'l'I Inspect
1. Install a tachometer or scan tool.
2. Operate the vehicle until proper operating
temperature is reached.
3. Drive vehicle at 80 to 88 km/h (50 to 55 mph)
with light throttle (road load).
4. Maintaining throttle, lightly touch the brake
pedal and check for release of the TCC and a
slight increase in engine speed (RPM).
5. Release the brake, slowly accelerate and check
for a re-apply of the converter clutch and a
slight decrease in engine speed (RPM).
TORQUE CONVERTER EVALUATION
Torque Converter Stator
The torque converter stator roller clutch can have
one of two different type malfunctions:
A. Stator assembly freewheels in both directions.
B. Stator assembly remains locked up at all times.
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
Condition A-Poor Acceleration Low Speed
The car tends to have poor acceleration from a
standstill. At speeds above 50 to 55 km/h (30 to 35
mph), the car may act normal. If poor acceleration is
noted, it should first be determined that the exhaust
system is not blocked, and the transmission is in first
(1st) gear when starting out.
If the engine freely accelerates to high RPM in
"NEUTRAL" (N), it can be assumed that the engine
and exhaust system are normal. Checking for poor
performance in "Drive" and "Reverse" will help
determine if the stator is freewheeling at all times.
Condition 8-Poor Acceleration High Speed
Engine RPM and car speed limited or restricted
at high speeds. Performance when accelerating from
a standstill is normal. Engine may over-heat. Visual
examination of the converter may reveal a blue color
from over-heating.
If the converter has been removed, the stator
roller clutch can be checked by inserting two fingers
into the splined inner race of the roller clutch and
trying to tum the race in both directions. The inner
race should tum freely clockwise, but not tum or be
very difficult to tum counterclockwise.
Noise
Torque converter whine is usually noticed when
the vehicle is stopped and the transmission is in
"Drive" or "Reverse". The noise will increase when
engine RPM is increased. The noise will stop when
the vehicle is moving or when the torque converter
clutch is applied because both halves of the converter
are turning at the same speed.
Perform a stall test to make sure the noise is
actually coming from the converter:
1. Place foot on brake.
2. Put gear selector in "Drive".
3. Depress accelerator to approximately 1200 RPM
for no more than six seconds.
NOTICE: If the accelerator is depressed for more
than six seconds, damage to the transmission may
occur.
A torque converter noise will increase under
this load.
[I) Important
• This noise should not be confused with
pump whine noise which is usually
noticeable in "Park", "Neutral" and all other
gear ranges. Pump whine will vary with
pressure ranges.
7A-14A-21
The torque converter should be replaced under
any of the following conditions:
• External leaks in the hub weld area.
• Converter hub is scored or damaged.
• Converter pilot is broken, damaged or fits poorly
into crankshaft.
• Steel particles are found after flushing the cooler
and cooler lines.
• Pump is damaged or steel particles are found in
the converter.
• Vehicle has TCC shudder and/or no TCC apply.
Replace only after all hydraulic and electrical
diagnoses have been made. (Converter clutch
material may be glazed.)
• Converter has an imbalance which cannot be
corrected. (Refer to Converter Vibration Test
Procedure.)
• Converter is contaminated with engine coolant
containing antifreeze.
• Internal failure of stator roller clutch.
• Excess end play.
• Heavy clutch debris due to overheating (blue
converter).
• Steel particles or clutch lining material found
in fluid filter or on magnet when no internal
parts in unit are worn or damaged - indicates
that lining material came from converter.
The Torque Converter Should Not Be Replaced If:
• The oil has an odor, is discolored, and there is
no evidence of metal or clutch facing particles.
• The threads in one or more of the converter
bolt holes are damaged.
- Correct with thread insert. (Refer to
SECTION 6A.)
• Transmission failure did not display evidence
of damage or worn internal parts, steel particles
or clutch plate lining material in unit and inside
the fluid filter.
• Vehicle has been exposed to high mileage
(only). The exception may be where the torque
converter clutch damper plate lining has seen
excess wear by vehicles operated in heavy and/
or constant traffic, such as taxi, delivery or
police use.
TCCSHUDDER
The key to diagnosing Torque Converter Clutch
(TCC) shudder is to note when it happens and under
what conditions.
TCC Shudder should only occur during the
APPLY and/or RELEASE of the converter clutch;
SELDOM after the TCC plate is fully applied.
7A.14A·22 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS

While TCC Is Applying Or Releasing:
If the shudder occurs while TCC is applying,
the problem can be within the transmission or torque
converter. Something is not allowing the clutch to
become fully engaged, not allowing clutch to release,
or is trying to release and apply the clutch at the
same time. This could be caused by leaking turbine
shaft seals, a restricted release orifice, a distorted
clutch or housing surface due to long converter bolts,
or defective friction material on the TCC plate.
Shudder Occurs After TCC Has Applied:
In this case, most of the time there is nothing
wrong with the transmission! As mentioned above,
once the TCC has been applied, it is very unlikely
that it will slip. Engine problems may go unnoticed
under light throttle and load, but become noticeable
after TCC apply when going up a hill or accelerating,
due to the mechanical coupling between engine and
transmission.
REMEMBER: Once TCC is applied there is.no
torque converter (fluid coupling) assistance. Engine
or driveline vibrations could be unnoticeable before
TCC engagement.
Inspect the following components to avoid
• Oxygen sensor - May command engine too rich
or too lean for too long.
• Fuel pressure - May be too low.
• Engine mounts - Vibration of mounts can be
multiplied by TCC engagement.
• Axle joints ~ Check for vibration.
• TPS - TCC apply and release depends on TPS
in many engines. If TPS is out of specification,
TCC may remain applied during initial engine
crowd.
• Cylinder balance - Bad piston rings or poorly
sealing valves can cause low power in a
cylinder.
• Fuel contamination - Causes poor engine
performance.
FLEXPLATE/TOROUE CONVERTER VIBRATION
TEST PROCEDURE
• Start engine.
• With engine at idle speed and transmission in
"Park" (P) or "Neutral" (N), observe vibration.
• Key off.
!..-+I Remove or Disconnect

misdiagnosis of TCC Shudder and possibly 1. Flexplate shield attaching bolts.

disassembling a transmission and/or replacing a torque 2. Flexplate to torque converter attaching bolts.
converter unnecessarily: 3. Rotate torque converter 120 degrees (1/3 tum).
• Spark plugs - Inspect for cracks, high resistance

•
or broken insulator.
Plug wires - Look in each end. If there is red
E3 Install or Connect

dust (ozone) or black substance (carbon) present, 1. Flexplate to torque converter attaching bolts.
then the wires are bad. Also look for a white ~ lighten
discoloration of the wire indicating arcing
during hard acceleration. • Bolts to 62 N•m (46 lb. ft.)
• Distributor cap and rotor - Look for broken or 2. Flexplate shield attaching bolts.
uncrimped parts.
• Start engine and check for vibration. Repeat
• Coil - Look for black on bottom indication procedure until .best possible balance is obtained.
arcing while engine is misfiring.
• .Fuel injector - Filter may be plugged.
• Vacuum leak - Engine won't get correct amount
of fuel. May run rich or lean depending on
where the leak is. ·
• EGR valve - Valve may let in too much
unbumable exhaust gas and cause engine to
run lean.
• MAP/MAF sensor - Like vacuum leak, engine
won't get correct amount of fuel for proper
engine operation.
• Carbon on intake valves - Restricts proper flow
or air/fuel mixture into cylinders.
• Flat cam - Valves don't open enough to let
proper fuel/air mixture into cylinders.
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-23

TECH 1 PARAMETER IN PARK AT IDLE

ENGINE SPEED 550-750 RPM
TRANS OUTPUT SPD O RPM (1)
ENG COOL TEMP 85°C - 105°C (5)
TRANS FLUID TEMP 30°C - 130°C (5)
THROT POSITION .4- .6 V
THROTTLE ANGLE 0%
A/B/C RNG OFF ON OFF
TRANS RANGE SW. Park/Neutral
COMMANDED GEAR 1
ADAPTABLE SHIFT NO (3)
1-2 SOL I 2-3 SOL ON ON
CTR FDBK 1/2 2/3 ON ON (4)
3-2 CONTROL SOL 0%
3-2 CONTROL FDBK OFF
HOT MODE NO
TCC SLIP RPM 600-750
TCC SOLENOID OFF
CTR FDBK TCC OFF (4)
DESIRED PCS 1.01
ACTUAL PCS 1.01
PCS DUTY CYCLE 40- 60%
VEHICLE SPEED 0
4WD LOW SWITCH OFF
CRUISE ENGAGED OFF
TCC BRAKE SWITCH Released
KICKDOWN ENABLED NO
1-2 SHIFT TIME .3 - 1.35 Sec. (2)(3)
1-2 SHIFT ERROR 0 - 6.25 Sec. (2)(3)
2-3 SHIFT TIME .3 - 1.35 Sec. (2)(3)
CURR. ADAPT CELL N/A < 25% TP
TRANS CALIB ID Internal ID Only
SYSTEM VOLTS 13.6
PRESS ADAPT 25% TP -5 - 10
PRESS ADPT 40% TP -5 - 10
PRESS ADPT 70% TP -5 - 10
CURR. ADAPT PSI -5 - 10

I. There may be a small speed reading due to vehicle vibration.

2. Zero until a shift occurs.
3. 'Yes' means the shift time is an accurate and valid number. (If shift was adaptable.)
If shift was adaptable, 'No' indicates the shift time is not accurate for one or more of the following reasons:
• Transmission is in 02 or DI
• There is a long shift delay
• There is a long' shift time
• There has been a significant throttle angle change
• Transmission is in hot mode
• A shift starts too soon after the solenoids change states
• Diagnostic codes are set (21, 22, 24, 28, 53, 58, 59, 72, 73, 75, 79, 81 or 82)
• There has been a significant vehicle speed change
• 4WD lo switch is on
4. Should match commanded solenoid state.
5. Normal operating temperature.
RH0065-4L60-E

Figure 14 Typical TECH 1 Data Values

7A-14A-24 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

GARAGE SHIFTS
EXAMPLE ONLY
TECH 1 INFORMATION

PARK DRIVE 4 REVERSE

ENGINE SPEED 639 RPM 538 RPM 524 RPM
TRANS FLUID TEMP 81°C 81°C 81°C
A/ 8/C RNG OFF ON OFF OFF ON ON ON ON OFF
TRANS RANGE SW P-N DRIVE 4 REV
DESIRED PCS 1.07 AMPS 1.07 AMPS .96AMPS
ACTUAL PCS 1.11 AMPS 1.07 AMPS .98AMPS

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

• ENGINE SPEED should drop approximately 50 RPM.

- This verifies that the transmission has engaged.

• When DESIRED PCS= 1.07 AMPS, the transmission is commanded to minimum line pressure.

• ACTUAL PCS AMPS should always be within .16 AMPS of DESIRED PCS.

• PRNDL SWITCH should match the selected gear range.

- IF not, the Transmission Pressure Switch Assembly should be checked.
- A I BI C RNG should be used to identify the failed circuit.
RH0222-4L60-E-C

Figure 15 Example of TECH 1 Information (Garage Shifts)

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-25

1-2 UPSHIFTS
EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application.)
TECH 1 INFORMATION

1STGEAR 2NDGEAR • If COMMANDED GEAR changes from 1 to 2 and

the vehicle does not shift (ENGINE SPEED
ENGINE SPEED 2476 RPM 2146 RPM
should drop approximately 250 RPM)
TRANS OUTPUT SPD 767 RPM 1086 RPM
TRANS FLUID TEMP 83°C 83°C - Refer to Diagnosis Charts (6E3)
THROTILE POSITION 2.16 VOLTS 2.12 VOLTS • 2ND GEAR START must display NO to start
THROTILE ANGLE 41 % 38% in first gear
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 1 2
ADAPTABLE SHIFT NO YES
1-2 SOL 2-3 SOL ON ON OFF ON HARSH 1-2 UPSHIFT
3-2 CONTROL SOL 0% 90% • 1-2 SHIFT TIME and 1-2 SHIFT ERROR are not
TCC SLIP SPEED +257 +408 accurate unless ADAPTABLE SHIFT is YES
1-2 SHIFT TIME 1.30 SEC 0.83 SEC
1-2 SHIFT ERROR 5.95 SEC 0.03 SEC • 1-2 SHIFT TIME is normally between 0.3 SEC
and 1.35 SEC (This value is not accurate unless
CURR ADAPT CELL
ADAPTABLE SHIFT is YES).
CURR ADAPT PSI
2BD GEAR START NO NO - If not, refer to Diagnosis Charts (6E3)
PRESS ADPT 25% TP -1 -1 • 1-2 SHIFT ERROR should be below 1.0 SEC
PRESS ADPT 31%TP -1 -1 (This value is not accurate unless ADAPTABLE
PRESS ADPT 38% TP -1 -1 SHIFT is YES).
PRESS ADPT 44%TP -1 -1
PRESS ADPT 50%TP -1 -1 • If any PRESS ADPT XX%TP cell is - 5
(lowering line pressure to adapt for harsh shifts)
PRESS ADPT 56% TP -1 -1
and if 1-2 SHIFT TIME is below 0.3 SEC, then an
PRESS ADPT 63% TP -1 -1
internal transmission problem is indicated.
PRESS ADPT 69%TP -1 -1 Refer to Diagnosis Charts (6E3)
PRESS ADPT 75% TP -1 -1
PRESS ADPT 81%TP -1 -1
PRESS ADPT 88%TP -1 -1
PRESS ADPT 94%TP -1 -1
PRESS ADPT100%TP -1 -1 SOFT 1-2 UPSHIFT
3-2 CONTROL SOL 0% 90% • 1-2 SHIFT TIME and 1-2 SHIFT ERROR are not
* THERE IS APPROXIMATELY 2 SECONDS OF DATA accurate unless ADAPTABLE SHIFT is YES
MISSING BETWEEN EACH COLUMN
• 1-2 SHIFT TIME is normally between 0.3 SEC and
1.35 SEC (This value is not accurate unless
ADAPTABLE SHIFT is YES).
NO 1-2 UPSHIFT - If not, refer to Diagnosis Charts (6E3)
• TRANS OUTPUT SPD must be greater than
• 1-2 SHIFT ERROR should be below 1.0 SEC
300 RPM to upshift
(This value is not accurate unless ADAPTABLE
- Refer to 1993 HYDRA-MATIC 4L60-E SHIFT is YES).
SHIFT SPEED CHART
• If any PRESS ADPT XX%TP cell is+ 10
• ENGINE SPEED will drop approximately (increasing line pressure to adapt for soft shifts)
250 RPM during a shift and if 1-2 SHIFT TIME is above 1.35 SEC, then
an internal transmission problem is indicated.
• TRANS RANGE SW should match the selected
Refer to Diagnosis Charts (6E3).
gear range

• THROTTLE ANGLE should equal 0% at idle and

100% at wide-open-throttle
RH0223-4L60-E-C

Figure 16 Example of TECH 1 Information (1-2 Upshifts)

7A-14A-26 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

2-3 UPSHIFTS
EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application.)
TECH 1 INFORMATION

2NDGEAR 3RDGEAR
ENGINE SPEED 3039 RPM 2770 RPM
TRANS OUTPUT SPD 1760 RPM 1970 RPM
TRANS FLUID TEMP 86°C 86°C
THROTTLE POSITION 2.82 VOLTS 2.84 VOLTS
THROTTLE ANGLE 61 % 61 %
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 2 3
1-2 SOL 2-3 SOL OFF ON OFF OFF
3-2 CONTROL SOL 90% 90%
2-3 SHIFT TIME 1.60 SEC 0.85 SEC
2ND GEAR START NO NO

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

NO 2-3 UPSHIFT

• TRANS OUTPUT SPD must be greater than 750 RPM to upshift

- Refer to 1993 HYDRA-MATIC 4L60-E SHIFT SPEED CHART

• ENGINE SPEED will drop approximately 250 RPM during a shift

• PRNDL SWITCH should match the selected gear range

• THROTTLE ANGLE should equal 0% at idle and 100% at wide-open-throttle

• If COMMANDED GEAR changes from 2 to 3 and the vehicle does not shift
(ENGINE SPEED should drop approximately 250 RPM)
- Refer to Diagnosis Charts (6E3)

HARSH OR SOFT 2-3 UPSHIFT

• 2-3 SHIFT TIME is normally between 0.3 SEC and 1.35 SEC however the Tech 1 will display the
last shift time. If the conditions of the last shift are unknown (lift foot upshift, manual upshift),
it is recommended to repeat the upshift in the following manner.
- To achieve an accurate shift time
- Accelerate the vehicle from rest holding the throttle steady.
- If not, refer to Diagnosis Charts (6E3)

RH0225-4L60-E-C

Figure 17 Example of TECH 1 Information (2-3 Upshifts)

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-27

3-4 UPSHIFTS
EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application;)
TECH 1 INFORMATION

3RDGEAR 4THGEAR
ENGINE SPEED 1757 RPM 1617 RPM
TRANS OUTPUT SPD 1456 RPM 1534 RPM
TRANS FLUID TEMP 42°C 42°C
THROTILE ANGLE 20% 21 %
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 3 4
1-2 SOL 2-3 SOL OFF OFF ON OFF

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

NO 3-4 UPSHIFT

• TRANS OUTPUT SPD must be greater than 1250 RPM to upshift

- Refer to 1993 HYDRA-MATIC 4L60-E SHIFT SPEED CHART

• ENGINE SPEED will drop approximately 100 RPM during a shift

• PRNDL SWITCH should match the selected gear range

- In Drive 2 the transmission will not upshift to 3rd or 4th gears
- In Drive 3 the transmission will not upshift to 4th gear but TCC will normally apply

• THROTILE ANGLE should equal 0% at idle and 100% at wide-open-throttle

• If COMMANDED GEAR changes from 3 to 4 and the vehicle does not shift
(ENGINE SPEED should drop approximately 100 RPM)
- Refer to Diagnosis Charts (6E3).

RH0226-4L60-E-C

Figure 18 Example of TECH 1 Information (3-4 Upshifts)

7A-14A-28 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

TCCSYSTEM
EXAMPLE ONLY
TECH 1 INFORMATION

RELEASED APPLIED RELEASED

ENGINE SPEED 1867 RPM 1353 RPM 1769
TRANS OUTPUT SPD 1909 RPM 1950 RPM 1883
TRANS FLUID TEMP 64°C 64°C 64°C
THROTTLE ANGLE 27% 27% 38%
TRANS RANGE SW DRIVE 4 DRIVE 4 DRIVE 4
COMMANDED GEAR 4 4 4
1-2 SOL 2-3 SOL ON OFF ON OFF ON OFF
HOT MODE NO NO NO
COMMANDED TCC OFF ON OFF
TCC SLIP SPD +531 RPM -1 RPM +447 RPM
TCC BRAKE SWITCH RELEASED RELEASED RELEASED

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

TCC DOES NOT APPLY

• COMMANDED TCC will display ON only if
- PRNDL SWITCH displays DRIVE 4 or DRIVE 3
- TRANS OUTPUT SPD must be greater than approximately 1800 RPM
- TCC BRAKE SWITCH displays APPLIED
- THROTTLE ANGLE must be at least approximately 2%
- THROTTLE ANGLE must remain steady
- TRANS FLUID TEMP must be above
- ENG COOL TEMP must be above
- TCC SLIP SPD is less than -60 RPM
- If the cruise control is on, then TCC uses a shift pattern that requires a higher vehicle speed.

• TCC SLIP SPD should be +/-30 RPM if TCC is applied

TCC DOES NOT RELEASE

• The Torque Converter Clutch is fed by 2nd gear fluid.
- The earliest TCC can apply is 2nd gear

• If HOT MODE displays YES, the TCC is engaged in 4th gear or Drive 3, 3rd gear, except
for the following conditions:
- TCC BRAKE SWITCH displays APPLIED
- THROTTLE ANGLE must be at least approximately 2%
- A DTC is current

RH0228-4L60-E-C

Figure 19 Example of TECH 1 Information (TCC System)

 4L60-E AUTOMATIC TRANSMISSIO.N DIAGNOSIS 7A-14A-29

3-2 DETENT DOWNSHIFTS

EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application.)
TECH 1 INFORMATION

3RDGEAR 2ND GEAR

ENGINE SPEED 1414 RPM 2430 RPM
TRANS OUTPUT SPD 1059 RPM 1315 RPM
TRANS FLUID TEMP 75°C 75°C
THROTTLE ANGLE 10% 100 %
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 3 2
1-2 SOL 2-3 SOL OFF OFF OFF ON
3-2 CONTROL SOL 90% 47%

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

NO 3-2 DOWNSHIFT

• If COMMANDED GEAR changes from 3 to 2 and the vehicle does not shift
(ENGINE SPEED should dramatically increase)

HARSH OR SOFT 3-2 DOWNSHIFTS

• If 3-2 CONTROL SOL drops from 90% to a lower value during the shift, and the shift is harsh or soft

RH0229-4L60-E-C

Figure 20 Example of TECH 1 Information (3-2 Detent Downshifts)

7A-14A-30 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

4-2 DETENT DOWNSHIFTS

EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application.)
TECH 1 INFORMATION

4TH GEAR 2NDGEAR

ENGINE SPEED 919 RPM 2788 RPM
TRANS OUTPUT SPD 1390 RPM 1555 RPM
TRANS FLUID TEMP 79°C 79°C
THROTTLE ANGLE 0% 100%
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 4 2
1-2 SOL 2-3 SOL ON OFF OFF ON
3-2 CONTROL SOL 90% 59%

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

NO 4-2 DOWNSHIFT

• If COMMANDED GEAR changes from 3 to 2 and the vehicle does not shift
(ENGINE SPEED should dramatically increase)

HARSH OR SOFT 4-2 DOWNSHIFTS

• If 3-2 CONTROL SOL drops from 90% to a lower value during the shift, and the shift is harsh or soft

RH0230-4L60-E-C

Figure 21 Example of TECH 1 Information (4-2 Detent Downshifts)

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-31

4-3 DETENT DOWNSHIFTS

EXAMPLE ONLY (Refer to 1994 Hydra-matic 4L60-E Shift Speed Chart for Vehicle Application.)
TECH 1 INFORMATION

4TH GEAR 3RDGEAR

ENGINE SPEED 1434 RPM 2240 RPM
TRANS OUTPUT SPD 1434 RPM 1688 RPM
TRANS FLUID TEMP 80°C 80°C
THROTTLE ANGLE 19 % 54%
TRANS RANGE SW DRIVE 4 DRIVE 4
COMMANDED GEAR 4 3
1-2 SOL 2-3 SOL ON OFF OFF OFF
3-2 CONTROL SOL 90% 90%

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISSING BETWEEN EACH COLUMN

NO 4-3 DOWNSHIFT
• If COMMANDED GEAR changes from 3 to 2 and the vehicle does not shift
(ENGINE SPEED should dramatically increase)

RH0231-4L60-E-C

Figure 22 Example of TECH 1 Information (4-3 Downshifts)

7A-14A-32 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

MANUAL DOWNSHIFTS
EXAMPLE ONLY
TECH 1 INFORMATION

DRIVE 4 DRIVE 3 DRIVE2 DRIVE 1

ENGINE SPEED 1205 RPM 1543 RPM 2172 RPM 2087 RPM
TRANS OUTPUT SPD 1714 RPM 1638 RPM 1412 RPM 899 RPM
THROTTLE ANGLE 0% 0% 0% 0%
TRANS RANGE SW DRIVE 4 DRIVE 3 DRIVE 2 DRIVE 1
COMMANDED GEAR 4 3 2

* THERE IS APPROXIMATELY 2 SECONDS OF DATA MISStNG BETWEEN EACH COLUMN

• ENGINE SPEED should increase as lower gears are selected

• PRNDL SWITCH should match the selected gear range

- In Drive 2 the transmission starts in 2nd gear

RH0232-4L60-E-C

Figure 23 Example of TECH 1 Information (Manual Downshifts)

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-33

1994 HVDRA-MATIC 4L60-E SHIFT SPEED CHART

1-2 SHIFT+/- 250 RPM 2-3 SHIFT +/- 200 RPM 3-4 SHIFT+/- 150 RPM
AXLE
TPS TPS TPS
2-1 +/- 1-2 2-3
ENGINE BODY
RATIO 100 RPM WOT WOT
10 25 50 10 25 50 10 25 50
3.4L F 3.23 472 837 1072 815 1523 1994 1373 2016 N/A 1286 1501 2874
(L32l
4.3L 8 2.93 376 581 924 650 992 1642 992 1300 N/A 1027 1505 2395
(L99l
4.3L 8 2.73 376 615 1026 650 1026 1711 958 1403 N/A 1027 1711 2395
(L99)

1-2 SHIFT +/- 250 RPM 2-3 SHIFT +/- 200 RPM 3-4 SHIFT+/- 150 RPM
AXLE
TPS TPS TPS
2-1 +/- 1-2 2-3
ENGINE BODY
RATIO 100 RPM WOT WOT
10 25 50 10 25 50 10 25 50
5.7L 8 3.08 457 724 1182 724 1220 2212 1106 1716 N/A 1258 1716 3051
(LT1)
5.7L 8/0 2.93 317 570 951 570 951 1680 887 1268 N/A 982 1331 2250
(LT1)
5.7L 8/0 2.56 348 602 1046 602 1077 1902 919 1458 N/A 951 1648 2536
(LT1)

F
Normal 2.73 434 543 1375 760 1303 2570 977 1448 N/A 1339 1737 3366
5.7L Mode

(LT1)
F
Pertormance
Mode
2.73 434 651 1194 760 1267 2280 977 1737 N/A 1339 1520 3004
(Pontiac Only)

F
Normal 3.23 481 788 1182 832 1576 2190 1401 1883 N/A 1620 1664 3197
5.7L Mode

(LT1)
F
Pertormance
Mode
3.23 481 788 1357 876 1357 2934 1401 1883 N/A 1620 1576 3197
(Pontiac Only)

5.7L y 2.59 386 737 1193 751 1333 2211 1053 1860 N/A 1404 1755 3439
(LT1)
5.7L y 3.07 456 830 1286 871 1618 2407 1203 2241 N/A 1618 1743 3237
(LT1)

1. ALL SPEEDS ARE GIVEN IN TRANSMISSION OUTPUT SHAFT RPM

2. SPEEDS ARE BASED ON PERCENT THROTILE POSITION SENSOR (TPS) DATA
3. USE A TECH 1 OR OTHER SCAN TOOL TO MONITOR THIS DATA
4. ALL SHIFT SPEEDS ARE APPROXIMATE

RH0009-4L60-E-C

Figure 24 1994 4L60-E Shift Speed Chart

7A-14A-34 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

NOTE: This procedure cannot be used 4L60-E TRANSMISSION

on the pressure switch assembly.
See figure 28. INTERNAL WIRING HARNESS CHECK

G)
INSTALL J 39775 AT THE TRANSMISSION PASS-THRU
CONNECTOR AND MEASURE RESISTANCE BETWEEN TERMINALS
"X" AND "X" WITH J 39200. (SEE FIGURE 27)
DOES RESISTANCE MATCH CHART?

I
I I
I YES I I NO I
Cg)
I I
@ DISCONNECT THE HARNESS AT THE
WITH J 39200 MEASURE THE
RESISTANCE BETWEEN EACH COMPONENT AND MEASURE THE
TERMINAL AND GROUND RESISTANCE WITH J 39200.
I DOES THE RESISTANCE MATCH THE CHART?
I I
I I
I
OPEN CIRCUIT OR LOW
HIGH RESISTANCE RESISTANCE
I YES I I NO I
I I I
PROBLEM IS ® INSPECT THE TRANS REPLACE
INTERMITTENT INTERNAL WIRING COMPONENT
REFER TO 7A14C HARNESS FOR AN OPEN
OR SHORT CIRCUIT

@ DISCONNECT THE TRANS HARNESS AT THE

COMPONENT. WITH J 39200 MEASURE THE
RESISTANCE BETWEEN THE COMPONENT'S
TERMINALS AND GROUND
I

I OPEN CIRCUIT OR
HIGH RESISTANCE
I
LOW
RESISTANCE

® INSPECT THE TRANS

INTERNAL WIRING HARNESS
REPLACE
COMPONENT
I
I
FOR A SHORT TO GROUND

·.. G) This test measures the resistance of the component at ® Check the internal wiring harness for continuity,
the transmission pass-thru connector. pinched wires and corrosion.
@ This test checks for a short to ground in the internal @ This test checks for a short to ground in the component
wiring harness or component. (cannot be used on TCC solenoid).
@ This test measures the resistance of the component.
PH0217-4L60-E-C

Figure 25 Internal Wiring Harness Check

 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-35

RANGE A RANGE B RANGE C

3·2 1·2
CONTROL TCC SHIFT
SOLENOID SOLENOID SOLENOID

PRESSURE
SWITCH
'--"""-"'"'-----....1 ASSEMBLY

INTERNAL TRANSMISSION WIRING HARNESS

N.C. = NORMALLYCLOSED SWITCH
N.O. = NORMALLY OPEN SWITCH
B c D

69
M
s
R
394 367a
367b
T N p

377 CAVITY FUNCTION

66
A 1-2 SHIFT SOLENOID (LOW)

B 2-3 SHIFT SOLENOID (LOW)

c PRESSURE CONTROL SOLENOID (HIGH)

D PRESSURE CONTROL SOLENOID (LOW)

E BOTH SHIFT SOLENOIDS, TCC SOLENOID,

66 SOLENOID ASSEMBLY, WIRING HARNESS AND AND 3-2 CONTROL SOLENOID (HIGH)
69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE
367a 1·2 SHIFT SOLENOID L TRANSMISSION FLUID TEMPERATURE
367b 2-3 SHIFT SOLENOID (HIGH)
377 PRESSURE CONTROL SOLENOID
394 3-2 CONTROL SOLENOID M TRANSMISSION FLUID TEMPERATURE
(LOW)

N RANGE SIGNAL "A"

p RANGE SIGNAL "C"

R RANGE SIGNAL "B"

s 3-2 CONTROL SOLENOID (LOW)

T TCC SOLENOID (LOW)

RH0028·4L60-E

Figure 26 Wiring Diagram

7A-14A-36 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

4L60-E COMPONENT RESISTANCE CHART

WIRE PASS-THRU RESISTANCE

COMPONENT CKT#
COLOR PIN @20°C

RED E * 11498
1-2 SHIFT SOLENOID 20 - 40 Ohms
GRN LT A 1222

RED E * 1149A
2-3 SHIFT SOLENOID 20 - 40 Ohms
YEL B 1223

RED E * 1149C
3-2 CONTROL SOLENOID 9-140hms
WHT s 897

PRESSURE CONTROL SOLENOID

PPL c 3.5-8 Ohms
1228

BLU LT D 1229

RED E * 1149E
TCC SOLENOID 20 - 40 Ohms
BLACK T 422A

* Spliced internally to Pin E.

PH0218-4L60-E

Figure 27 Component Resistance Chart

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-37

4L60-E TRANSMISSION
PRESSURE SWITCH ASSEMBLY
RESISTANCE CHECK

INSTALL J 39775 AT THE TRANSMISSION PASS-THRU CONNECTOR. WITH

ENGINE RUNNING, MEASURE RESISTANCE BETWEEN EACH TERMINAL
(N, RAND P) AND GROUND WITH J 39200. (SEE CHART BELOW). MOVE THE
GEAR SELECTOR THROUGH THE DIFFERENT GEAR RANGES.

I
I I
NO YES I
I I
I I PROBLEM IS INTERMITTENT.
REFER TO 7A14C
RESISTANCE MEASURES LOW RESISTANCE MEASURES HIGH
WHEN CHART INDICATES HIGH WHEN CHART INDICATES LOW

I I
DISCONNECT THE WIRING DISCONNECT THE WIRING
HARNESS FROM THE PRESSURE HARNESS FROM THE PRESSURE
SWITCH ASSEMBLY. MEASURE SWITCH ASSEMBLY. MEASURE
THE RESISTANCE OF THE THE RESISTANCE FROM:
TRANSMISSION WIRING WIRING HARNESS
HARNESS FROM PASS-THRU PASS-TH RU PSA CONNECTOR
TERMINALS N, RAND PTO TERMINAL TERMINAL
GROUND.
N to c
I R
p
to E
to D
I I
LOW HIGH I
RESISTANCE RESISTANCE I I
I I
REPLACE
INTERNAL
REPLACE
PRESSURE
LOW
RESISTANCE

I
I HIGH
RESISTANCE

I
I
TRANSMISSION SWITCH REPLACE REPLACE
WIRING ASSEMBLY PRESSURE INTERNAL
HARNESS SWITCH TRANSMISSION
ASSEMBLY WIRING
HARNESS

Pressure Switch Assembly (PSA) Resistance Chart

Range IMPORTANT:
Gear Selector Position A B c Whenever the transmission pass-thru connector is
PARK H L H disconnected from the vehicle harness and the
REVERSE L L H engine is running, multiple transmission Diagnostic
Trouble Codes will set. Be sure to clear these codes
NEUTRAL H L H
when finished with this procedure.
D4 H L L
D3 H H L
D2 H H H
D1 L H H
When range "X" is measured for resistance to ground,
H = High resistance (over 100 Ohms) - open circuit
L = Low resistance (under 200 Ohms) - grounded circuit
RH0219-4L60-E

Figure 28 Pressure Switch Assembly Resistance Check

7A-14A-38 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

HYDRA-MATIC 4L60-E ELECTRONIC COMPONENT MALFUNCTIONS

This chart gives some general information about electronic component malfunctions. Use this information to
become familiar with possible conditions caused by transmission/vehicle electrical components. Refer to the
diagnosis charts for more specific information.

COMPONENT/SYSTEM CAN EFFECT

Throttle Position Sensor - Shift pattern (erratic).

- Shift quality (firm or soft).
- Engine (rough).

Output Speed Sensor - Shift pattern (erratic).

- TCC apply (at wrong time).
- Shift quality (harsh or soft).

Pressure Switch Assembly - TCC apply (no apply).

- Shift pattern (no fourth gear in hot mode).
- Shift quality (harsh).
- Line pressure (high).
- Manual downshift (erratic).
- No 4th gear if in hot mode.

Transmission Fluid Temperature Sensor - TCC control (on or off).

- Shift quality (harsh or soft).

Engine Coolant Temperature Sensor - TCC control (no apply).

- Shift quality (harsh).

Shift Solenoids - Gear application (wrong gear, only two gears, no shift).

Brake Switch - TCC apply (no apply).

- No 4th gear if in hot mode.

System Voltage - Line pressure (high).

- Gear application (third gear only).
- TCC control (no apply).
- No 4th gear if in hot mode.

3-2 Control Solenoid - Gear application (third gear only).

- 3-2 downshifts (flare or tie-up).

Pressure Control Solenoid - Line pressure (high or low).

- Shift quality (harsh or soft).

TCC Solenoid - TCC apply (no apply).

- No 4th gear if in hot mode.

4WD Low Switch - Incorrect shift pattern.

RH0007-4L60-E

Figure 29 Component Malfunctions

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-39

HVDRA-MATIC 4L60-E ELECTRONIC COMPONENT MALFUNCTIONS

(continued)

COMPONENT/SYSTEM CAN EFFECT

Cruise Control - Delays 3-4 upshift and TCC apply during heavy throttle

Acceleration Slip Regulation (ASR) - Downshift

(Y-car only)

2nd Gear Start Switch (Second) - 2nd Gear starts

(V6 Pontiac F-car only)

Manual Switch - Shift pattern

(V8 Pontiac F-car only)

Performance Switch - Shift quality

(V8 Pontiac F-car only) - Shift pattern

RH0221-4L60-E

Figure 30 Component Malfunctions

7A-14A-40 4L60-E AUTOMATIC TRANSMISSION· DIAGNOSIS

CONDITION INSPECT .COMPONENT FOR CAUSE

OIL PRESSURE HIGH OR
LOW
(Verify With Gage - Refer To Line
Pressure Check Procedure)
• Oil Pump Assembly (4)
• Oil Filter (72)
• Valve Body (60)
• Pressure Control Solenoid (377)
• System Voltage
• Pressure Switch Assembly (69)
• Case (8)
• Possible Codes:
- 24 Vehicle Speed Sensor
Signal Low
- 52 Long System Voltage High
- 53 System Voltage High
- 72 Vehicle Speed Sensor Loss
- 73 Pressure Control
Solenoid Current
- 75 System Voltage Low
- 81 2-3 Shift Solenoid
Circuit Fault
- 82 1-2 Shift Solenoid
Circuit Fault
- Pressure regulator valve (216) stuck.
- Pressure regulator valve spring (217).
- Rotor guide (211) omitted or misassembled.
- Rotor (212) cracked or broken.
- Reverse boost valve (219) or sleeve (220)
stuck, damaged or incorrectly assembled.
- Orifice hole in pressure regulator valve
(217) plugged.
- Sticking slide (203) or excessive rotor
clearance.
- Pressure relief ball (228) not seated or
damaged. ·
- Porosity in pump cover or body,
- Wrong pump cover.
- Pump faces not flat.
- Excessive rotor clearance.
- Intake pipe restricted by casting flash.
- Cracks in filter body or intake pipe.
- 0-ring seal (71) missing, cut or damaged.
- Wrong grease used on rebuild.
- Manual valve (340) scored or damaged.
- Spacer plate (48) or gaskets (47 and 52)
incorrect, misassembled or damaged.
- Face not flat.
- 2-3 Shift valve (369) stuck.
- Checkballs omitted or misassembled.
- Damage to pins or seal.
- Contamination.
- Damaged seals.
- Case to valve body face not flat.

HARSH SHIFfS • Possible Codes:

- 21 Throttle Position Sensor
Circuit (High)
- 22 Throttle Position Sensor
Circuit (Low)
- 28 Fluid Pressure Switch
Assembly Fault
- 73 Pressure Control
Solenoid Current
ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC 4L60-E UNIT REPAIR SECTION
PH0013-4L60-E

Figure 31 Diagnosis Chart A

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
CONDITION INSPECT COMPONENT
HARSH SHIFTS • Throttle Position Sensor
(Continued) • Vehicle Speed Sensor (36)
• Pressure Switch Assembly (69)
• Trans Fluid Temperature
Sensor (69)
• Engine Coolant Temperature
Sensor
• Pressure Control Solenoid (377)
INACCURATE SHIFT POINTS • Oil Pump Assembly (4)
• Valve Body Assembly (60)
• Case (8)
• Throttle Position Sensor
• Vehicle Speed Sensor (36)
• 4WD Low Switch
IST GEAR STARTS WHILE IN • Second Gear Start Switch
SECOND GEAR START MODE
(PONTIAC F-CAR ONLY)
EARLY SHIFTS • Possible Codes:
- 69 TCC Stuck "ON"
FIXED SHIFT POINTS • Possible Codes:
- 21 Throttle Position Sensor
Circuit (High)
- 22 Throttle Position Sensor
Circuit (Low)
IST GEAR RANGE ONLY • Valve Body (60)
-NOUPSHIFT
• Case (8)
• Shift Solenoids (379)
ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION
Figure 32 Diagnosis Chart B
7A-14A-41
FOR CAUSE
- Open or shorted circuit.
- Open or shorted circuit.
- Contamination.
- Damaged seals.
- Open or shorted circuit.
- Open or shorted circuit.
- Damage to pins or seal.
- Contamination.
- Stuck pressure regulator valve (216).
- Sticking pump slide (203).
- Spacer plate (48) or gaskets (47 and 52)
misassembled, damaged or incorrect.
- Porous or damaged valve body pad.
- 2-4 Servo Assembly (12-29)
a. 2-4 accumulator porosity.
b. Damaged servo piston seals.
c. Apply pin damaged or improper length.
- 2-4 Band Assembly (602).
a. Burned.
b. Anchor pin not engaged.
- Disconnected.
- Damage.
- Disconnected.
- Damaged.
- Bolt not tightened.
- Disconnected.
- Damaged.
- Open or shorted circuit.
(Refer to Second Gear Start Switch Circuit
check. Section 6E3-C8.)
- 1-2 Shift valve (366) sticking.
- Spacer plate (48) or gaskets (47 and 52)
mispositioned or damaged.
- Case to valve body face not flat or
damaged.
- Stuck or damaged.
- Electrical connection.
RH0014-4L60-E-C
7A-14A·42 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
CONDITION INSPECT COMPONENT
lST GEAR RANGE ONLY • 2-4 Servo Assembly (12-29)
- NO UPSHIFfS
(Continued)
• 2-4 Band Assembly (602)
SLIPS IN lST GEAR • Forward Clutch Assembly
• Forward Clutch Accumulator
• Input Housing and Shaft
Assembly (621)
• Valve Body (60)
• Low Roller Clutch (678)
• Torque Converter (1)
• 1-2 Accumulator Assembly
(54-59)
• Line Pressure
• 2-4 Servo Assembly (12-29)
ALL ILLUSTRATION NUMBERS REFERENCE HVDRA·MATIC 4L60·E UNIT REPAIR SECTION
Figure 33 Diagnosis Chart C
FOR CAUSE
- Restricted or blocked apply
passages case.
- Nicks or burrs on servo pin ( 13) or
pin bore in case
- 4th Servo piston (25) in backwards.
- 2-4 Band (602) worn or damaged.
- Band anchor pin not engaged.
- Clutch plates (649) worn.
- Porosity or damage in forward
clutch piston (630).
- Forward clutch piston inner and
outer seals (629) missing, cut or
damaged.
- Input housing to forward clutch
housing 0-ring seal (622) missing,
cut or damaged.
- Damaged forward clutch housing (628).
- Forward clutch housing retainer and
ball assembly (627) not sealing
or damaged.
- Piston seal (353) missing, cut or
damaged.
- Piston (354) out of its bore.
- Porosity in the piston or valve
body (350).
- Stuck abuse valve (357).
- Turbine shaft seals (619) missing,
cut or damaged.
- 1-2 Accumulator valve (371) stuck.
- Face not flat, damaged lands or
interconnected passages.
- Spacer plate (48) or gaskets (47 and 52)
incorrect, mispositioned or damaged.
- Damage to lugs or inner ramps.
- Rollers not free moving.
- Inadequate spring tension.
- Damage to inner splines.
- Lube passage plugged.
- Stator roller clutch not holding.
- Porosity in piston (56) or 1-2 Accumulator
cover and pin assembly (57).
- Damaged ring grooves on piston.
- Piston seal (55) missing, cut or damaged.
- Valve body to spacer plate gasket (52) at
1-2 Accumulator cover, missing or
damaged.
- Leak between piston and pin.
- Broken 1-2 Accumulator spring (54).
- (See Causes of High or Low Oil Pressure.)
- 4th Servo piston (25) in backwards.
RH0015-4L60-l:-C
 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-43

CONDITION INSPECT COMPONENT FOR CAUSE

SLIPPING OR ROUGH 1-2 • Valve Body Assembly (60)
SHIFf
• 2-4 Servo Assembly (12-29)
• 2nd Accumulator (54-59)
• 2-4 Band (602)
• Oil Pump Assembly (4) or
Case (8)
- 1-2 Shift valve train (365-366) stuck.
- Gaskets (47 and 52) or spacer plate (48)
incorrect, mispositioned or damaged.
- l-2 Accumulator valve (371) stuck.
- Face not flat.
- Apply pin (13) too long or too short.
- 2nd servo apply piston seal missing, cut or
damaged.
- Restricted or missing oil passages.
- Servo bore in case damaged.
- Porosity in 1-2 accumulator housing (57)
or piston (56).
- Piston seal or groove damaged.
- Nicks or burrs in 1-2 accumulator housing.
- Missing or restricted oil passage.
- Worn or mispositioned.
- Faces not flat.

NO 2-3 SHIFT OR 2-3 • Converter (I) - Internal damage.

SHIFf SLIPPING, ROUGH
OR HUNTING • Oil Pump (4) - Stator shaft (214) sleeve scored or off
location.
• Valve Body (60) - 2-3 Valve train (268-269) stuck.
- Accumulator valve (371) stuck.
- Spacer plate (48) or gaskets (47 and 52)
incorrect, mispositioned or damaged.
• Input Housing Assembly (621) - Clutch plates worn [3-4 (654)
or forward (649)].
- Excessive clutch plate travel.
- Cut or damaged piston seals
[3-4 (624) or forward (629)].
- Porosity in input clutch housing (621) or
piston (623).
- 3-4 Piston checkball (620) stuck, damaged
or not sealing.
- Restricted apply passages.
- Forward clutch piston retainer and ball
assembly (627) not seating.
- Sealing balls loose or missing.
• Case (8) - 3rd Accumulator retainer and ball assembly
not seating.
• 2-4 Servo Assembly (12-29) - 2nd Apply piston seals (18 and 19) missing,
cut or damaged.
• Possible Codes:
- 24 Vehicle Speed Sensor
Signal Low
- 72 Vehicle Speed Sensor Loss

ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION

PH0016-4L60-E

Figure 34 Diagnosis Chart D

7A-14A-44 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
CONDITION INSPECT COMPONENT
2ND AND 3RD GEARS ONLY • Possible Codes:
OR - 82 1-2 Shift Solenoid
lST AND 4TH GEARS ONLY Circuit Fault
• Shift Solenoids (379)
THIRD GEAR ONLY • Possible Codes:
- 53 System Voltage High
- 75 System Voltage Low
- 81 2-3 Shift Solenoid
Circuit Fault
- 84 3-2 Control Solenoid
Circuit Fault
• System Voltage
• 3-2 Control Solenoid (394)
3-2 FLARE OR TIE-UP • 3-2 Control Solenoid (394)
NO 3-4 SHIFT/SLIPPING • Oil Pump Assembly (4)
OR ROUGH 3-4 SHIFT
• Valve Body Assembly (60)
• 2-4 Servo Assembly (12-29)
• Case (8)
• Input Housing Assembly (621)
• 2-4 Band Assembly (602)
ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION
Figure 35 Diagnosis Chart E
FOR CAUSE
- Sediment.
- Electrical Connection.
- Damaged seal.
- Shorted or damaged.
- Contamination.
- Damaged seal.
Faces not flat.
- Pump cover retainer and ball assembly
omitted or damaged.
- Valves stuck.
• 2-3 Shift valve (368-369) train.
• Accumulator valve (371).
• 1-2 Shift valve train (365-366).
• 3-2 Control valve (391).
- Spacer plate (48) or gaskets (47 and 52)
incorrect, mispositioned or damaged.
- Incorrect band apply pin (13).
- Missing or damaged servo seals
(26 and 27).
- Porosity in pistons, cover or case.
- Damaged piston seal grooves.
- Plugged or missing orifice cup plug (11 ).
- 3rd Accumulator retainer and ball assembly
leaking.
- Porosity in 3-4 accumulator piston (44)
or bore.
- 3-4 Accumulator piston seal (45) or seal
grooves damaged.
- Plugged or missing orifice cup plug.
- Restricted oil passage.
- Refer to Slipping 2-3 Shift.
- Worn or misassembled.
RH0017-4L60-E-C
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
CONDITION INSPECT COMPONENT
NO 3-4 SHIFT/SLIPPING • Possible Codes:
OR ROUGH 3-4 SHIFT - 21 Throttle Position Sensor
(Continued) Circuit (High)
- 22 Throttle Position Sensor
Circuit (Low)
- 28 Fluid Pressure Switch
Assembly Fault
- 37 Brake Switch Stuck "ON"
- 38 Brake Switch Stuck "OFF"
- 90 TCC Solenoid Circuit Fault
[fil
NO REVERSE OR SLIPS IN • Input Housing Assembly (621)
REVERSE
• Manual Valve Link (705)
• Oil Pump Assembly (4)
• Valve Body Assembly (60)
• Reverse Input Clutch
Assembly (605)
• Lo And Reverse Clutch
ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION
Figure 36 Diagnosis Chart F
7A-14A-45
FOR CAUSE
- 3-4 Apply ring (625) stuck in applied
position.
- Forward clutch not releasing.
- Turbine shaft seals (619) missing, cut or
damaged.
- Disconnected.
- Retainer and ball assembly missing or
damaged.
- Stator shaft seal rings (230) or ring grooves
damaged.
- Stator shaft sleeve scored or damaged.
- Reverse boost valve (219) stuck, damaged
or misassembled.
- Cup plug missing.
- Restricted oil passage.
- Faces not flat.
- Converter clutch valve (224) stuck.
- 2-3 Shift valve (369) stuck.
- Manual linkage (705) not adjusted.
- Spacer plate (48) and gaskets (47 and 52)
incorrect, mispositioned or damaged.
- Lo overrun valve (361) stuck.
- Orificed cup plug restricted, missing or
damaged.
- Clutch plate (612) worn.
- Reverse input housing and drum assembly
(605) cracked at weld.
- Clutch plate retaining ring out of groove.
- Return spring assembly retaining ring (610)
out of groove.
- Seals (608) cut or damaged.
- Restricted apply passage.
- Porosity in piston (607).
- Belleville plate (611) installed incorrectly.
- Excessive clutch plate travel.
- Oversized housing.
- Clutch plates (682) worn.
- Porosity in piston (695).
- Seals (696) damaged.
- Return spring assembly retaining ring
(693) mispositioned.
- Restricted apply passage.
RH0018-4L60-E-C
7A-14A-46 4L&O~E AUTOMATIC TRANSMISSION DIAGNOSIS

CONDITION INSPECT COMPONENT FOR CAUSE

NO PART THROTTLE OR • 2-4 Servo Assembly (12-29) - Servo cover retaining ring (29) omitted
DELAYED DOWNSHIFIS or misassembled.
- 4th Apply piston (25) damaged or
misassembled.
- Servo inner housing (20) damaged or
misassembled.
• Valve Body Assembly (60) - 3-2 Downshift valve (389) stuck.
- 4-3 Sequence valve body channel blocked.

HARSH GARAGE SHIFT • Valve Body Assembly (60) - Orifice cup plug missing.
- Checkball missing.

NO OVERRUN BRAKING • External Linkage - Not adjusted properly.

- MANUAL 3-2-1
• Valve Body Assembly (60)
• Input Clutch Assembly (621)
- 4-3 Sequence valve (382) stuck.
- Checkball mispositioned.
- Spacer plate (48) and gaskets (47 and 52)
incorrect, damaged or mispositoned.
- Turbine shaft oil passages plugged or not
drilled.
- Turbine shaft seal rings (619) damaged.
- Turbine shaft sealing balls loose or
missing.
- Porosity in forward (630) or overrun clutch
piston (632).
- Overrun piston seals (631) cut or damaged.
- Overrun piston checkball (633) not sealing.

NO TORQUE CONVERTER • Electrical - 12 Volts not supplied to transmission.

CLUTCH APPLY - Outside electrical connector damaged.
- Inside electrical connector, wiring harness
or solenoid damaged.
- Electrical short (pinched solenoid wire).
- Solenoid not grounded.
• TCC Solenoid
• Engine Speed Sensor
• Converter (1) - Internal damage.
• Engine Coolant Temperature
Sensor
• Oil Pump Assembly (4) - Converter clutch valve (224) stuck or
assembled backwards.
- Converter clutch valve retaining ring (222)
mispositioned.
- Pump to case gasket (6) mispositioned.
- Orifice cup plug restricted or damaged.
- Solenoid 0-ring seal (67) cut or damaged.
- High or uneven bolt torque (pump body to
cover).

ALL ILLUSTRATION NUMBERS REFERENCE HYDRA,;MATIC 4L60-E UNIT REPAIR SECTION

PH0019-4L60-E

Figure 37 Diagnosis Chart G

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-47

CONDITION INSPECT COMPONENT FOR CAUSE

NO TORQUE CONVERTER • Trans Fluid Temperature

CLUTCH APPLY Sensor (69)
(Continued)
• Input Housing and Shaft (621) - Turbine shaft 0-ring seal (618) cut or
damaged.
- Turbine shaft retainer and ball assembly
(617) restricted or damaged.
• Brake Switch
• Pressure Switch Assembly (69) - Contamination.
- Damaged seals.

• Valve Body Assembly (60) - TCC signal valve (380) stuck.

- Solenoid 0-ring leaking.
• Solenoid Screen - Blocked.
• Possible Codes:
- 21 Throttle Position Sensor
Circuit (High)
- 22 Throttle Position Sensor
Circuit (Low)
- 28 Fluid Pressure Switch
Assembly Fault
- 37 Brake Switch Stuck "ON"
- 38 Brake Switch Stuck "OFF"
- 52 Long System Voltage High
- 53 System Voltage High
- 67 TCC Solenoid Circuit Fault
- 75 System Voltage Low
- 81 2-3 Shift Solenoid
Circuit Fault

TORQUE CONVERTER • Torque Converter Assembly (1) - Internal damage.

CLUTCH SHUDDER
• Oil Pump Assembly (4) - Converter clutch valve (224) stuck.
- Restricted oil passage.
• Oil Filter (72) - Crack in filter body.
- Flash restricting filter neck.
- 0-ring seal (71) cut or damaged.
• Miscellaneous - Low oil pressure.
- Engine not tuned properly.
• Input Housing and Shaft Assembly - Turbine shaft 0-ring (618) cut or
(621) damaged.
- Turbine shaft retainer and ball assembly
(617) restricted or damaged.

rec APPLY WITH A • Possible Codes:

COLD ENGINE - 14 Engine Coolant Temp Sensor
Circuit (High)
- 15 Engine Coolant Temp Sensor
Circuit (Low)

ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION

PH0020-4L60-E

Figure 38 Diagnosis Chart H

7A-14A-48 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

CONDITION INSPECT COMPONENT FOR CAUSE

NO TORQUE CONVERTER • TCC Solenoid - External ground.

CLUTCH RELEASE - Clogged exhaust orifice.
• Converter (1) - Internal damage.
• Valve Body Assembly (60) - Converter clutch apply valve stuck in apply
position.

• Oil Pump Assembly (4) - Converter clutch valve (224) stuck.

• PCM - External ground.

TCC ON IN ALL GEARS • Possible Codes:

- 85 TCC Stuck "On"

DRIVES IN NEUTRAL • Forward Clutch - Not releasing.

• Manual Valve Link (705) - Disconnected.
• Case (8) - Face not flat.
- Internal leakage.

2ND GEAR START • Forward Clutch Sprag Assembly - Sprag assembly installed backwards.
(DRIVE RANGE) (642)

NO PARK • Parking Linkage (63, 79-90) - Actuator rod assembly (85) bent or
damaged.
- Actuator rod spring binding or improperly
crimped.
- Actuator rod not attached to inside detent
lever (788).
- Parking lock bracket (86) damaged or not
torqued properly.
- Inside detent lever (88) not torqued
properly.
- Detent roller and spring assembly (63)
mispositioned or not torqued properly.
- Parking pawl (81) binding or damaged.

RATCHETING NOISE • Parking Pawl (81) - Parking pawl return spring (80) weak,
damaged or misassembled.

OIL OUT THE VENT • Oil Pump (4) - Chamfer in pump body rotor pocket too
large.
• Miscellaneous - Fluid level - overfilled.

ALL ILLUSTRATION NUMBERS REFERENCE HVDRA-MATIC 4L60-E UNIT REPAIR SECTION

RH0021-4L60-E-C

Figure 39 Diagnosis Chart I

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-49

CONDITION INSPECT COMPONENT FOR CAUSE

VIBRATION IN REVERSE AND • Oil Pump (4) - Broken vane rings (210).
WHINING NOISE IN PARK

NO DRIVE IN ALL RANGES • Torque Converter ( 1) - Converter to flex plate bolts missing.

NO DRIVE IN DRIVE RANGE • Torque Converter (1) - Stator roller clutch not holding.
- Converter not bolted to flex plate.

FRONT OIL LEAK • Torque Converter (1) - Welded seam leaking.

- Damaged converter hub.
• Torque Converter Seal (243) - Damaged seal assembly.
- Missing garter spring.

DELAY IN DRIVE AND • Torque Converter (1) - Converter drainback.

REVERSE

ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC 4L60-E UNIT REPAIR SECTION

PH0022-4L60-E

Figure 40 Diagnosis Chart J

7A-14A-50 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
FLUID LEAK DIAGNOSIS AND REPAIR
The cause of most external leaks can generally
be located and repaired with the transmission in the
vehicle.
METHODS FOR LOCATING LEAKS
General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 15 miles or until
normal operating temperatures are reached.
4. Park the vehicle over clean paper or cardboard.
5. Shut the engine off and look for fluid spots on
the paper.
6. Make necessary repairs.
Powder Method
1. Thoroughly clean the suspected leak area with
solvent.
2. Apply an aerosol type powder (foot powder) to
the suspected leak area.
3. Operate the vehicle for about 15 miles or until
normal operating temperatures are reached.
4. Shut the engine off.
5. Inspect the suspected leak area and trace the
leak path through the powder to find the source.
6. Make necessary repairs.
Dye and Black Light Method
1. Follow the manufacturer's recommendation for
the amount of dye to be used.
2. Find the leak with a black light.
3. Make necessary repairs.
REPAIRING THE LEAK
Once the leak has been pinpointed and traced
back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to repair a
leak, check to be sure that the following conditions
are correct as they may cause a leak.
Gaskets
• Fluid level or pressure is too high.
• Plugged vent or drain-back holes.
• Improperly torqued fasteners or dirtyI damaged
threads.
• Warped flanges or sealing surface.
• Scratches, burrs, or other damage to the sealing
surface.
• Damaged or worn gasket.
• Cracking or porosity of the component.
• Improper sealant used (where applicable).
• Porosity.
Seals
• Fluid level or pressure is too high.
• Plugged vent or drain-back holes.
• Dam;:tged seal bore ( scratched, burred or
nicked).
• Damaged or worn seal.
• Improper installation.
• Cracks in component.
• Manual or output shaft surface scratched,
nicked, or missing.
• Loose or worn bearing causing excess seal wear.
POSSIBLE POINTS OF OIL LEAKS
1. Transmission and transmission oil pan:
• Attaching bolts not torqued correctly.
• Improperly installed or damaged gasket.
• Oil pan or mounting face not flat.
2. Case Leak:
• Filler tube multi-lip seal damaged or
missing.
• Filler tube bracket misaligned.
• Speed sensor seal damaged.
• Manual shaft seal damaged.
• Oil cooler connector fittings loose or
damaged.
• Propeller shaft oil seal worn or damaged.
• Line pressure pipe plug loose.
• Porous casting.
3. Leak at converter end:
• Converter seal damaged.
- Seal lip cut (check converter hub for
damage).
- Bushing moved forward and damaged.
- Garter spring missing from seal.
• Converter leak in weld area.
• Porous casting (case or pump).
4. Fluid comes out vent pipe or fill tube:
• Overfilled.
• Water or coolant in fluid (fluid will appear
milky).
• Case porous.
• Incorrect fluid level indicator.
• Plugged vent.
• Drain back holes plugged.
• The alignment of the oil pump to case
gasket (if equipped).
CASE POROSITY REPAIR
1. Clean the leak area with solvent and air dry.
CAUTION: Epoxy adhesive may cause skin
irritations and eye damage. Read and
follow all information on the container
label as provided by the manufacturer.
2. Mix a sufficient amount of epoxy adhesive
(GM PIN 1052533 or equivalent) following the
manufacturer's recommendations.
3. While the transmission case is hot, apply epoxy
adhesive with a clean, dry soldering acid brush.
4. Allow the epoxy adhesive to cure for three hours
before starting the engine.
5. Repeat fluid leak diagnosis procedures.
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-51

A BOTTOM PAN GASKET F OIL PUMP SEAL ASSEMBLY K MANUAL SHAFT SEAL
B CASE G OIL PUMP TO CASE SEAL L SPEED SENSOR SEAL
C COOLER CONNECTORS H CONVERTER M EXTENSION TO CASE SEAL
D SERVO COVER SEAL I VENT N EXTENSION OIL SEAL ASSEMBLY
E OIL FILL TUBE SEAL J ELECTRICAL CONNECTOR SEAL O LINE PRESSURE PLUG

PH0029-4L60-E

Figure 41 leak Inspection Points

7A-14A-52 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

PARK ~ INTAKE & DECREASE

l!:!I CONVERTER & LUBE
(Engine Running) MAINLINE
CJ SOLENOID SIG.
CJ ACCUMULATOR
CJ AC TUATOR FEED
CJ TORQUE SIGNAL

-'
..,.
c::, .... '--'
2
:::,
0.. -' :::,
;;:; '--' a:
'f a:
w
~ M
>
a: 0

2ND & 4TH

SERVO

Figure 42 Park - Engine Running

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
PARK - (Engine Running)
With the gear selector lever in the Park (P) position and the engine running, line pressure from the oil pump assembly is directed
to various components in the valve body and oil pump.
PRESSURE REGULATION
Pressure Regulator Valve: Regulates oil pump output (line
pressure) in response to torque signal fluid pressure, spring
force and line pressure acting on the end of the valve. Line
pressure is routed through the valve and into both the con-
verter feed and decrease fluid circuits. Regulated line pressure
is also directed to the manual valve, converter clutch signal
valve and actuator feed limit valve.
Pressure Relief Valve: Controlled by spring force, this check-
ball limits the maximum value of line pressure. When line
pressure reaches this limiting value, fluid is exhausted past
the ball and returns to the sump.
Line Pressure Tap: Provides a location to measure line
pressure with a fluid pressure gage.
Actuator Feed Limit (AFL) Valve: Biased by spring force
and orificed AFL fluid, it limits the maximum value of line
pressure entering the AFL fluid circuit. Below this limiting
value, AFL fluid pressure equals line pressure. AFL fluid is
routed to the pressure control solenoid, 3-2 control solenoid,
1-2 and 2-3 shift solenoids, and the 2-3 shift valve train.
Pressure Control Solenoid: Controlled by the Powertrain
Control Module (PCM), it regulates filtered AFL fluid into
torque signal fluid pressure. This regulation is controlled by
varying the current value to the solenoid in relation to throttle
position and other vehicle operating conditions.
TORQUE CONVERTER CLUTCH (TCC)
Torque Converter Clutch Signal Valve: The valve may be
in a position to allow line pressure to enter the converter
clutch (CC) signal fluid circuit. If this occurs with the 2nd
clutch fluid circuit empty, CC signal fluid pressure orificed to
the end of the CC signal valve will close the valve and block
line pressure. Any fluid in the CC signal fluid circuit will
exhaust through the normally open and closed TCC solenoid.
Converter Clutch Apply Valve: Held in the release position
by spring force, it directs converter feed fluid into the release
fluid circuit. Also, fluid returning from the converter in the
apply fluid circuit is routed through the valve and into the
cooler fluid circuit.
Torque Converter: Release fluid pressure unseats the TCC
apply checkball (#9), keeps the pressure plate released from
the converter cover and fills the converter with fluid. Fluid
exits the converter between the converter hub and stator shaft
in the apply fluid circuit.
Cooler and Lubrication System: Cooler fluid from the con-
verter clutch apply valve is routed through the transmission
fluid cooler and into the lubrication fluid circuits.
Figure 43 Park - Engine Running (Legend)
7A-14A-53
Manual Valve: Controlled by the selector lever and manual
shaft, the manual valve is in the Park (P) position and directs
line pressure into the PR (Park/Reverse) fluid circuit. Line
pressure is blocked from entering any other fluid circuit at the
manual valve.
LO AND REVERSE CLUTCH APPLIES
Lo and Reverse Clutch Piston: PR fluid seats the lo/reverse
clutch checkball (#10) and is orificed to the outer area of the
piston. Orificing PR fluid around the #10 checkball helps
control the lo and reverse clutch apply. Also, lo/reverse fluid
pressure from the lo overrun valve acts on the inner area of
the lo and reverse clutch piston to increase the clutch holding
capacity.
Lo Overrun Valve: PR fluid pressure moves the valve against
spring force and fills the lo/reverse fluid circuit. Lo/reverse
fluid is orificed (#23) back to the lo/overrun valve to assist
PR fluid in moving the valve against spring force. Spring
force provides a time delay for PR fluid filling the lo/reverse
fluid circuit. Lo/reverse fluid is routed to the inner area of the
lo and reverse clutch piston to increase the holding capacity
of the clutch.
Pressure Switch Assembly (PSA): The PSA consists of five
fluid pressure switches: D2 and D3 are normally closed and
D4, Lo and Rev are normally open. All fluid circuits routed to
the assembly are empty and the PSA signals the PCM that the
transmission is in either Park or Neutral.
Shift Solenoids (1-2 and 2-3): Both shift solenoids, which
are normally open, are energized by the PCM and block fluid
from exhausting. This maintains AFL fluid pressure at sole-
noid "B" and signal "A" fluid pressure at the 1-2 solenoid.
Shift Valves (1-2, 2-3 and 3-4): Signal "A" fluid pressure
holds the 1-2 shift valve in the downshifted position and the
3-4 shift valve in the upshifted (First and Fol\rth gear) posi-
tion. AFL fluid pressure from 2-3 shift solenoid holds the 2-3
shift valve train in the downshifted position.
SUMMARY
SHIFT SOLENOID 2-4 REVERSE OVERRUN FORWARD FORWARD 3-4 LO/ROLLER LO/REV.
,.2 I 2·3
BAND INPUT
CLUTCH
CLUTCH CLUTCH SPRAG CL. CLUTCH
ASSEMBLY
CLUTCH CLUTCH
ON' I ON' APPLIED
' SHIFT SOLENOID STATE IS A FUNCTION OF VEHICLE SPEED AND MAY CHANGE IF VEHICLE SPEED
INCREASES SUFFICIENTLY IN PARK, REVERSE OR NEUTRAL. HOWEVER, THIS DOES NOT AFFECT
TRANSMISSION OPERATION.
RH0031-4L60-E
7A-14A-54 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

lul INTAKE & DECREASE

REVERSE lul CONVERTER & LUBE
MAINLINE
CJ SOLENOID SIG.
CJ ACCUMULATOR
CJ ACTUATOR FEED
CJ TORQUE SIGNAL

#10

~
0
0
u

_,
.,,. I-
u
c ::, _, z
::,
0.. u
;;; .,,. Cl:
Cl:
a; «> w
>
Cl: 0

Figure 44 Reverse
 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
REVERSE
When the gear selector lever is moved to the Reverse (R) position (from the Park position), the following changes occur to the
transmissions hydraulic and electrical systems:
Manual Valve: The manual valve moves to the Reverse
position and line pressure enters the reverse fluid circuit. As
in Park, line pressure also fills the PR (Park/Reverse) fluid
circuit. All other fluid circuits are blocked by the manual
valve.
Lo and Reverse Clutch: As in Park, PR fluid pressure acts
on the outer area of the lo and reverse clutch piston to apply
the lo and reverse clutch. Also, lo/reverse fluid from the lo
overrun valve acts on the inner area of the piston to increase
the holding capacity of the clutch (see Note Below).
REVERSE INPUT CLUTCH APPLIES
Reverse Input Checkball (#3): Reverse fluid pressure seats
the #3 checkball, flows through orifice #17 and fills the
reverse input fluid circuit. This orifice helps control the re-
verse input clutch apply rate when engine speed is at idle.
Reverse Abuse Valve: Reverse fluid pressure acts on the end
of the valve opposite of spring force. At engine speeds above
idle, reverse fluid pressure, which is fed by line pressure,
increases and moves the valve against spring force (as shown).
Reverse fluid can then fill the reverse input fluid circuit
through the reverse abuse valve. This bypasses the control of
orifice #17 and provides a faster clutch apply.
Boost Valve: Reverse input fluid pressure moves the boost
valve against the pressure regulator valve spring. The spring
acts on the pressure regulator valve to increase the operating
range of line pressure in Reverse. Reverse input fluid also
flows through the valve and to the reverse input clutch piston.
Remember that torque signal fluid pressure continually acts
on the boost valve to control line pressure in response to
vehicle operating conditions.
Reverse Input Clutch Piston: Reverse input fluid pressure
moves the piston to apply the reverse input clutch plates and
obtain Reverse.
Reverse Input Air Bleed Check ball: This ball and capsule
is located in the reverse input fluid circuit in the oil pump to
provide an air escape when the fluid pressure increases. It
also allows air into the circuit to displace the fluid when the
clutch releases.
Figure 45 Reverse (Legend)
7A-14A-55
Pressure Switch Assembly (PSA): Reverse input fluid pres-
sure closes the normally open reverse switch in the PSA.
This signals the PCM that the manual valve is in the Reverse
(R) position.
Shift Solenoids (1-2 and 2-3): Both solenoids are energized
as in Park range. Signal "A" and actuator feed limit (AFL)
fluids are blocked from exhausting through the shift sole-
noids to maintain fluid pressure in these circuits at the end of
the shift valves.
Shift Valves (1-2, 2-3 and 3-4): Signal "A" fluid pressure
holds the 1-2 shift valve in the downshifted position and the
3-4 shift valve in the upshifted (First and Fourth gear) posi-
tion. AFL fluid pressure from shift the 2-3 solenoid holds the
2-3 shift valve train in the downshifted position.
Pressure Control Solenoid: It continues to regulate AFL
fluid into torque signal fluid pressure. The PCM varies the
current at the solenoid to regulate torque signal fluid pressure
in response to throttle position and other PCM input signals.
Torque signal fluid pressure is used to control line pressure at
the boost and pressure regulator valves.
Note: The explanation in each gear range is, for the most
part, limited to what changes from the range on the previous
page. However, some component descriptions are repeated
for clarity and continuity. Also, refer to the appropriate Gen-
eral Motors Service Manual for specific fluid pressure
information.
SUMMARY
SHFI' SOl!NOID 2,4 REVERSE OVERRUN FORWARD FORWARD u LO/ROWR LO/REV.
NUT CLUTCH ClUTCH Sl'RAG CL CLUTCH ClUTCH
1-2 I 2,3
IIMD
ClUTCH ASSEMBLY
CLUTCH
ON' I ON' APPLIED APPLIED
c
* SHIFT SOLENOID STATE IS A FUNCTION OF VEHICLE SPEED AND MAY CHANGE IF VEHICLE SPEED
INCREASES SUFFICIENTLY IN PARK, REVERSE OR NEUTRAL. HOWEVER, THIS DOES NOT AFFECT
TRANSMISSION OPERATION.
RH0033-4L60-E
7A-14A-56 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

EAi INTAKE & DECREASE

NEUTRAL l!:!l CONVERTER & LUBE
(Engine Running) CJ MAINLINE
CJ SOLENOID SIG.
CJ ACCUMULATOR
CJ ACTUATOR FEED
CJ TORQUE SIGNAL

~-,n- - - ~ ~:::,
..J
a:
~
a:
@

..J
..,. .... u
2
0 :::, ..J :::,
0.. u a:
~ '1'
a; ffi
a: "' >
0

2ND & 4TH

SERVO

Figure 46 Neutral - Engine Running

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-57

NEUTRAL - (Engine Running)

When the gear selector lever is moved to the Neutral position (N), from the Reverse position, the following changes occur to the
transmissions hydraulic and electrical systems:

Manual Valve: In the Neutral position, the manual valve
blocks line pressure from entering any other fluid circuits.
Reverse and PR fluids exhaust past the manual valve.
LO and REVERSE CLUTCH RELEASES
Lo and Reverse Clutch Piston: PR and lo/reverse fluids
exhaust from the piston, thereby releasing the lo and reverse
clutch plates. Exhausting PR fluid unseats the lo/reverse check-
ball (#10) for a quick exhaust.
Lo Overrun Valve: Spring force closes the valve when PR
fluid pressure exhausts. Lo/reverse fluid exhausts through the
valve, into the lo/1st fluid circuit, past the 1-2 shift valve, into
the lo fluid circuit and through an exhaust port at the manual
valve.
REVERSE INPUT CLUTCH RELEASES
Reverse Input Clutch Piston: Reverse input fluid pressure
exhausts from the piston, through the boost valve, past the #3
checkball and to the manual valve. With reverse input fluid
exhausted, the reverse input clutch plates are released and the
transmission is in Neutral.
Reverse Input Checkball (#3): Exhausting reverse input
fluid unseats the ball for a quick exhaust through the reverse
fluid circuit and past the manual valve.
Pressure Switch Assembly (PSA): Reverse input fluid ex-
hausts from the PSA. With no other fluid routed to it, the
PSA signals the PCM that the transmission is operating in
either Park or Neutral.
Note: In Park, Reverse, and Neutral the shift solenoids are
shown energized. This is the normal operating state when the
vehicle is stationary or at low vehicle speeds. However, the
PCM will change the shift solenoid states depending on
vehicle speed. For example, if Neutral is selected when the
transmission is operating in Second Gear, the shift solenoids
will remain in a Second Gear state. However, with the manual
valve blocking line pressure, the shift solenoid states do not
affect transmission operation in Park, Reverse and Neutral.
SUMMARY
SHIFT SOLENOID REVERSE FORWARD
2-4 OVERRUN FORWARD 3-4 LO/ROLLER LO/REV.

Reverse Abuse Valve: Reverse fluid pressure exhausts and

1-Z I Z-3
BAND INPUT
CLUTCH
CLUTCH CLUTCH SPRAG CL. CLUTCH
ASSEMBLY
CLUTCH CLUTCH

spring force closes the valve.

ON' I ON'

' SHIFT SOLENOID STATE IS A FUNCTION OF VEHICLE SPEED AND MAY CHANGE IF VEHICLE SPEED
Boost Valve: Reverse input fluid pressure exhausts and line INCREASES SUFFICIENTLY IN PARK, REVERSE OR NEUTRAL. HOWEVER, THIS DOES NOT AFFECT
TRANSMISSION OPERATION.
pressure returns to the normal operating range as in the Park
and Overdrive positions.

RH0035-4L60-E

Figure 47 Neutral - Engine Running (Legend)

7A-14A-58 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

~ INTAKE & DECREASE

OVERDRIVE RANGE !!!I CONVERTER & LUBE
FIRST GEAR l!!!!!I MAINUNE

.....
u
..... 2
u
..,. a: ::,
..,.c
"' ffi>
0

2ND & 4TH

SERVO

Figure 48 Overdrive Range - First Gear

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
OVERDRIVE RANGE - FIRST GEAR
When the gear selector lever is moved to the Overdrive (@) position, from the Neutral position, the following changes occur to
the transmissions hydraulic and electrical systems:
Manual Valve: Line pressure flows through the manual valve
and fills the 04 fluid circuit. All other fluid circuits remain
empty with the manual valve in the Overdrive position.
FORWARD CLUTCH APPLIES
Forward Clutch Accumulator Checkball (#12): D4 fluid
pressure seats the ball and is orificed (#22) into the forward
clutch feed fluid circuit. This orifice helps control the for-
. ward clutch apply rate.
Forward Clutch Piston: Forward dutch feed fluid pressure
moves the piston to apply the forward clutch plates and
obtain First gear.
Forward Clutch Accumulator Piston: Forward clutch feed
fluid pressure moves the piston against spring force. This
action absorbs some of the initial increase of forward clutch
feed fluid pressure to cushion the forward clutch apply.
Forward Clutch Abuse Valve: 04 fluid pressure acts on the
valve opposite of spring ·force. At engine speeds greater than
idle, 04 fluid pressure increases and moves the valve against
spring force (as shown). 04 fluid can then quickly fill the·
forward clutch feed fluid circuit, thereby bypassing the con-
trol of orifice #22 and providing a faster apply of the forward
clutch. Otherwise; with increased throttle opening and engine
torque, the clutch may slip during apply.
Pressure Switch Assembly (PSA): D4 fluid pressure is routed
to the PSA and closes the normally open 04 fluid pressure
switch. This signals the PCM that the transmission is operat-
ing in Overdrive range.
1-2 Shift Solenoid: Energized (ON) as in Neutral, the nor-
mally open solenoid is closed and blocks signal "A" fluid
from exhausting through the solenoid. This maintains pres-
sure inJhe signal "A" fluid circuit.
2-3 Shift Solenoid: Energized (ON) as in Neutral, the nor-
mally open solenoid is closed and blocks actuator feed limit
(AFL) fluid from exhausting through the solenoid. This main-
tains AFL fluid pressure at the solenoid end of the 2-3 shift
valve.
Figure 49 Overdrive Range - First Gear (Legend)
7A-14A-59
2-3 Shift Valve Train: AFL fluid pressure at the solenoid
end of the 2-3 shift valve holds the valve train in the down-
shifted position against AFL fluid pressure acting on the 2-3
shuttle valve. In this position, the 2-3 shift valve blocks AFL
fluid from entering the 0432 fluid circuit. The 0432 fluid
circuit is open to an exhaust port past the valve.
1-2 Shift Valve: Signal "A" fluid pressure holds the valve in
the downshifted position against spring force. In the First
gear position the valve blocks 04 fluid from entering the 2nd
fluid circuit.
Accumulator Valve: Biased by torque signal fluid pressure,
spring force and orificed accumulator fluid pressure at the
end of the valve, the accumulator valve regulates 04 fluid
into accumulator fluid pressure. Accumulator fluid is routed
to both the 1-2 and 3-4 accumulator assemblies in prepara-
tion for the 1-2 and 3-4 upshifts respectively.
Rear Lube: 04 fluid is routed through an orifice cup plug
(#24) in the rear of the transmission case to feed the rear lube
fluid circuit.
Pressure Control Solenoid: Remember that the pressure
control solenoid continually varies torque signal fluid pres-
sure in relation to throttle position and vehicle operating
conditions. This provides a precise control of line pressure.
3.2 Control Solenoid: The PCM keeps the solenoid OFF in
First gear and the normally closed solenoid blocks AFL fluid
from entering the 3-2 signal fluid circuit.
SUMMARY
SHIFT SOI.ENOID 2-4 REVERSE OVBUIUN FORWARD FORWARD 3-4 LO/ROUER LO/REV.
INPUT CLUTCH CLUTCH SPRAG CL. CLUTCH CLUTCH
,-2 I 2-3 BAND
CLUTCH ASSEMBLY
CLUTCH
ON I ON APPLIED HOLDING HOLDING
RH0037-4L60-E
7A-14A-60 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

O INTAKE & DECREASE

OVERDRIVE RANGE lul CONVERTER & LUBE
SECOND GEAR GJ MAINLINE
CJ SOLENOID SIG.
CJ ACCUMULATOR
CJ ACTUATOR FEED
CJ TORQUE SIGNAL

__,
<..>
__, z
..,.
'-' ::,
a:
d, ffi 0
>
0

<..>
0
z
"'

2ND & 4TH

SERVO

Figure 50 Overdrive Range - Second Gear

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
OVERDRIVE RANGE - SECOND GEAR
As vehicle speed increases, and other operating conditions are appropriate, the PCM de-energizes the 1-2 shift solenoid to shift
the transmission into Second gear.
1-2 Shift Solenoid: De-energized (turned OFF) by the PCM,
the normally open solenoid opens and signal "A" fluid ex-
hausts through the solenoid.
Note: Actuator feed limit (AFL) fluid continues to feed the
signal "A" fluid circuit through orifice #25. However, the
exhaust port through the solenoid is larger than orifice #25 to
prevent a pressure buildup in the signal "A " fluid circuit.
Exhausting signal "A" fluid is represented by the blue ar-
rows.
2-3 Shift Solenoid: Energized (ON) as in First gear, it blocks
AFL fluid from exhausting through the solenoid. This main-
tains AFL fluid pressure at the solenoid end of the 2-3 shift
valve.
2-4 BAND APPLIES
1-2 Shift Valve: Without signal "A" fluid pressure, spring
force moves the valve into the upshifted position. D4 fluid is
routed through the valve and fills the 2nd fluid circuit.
1-2 Shift Checkball (#8): 2nd fluid pressure seats the #8
checkball, flows through orifice # 16 and fills the 2nd clutch
fluid circuit. This orifice helps control the 2-4 band apply
rate.
2-4 Servo Assembly: 2nd clutch fluid pressure moves the
2nd apply piston against servo cushion and servo return spring
forces. The apply piston moves the band apply pin to apply
the 2-4 band. These spring forces help control the 2-4 band
apply rate.
1-2 Accumulator: 2nd clutch fluid pressure also moves the
1-2 accumulator piston against spring force and accumulator
fluid pressure. This action absorbs initial 2nd clutch fluid
pressure to cushion the 2-4 band apply rate. Also, the move-
ment of the 1-2 accumulator piston forces some accumulator
fluid out of the accumulator assembly. This accumulator fluid
is routed back to the accumulator valve.
Accumulator Valve: Accumulatorfluidforcedoutofthe 1-2
accumulator is orificed (#30) to the end of the accumulator
valve. This pressure moves the valve against spring force and
torque signal fluid pressure to regulate the exhaust of excess
accumulator fluid. This regulation provides additional con-
trol for the 2-4 band apply rate. The oil circuit shows the
exhaust of accumulator fluid during the shift by the arrow
directions in the accumulator fluid circuit.
2-3 Shift Valve Train: AFLfluid pressure from the 2-3 shift
solenoid holds the valve train in the downshifted position.
2nd fluid is routed through the 2-3 shuttle valve and fills the
servo feed fluid circuit.
Figure 51 Overdrive Range - Second Gear (Legend)
7A-14A-61
3-4 Relay Valve and 4-3 Sequence Valve: Spring force
holds these valves in the downshifted position (First, Second
and Third gear position). 2nd fluid is blocked by the 3-4 relay
valve and servo feed fluid is blocked by both valves in
preparation for a 3-4 upshift.
3-2 Downshift Valve: Spring force holds the valve closed,
blocking 2nd fluid and 2nd clutch fluid. This valve is used to
help control the 3-2 downshift.
3-2 Control Solenoid: In Second gear, the PCM operates the
normally closed solenoid at approximately a 90% duty cycle.
This opens the AFL fluid circuit to fill the 3-2 signal fluid
circuit (at 100% duty cycle the AFL fluid circuit is com-
pletely open).
3-2 Control Valve: 3-2 signal fluid pressure moves the valve
against spring force. This action does not affect the transmis-
sion operation in Second gear.
3-4 Shift Valve: Signal "A" fluid pressure exhausts and
spring force moves the valve into the downshift position
(Second and Third gear position).
TORQUE CONVERTER CLUTCH
Converter Clutch Signal Valve: 2nd clutch fluid pressure
opens the valve and line pressure feeds the converter clutch
(CC) signal fluid circuit. CC signal fluid is orificed (#8) to
the end of the CC signal valve and opposes 2nd clutch fluid
pressure. CC signal fluid is routed through a filter and ori-
ficed (#4) to the TCC solenoid.
TCC Solenoid: Under normal operating conditions in Sec-
ond gear the PCM keeps the normally open TCC solenoid
de-energized (OFF). CC signal fluid exhausts through the
open solenoid and spring force keeps the converter clutch
apply valve in the release position.
Note: The orifice cup plug (#4) in the CC signal fluid circuit
is smaller than the exhaust through the TCC solenoid. There-
fore,fluid pressure does not build up at the end of the converter
clutch apply valve.
SUMMARY
SHlfT SOLENOID u REVERSE OVERRUN FORWARD FORWARD
3-4 LO/ROLi.ER LO/REV.
INPUT CLUTCH CLUTCH SPRAG CL CLUTCH
,-2 I 2·3 BAND
CLUTCH ASSEMBLY
CLUTCH CLIITCH
OFF I ON APPLIED APPLIED HOLDING
RH0039-4L60-E
7A-14A-62 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

OVERDRIVE RANGE a INTAKE & DECREASE

[!!! CONVERTER& LUBE
THIRD GEAR MAINLINE
Cl SOLENOID SIG.
Cl ACCUMULATOR
Cl ACTUATOR FEED
Cl TORQUE SIGNAL

<I'
0

i'..'i
3ROACC- - I

1#7
2ND & 4TH
~ @
SERVO

Figure 52 Overdrive Range - Third Gear

 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS
OVERDRIVE RANGE - THIRD GEAR
As vehicle speed increases further, and other vehicle operating conditions are appropriate, the PCM de-energizes the normally
open the 2-3 shift solenoid to shift the transmission into Third gear.
2-3 Shift.Solenoid: De-energized (turned OFF) by the PCM,
the solenoid opens and actuator feed limit (AFL) fluid ex-
hausts through the solenoid.
Note: AFLfluid continues to feed the solenoid through orifice
#29. However, the exhaust port through the solenoid is larger
than orifice #29 to prevent a buildup of pressure in the AFL
fluid circuit at the solenoid end of the 2-3 shift valve. Ex-
hausting AFLfluid is represented by the arrows through the
solenoid.
3-4 CLUTCH APPLIES
2-3 Shift Valve Train: AFLfluid pressure at the 2-3 shuttle
valve moves the valve train toward the solenoid. In the up-
shifted position the following changes occur:
• AFL fluid is routed through the 2-3 shift valve and fills
the 0432 fluid circuit.
• 2nd fluid is blocked from entering the servo feed fluid
circuit and is orificed (#28) into the 3-4 signal fluid
circuit. This orifice helps control the 3-4 clutch apply
rate.
• Servo feed fluid exhausts past the valve, into the 3-4
accumulator fluid circuit and through an exhaust port at
the 3-4 relay valve.
3-4 Clutch Exhaust Checkball (#4): 3-4 signal fluid unseats
the ball and enters the 3-4 clutch fluid cirC)iit.
3-4 Clutch Piston: 3-4 clutch fluid pressure moves the piston
to apply the 3-4 clutch plates and obtain 3rd gear. However,
the 2-4 band must release as the 3-4 clutch applies.
2-4 BAND RELEASES and
3-4 CLUTCH ACCUMULATION
3rd Accumulator Check ball (#2): 3-4 clutch fluid pressure
unseats the ball and fills the 3rd accumulator fluid circuit.
3rd Accumulator Exhaust Checkball (#7): 3rd accumula-
tor fluid seats the ball against the orificed exhaust and is
routed to the release side of the 2nd apply piston. Before the
#7 checkball seats, air in the 3rd accumulator fluid circuit is
exhausted through the orifice.
2-4 Servo Assembly: 3rd accumulator fluid pressure acts on
the release side of the 2nd apply piston and assists servo
return spring force. The surface area on the release side of the
piston is greater than the surface area on the apply side.
Therefore, 3rd accumulator fluid pressure and servo return
Figure 53 Overdrive Range - Third Gear (Legend)
7A-14A-63
spring force move the 2nd apply piston against 2nd clutch
fluid pressure. This action serves two functions:
1. Move the apply pin to release the 2-4 band.
2. Act as an accumulator by absorbing initial 3-4 clutch
fluid to cushion the 3-4 clutch apply rate. Remember
that the 3rd accumulator fluid circuit is fed by 3-4 clutch
fluid.
3-2 Downshift Valve: 3-4 clutch fluid pressure moves the
valve against spring force. This opens the valve and allows
2nd fluid to feed the 2nd clutch fluid circuit through the
valve.
3-2 Control Solenoid and 3-2 Control Valve: The solenoid
remains at approximately 90% duty cycle and routes AFL
fluid into the 3-2 signal fluid circuit. 3-2 signal fluid pressure
holds the 3-2 control valve against _spring force, thereby
blocking the 3rd accumulator and 3-4 clutch fluid circuits.
1-2 Shift Solenoid and 1-2 Shift Valve: The 1-2 shift sole-
noid remains de-energized and signal "A" fluid is exhausted
through the solenoid. Also, 0432 fluid pressure from the 2-3
shift valve assists spring force to hold the 1-2 shift valve in
the upshifted position.
3-4 Shift Valve: Spring force holds the valve in the down-
shifted position, blocking 3-4 clutch fluid in preparation for a
3-4 upshift.
TORQUE CONVERTER CLUTCH
TCC Solenoid: Under normal operating conditions in Over-
drive Range - Third Gear the PCM keeps the normally open
TCC solenoid de-energized. CC signal fluid exhausts through
the open solenoid and spring force keeps the converter clutch
apply valve in the release position. However, at speeds above
approximately 121 km/h (75 mph) the PCM will command
TCC apply in Third gear.
SUMMARY
SHIFT SOLENOO 2-4 REV£RSE OVERRUN FORWARD FORWARD 3-4 LO/ROLLER LO/REV.
INPUT CI.UTCH CLUTCH SPRAGCL. CLUTCH CLUTCH
,.z I 2-3 BAND
CLUTCH ASSEMBLY
CLUTCH
Off I Off APPLIED HOLDING APPLIED
RH0041-4L60-E
7A-14A-64 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

!!::a INTAKE & DECREASE

OVERDRIVE RANGE Cul CONVERTER & LUBE
FOURTH GEAR TCC APPLIED MAINLINE
D SOLENOID SIG.
CJ ACCUMULATOR
D AC TUATOR FEED
D TORQUE SIGNAL

>-------~~
::,
...J
a:
;:1i
a:
13

...J
u
u z
..,. ::,
a:
M a:
0
~
0

...J

0
,_::, u
z
0.. ::,
u
,; ..,. a:
a:; M ffi
>
a: 0
u
0
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N

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0
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"'

Figure 54 Overdrive Range - Fourth Gear - Converter Clutch Applied

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
OVERDRIVE RANGE - FOURTH GEAR
Converter Clutch Applied
At higher vehicle speeds, the Hydra-matic 4L60-E transmission uses an Overdrive gear ratio (Fourth gear) to increase fuel
economy and maximize engine performance. When vehicle operating conditions are appropriate, the PCM energizes the 1-2 shift
solenoid to shift the transmission into Fourth gear.
1-2 Shift Solenoid: Energized (turned ON) by the PCM, the
normally open solenoid closes and blocks signal "A" fluid
from exhausting through the solenoid. This creates pressure
in the signal "A" fluid circuit.
2-3 Shift Solenoid: De-energized (OFF) as in Third gear, it
exhausts actuator feed limit (AFL) fluid through the solenoid.
1-2 Shift Valve: D432 fluid pressure from the 2-3 shift valve
and spring force hold the valve in the upshifted position
against signal "A" fluid pressure.
2-4 BAND APPLIES
3-4 Shift Valve: Signal "A" fluid pressure moves the valve
into the upshifted position against spring force. In this posi-
tion, the valve routes 3-4 signal fluid into the 4th signal fluid
circuit.
3-4 Relay Valve and 4-3 Sequence Valve: 4th signal fluid
pressure moves both valves into the upshifted (Fourth gear)
position against spring force acting on the 4-3 sequence valve.
This causes the following changes:
• Orificed (#7) 2nd fluid is routed through the 3-4 relay
valve and into the servo feed fluid circuit.
• Servo feed fluid is routed through the 4-3 sequence valve
and into the 4th fluid circuit.
• 3-4 accumulator fluid routed from the 2-3 shuttle valve
is blocked by both valves.
2-4 Servo Assembly: 4th fluid is routed through the centerof
the servo pin and acts on the apply side of the 4th apply
piston. 4th fluid pressure moves the 4th apply piston against
the apply pin spring force acting on the release side of the 4th
apply piston. This action moves the apply pin and applies the
2-4 band to obtain Fourth gear.
2-4 BAND APPLY ACCUMULATION
2-3 Shift Valve Train: The valve train remains in the up-
shifted position with AFL fluid pressure acting on the 2-3
shuttle valve. In addition to its operation in Third gear, the 2-
3 shift valve directs servo feed fluid into the 3-4 accumulator
fluid circuit.
3-4 Accumulator Assembly: 3-4 accumulator fluid pressure
moves the 3-4 accumulator piston against spring force and
orificed accumulator fluid pressure. This action absorbs ini-
tial 4th clutch apply fluid pressure to cushion the 2-4 band
apply. Remember that both the 3-4 accumulator and 4th fluid
circuits are fed by servo feed fluid. As 3-4 accumulator fluid
fills the accumulator, any air in the system will exhaust through
orifice #19. The piston movement forces some orificed accu-
mulator fluid out of the 3-4 accumulator assembly.
Figure 55 Overdrive Range - Fourth Gear - Converter Clutch Applied (Legend)
7A-14A-65
3-4 Accumulator Check ball ( #1): The accumulator fluid
forced from the accumulator unseats the #1 checkball and
enters the accumulator fluid circuit. This fluid is routed to the
accumulator valve. This is shown by the arrow directions in
the oil circuit.
Accumulator Valve: Accumulator fluid forced from the 3-4
accumulator is orificed to the end of the accumulator valve.
This fluid pressure, in addition to spring force and torque
signal fluid pressure, regulates the exhaust of excess accu-
mulator fluid pressure through the middle of the valve. This
regulation helps control the 2-4 band apply feel.
3-2 Control Solenoid and 3-2 Control Valve: Similar to
Third gear, the PCM operates the solenoid at approximately a
90% duty cycle, AFL fluid fills the 3-2 signal fluid circuit
and 3-2 signal fluid pressure holds the 3-2 control valve
against spring force.
TORQUE CONVERTER CLUTCH APPLIES
TCC Solenoid: When operating conditions are appropriate,
the PCM energizes the normally open TCC solenoid. This
closes the solenoid, blocks converter clutch signal fluid from
exhausting and creates pressure in the converter clutch signal
fluid circuit.
Converter Clutch Apply Valve: Converter clutch signal
fluid pressure moves the valve against spring force and into
the apply position. In this position, release fluid is open to an
exhaust port and converter feed fluid fills the apply fluid
circuit. Converter feed fluid also feeds the cooler fluid circuit
through orifice #3.
Torque Converter: Release fluid from behind the pressure
plate exhausts through the end of the turbine shaft. Apply
fluid pressure is routed between the converter hub and stator
shaft where it enters the torque converter. This fluid applies
the converter clutch against the converter cover and keeps
the converter filled with fluid.
TCC Apply Checkball (#9): Release fluid exhausting from
the converter seats the #9 checkball, located in the end of the
turbine shaft, and is orificed around the ball. Orificing the
exhausting release fluid controls the converter clutch apply
rate.
SUMMARY
SHIFT SOLENOID 2-4 REVERSE OVERRUN FORWARD FORWARD 3-4 LO/ROLU:R LO/REV.
INPUT CLUTCH CLUTCH SPRAG Cl. CLUTCH
,.2 I 2-3 BAND
CLUTCH ASSEMBLY
CLUTCH CLUTCH
ON I OFF APPLIED APPLIED APPLIED
RH0043-4L60-E
7A-14A-66 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

~ INTAKE & DECREASE

OVERDRIVE RANGE lul CONVERTER & LUBE
4-3 DOWNSHIFT iii MAINLINE
• soLENOIDSIG.
- ACCUMULATOR
O ACTUATOR FEED
O TORQUE SIGNAL

l=====:::;-i~
a:
~
a:
3

CJ

--'
LI
CJ
~

2NO & 4TH

SERVO

>:: >;

Figure 56 Overdrive Range - 4-3 Downshift

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A~14A-67

OVERDRIVE RANGE: 4-3 DOWNSHIFT

When the transmission is operating in Fourth gear, a forced 4-3 downshift will occur if there is a significant increase in throttle
position. At minimum throttle, vehicle speed will decrease gradually (coastdown) and the PCM will command a 4-3 downshift.
The PCM will also initiate a forced 4-3 downshift when throttle position remains constant but engine load is increased, such as
driving up a steep incline. To achieve a 4-3 downshift, the PCM de-energizes the 1-2 shift solenoid and the following changes
occur to the transmissions electrical and hydraulic systems:

1-2 Shift Solenoid: De-energized by PCM, the normally
open solenoid opens and signal "A" fluid exhausts through
the solenoid.
1-2 Shift Valve: As in Fourth gear, 0432 fluid pressure and
spring force hold the valve in the upshifted position.
2-4 BAND RELEASES
3-4 Shift Valve: With signal "A" fluid pressure exhausted,
spring force moves the valve into the downshifted position.
In this position, the valve blocks 3-4 signal fluid and 4th
signal fluid exhausts past the valve.
3-4 Relay Valve and 4-3 Sequence Valve: These valves
control the timing of the 2-4 band release. With 4th signal
fluid pressure exhausted, 3-4 accumulator fluid pressure moves
the 3-4 relay valve into the Third gear position. This opens 3-
4 accumulator fluid to an orificed exhaust (#5) past the 3-4
relay valve (shown by red arrows). Because the exhaust is
orificed, 3-4 accumulator fluid pressure momentarily holds
the 4-3 sequence valve against spring force before com-
pletely exhausting.
When exhausting 3-4 accumulator fluid pressure decreases
sufficiently, spring force will move the 4-3 sequence valve
into the Third gear position as shown. This opens both the 3-4
accumulator and 4th fluid circuits to a quick exhaust past the
4-3 sequence valve. In this position the valve blocks 2nd fluid
from entering the servo feed fluid circuit.
2-4 Servo Assembly: 4th fluid exhausts from the 4th apply
3-4 Accumulator Checkball (#1): As accumulator fluid fills
the 3-4 accumulator it seats the #1 checkball and is forced
through orifice #18. This orifice controls the rate at which
accumulator fluid pressure fills the 3-4 accumulator and 3-4
accumulator fluid exhausts from the accumulator assembly.
Accumulator Valve: Biased by torque signal fluid pressure
and spring force, the accumulator valve regulates drive fluid
into the accumulator fluid circuit.
2-3 Shift Solenoid: This solenoid remains de-energized as in
Fourth gear and AFL fluid exhausts through the solenoid.
2-3 Shift Valve Train: AFL fluid pressure at the 2-3 shuttle
valve holds the valves in the upshifted position. This allows
servo feed fluid to exhaust through the valve, into the 3-4
accumulator fluid circuit and past the 4-3 sequence valve.
Torque Converter Clutch: The PCM releases the converter
clutch prior to initiating the 4-3 downshift. However, if ve-
hicle speed is above approximately 121 km/h (75 mph), the
PCM will command TCC apply in Third gear.
Pressure Control Solenoid: Remember that the force motor
continually adjusts torque signal fluid pressure in relation to
the various PCM input signals (mainly throttle position).
SUMMARY
SHIFT SOLENOID 2·4 REVERSE OVERRUN FORWARD FORWARD 3-4 LO/llOUER LO/REV.
,.2 I 2.3 BAND INPUT
CLUTCH
CLUTCH CLUTCH SPRAGCL. CLUTCH CLUTCH
ASSEMBLY
CLUTCH

piston in the servo assembly. The apply pin spring moves the OFF I OFF APPLIED HOLDING APPLIED
4th apply piston and apply pin to release the band from the
reverse input drum and shift the transmission into Third gear.
3-4 Accumulator Assembly: 3-4 accumulator fluid exhausts
from the 3-4 accumulator piston. Orificed accumulator fluid
pressure and spring force move the piston to a Third gear
position.

RH0045-4L60-E

Figure 57 Overdrive Range - 4-3 Downshift (Legend)

7A-14A-68 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

~ INTAKE & DECREASE

OVERDRIVE RANGE !!:!! CONVERTER & LUBE
3-2 DOWNSHIFT MAINLINE
SOLENOID SIG.
l!B ACCUMULATOR
CJ ACTUATOR FEED
CJ TORQUE SIGNAL

l=====:::::;i~
a:
:5
a:

~
..,. I- '-'
z
0 ::, ~
CL ::,
:;;; ..,.
'-' a:
~
ci, ffi
>
a: 0
~
'-'
0
~

2ND &4TH
SERVO

Figure 58 Overdrive Range - 3-2 Downshift

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS
OVERDRIVE RANGE: 3-2 DOWNSHIFT
Similar to a forced 4-3 downshift, a forced 3-2 downshift can occur due to minimum throttle (coastdown conditions), heavy
throttle or increased engine load. To achieve a forced 3-2 downshift, the PCM energizes the 2-3 shift solenoid and the following
changes occur:
2-3 S,hift Solenoid: Energized by the PCM, the normally
open solenoid closes and blocks actuator feed limit (AFL)
fluid from exhausting through the solenoid. This creates pres-
sure in the AFL fluid circuit at the solenoid end of the 2-3
shift valve.
2-3 Shift Valve Train: AFL fluid pressure from the shift
solenoid moves both valves to the downshifted position against
AFL fluid pressure acting on the 2-3 shuttle valve. This
causes the following changes:
• AFL fluid is blocked from the D432 fluid circuit and
0432 fluid exhausts past the 2-3 shift valve.
• 2nd fluid is blocked from feeding the 3-4 signal fluid
circuit and 2nd fluid is routed into the servo feed fluid
circuit.
• 3-4 signal fluid is exhausted past the valve. 3-4 clutch
fluid and 3rd accumulator fluid, which were fed by 3-4
signal fluid, also exhaust.
3-4 CLUTCH RELEASES and 2-4 BAND APPLIES
3-4 Clutch Piston: 3-4 clutch fluid exhausts from the piston
and the 3-4 clutch plates are released.
3-4 Clutch Exhaust Check ball (#4): Exhausting 3-4 clutch
fluid seats the #4 checkball and is forced through orifice #13.
This orifice controls 3-4 clutch fluid exhaust and the 3-4
clutch release rate.
2-4 Servo Assembly: 3rd accumulator fluid exhausts from
the servo assembly. 2nd clutch fluid pressure moves the 2nd
apply piston against servo return spring force to move the
apply pin and apply the 2-4 band.
3-2 Downshift Valve and 1-2 Upshift Checkball (#8): 3-4
clutch fluid exhausts from the valve and spring force moves
the valve into the Second gear position. However, before
spring force overcomes exhausting 3-4 clutch fluid pressure,
2nd fluid feeds the 2nd clutch fluid circuit through the valve.
This bypasses the control of orifice #16 at the #8 checkball
and provides a faster 2-4 band apply. Remember that the #8
checkball and orifice #16 are used to help control the 2-4
band apply during a 1-2 upshift.
DOWNSHIFT TIMING and CONTROL
At higher vehicle speeds the 2-4 band apply must be delayed
to allow engine speed RPM to increase sufficiently for a
smooth transfer of engine load to the 2-4 band. Therefore,
exhaust of 3rd accumulator fluid must be delayed. However,
at lower speeds the band must be applied quickly. To provide
for the varying requirements for the 2-4 band apply rate,
Figure 59 Overdrive Range - 3-2 Downshift (Legend)
7A-14A-69
exhausting 3rd accumulator fluid is routed to both the 3rd
accumulator checkball (#2) and the 3-2 control valve.
3rd Accumulator Checkball (#2): Exhausting 3rd accumu-
lator fluid seats the #2 ball and is forced through orifice #12.
This fluid exhausts through the 3-4 clutch and 3-4 signal
fluid circuits and past the 2-3 shuttle valve. Orifice #12 slows
the exhaust of 3rd accumulator fluid and delays the 2-4 band
apply rate.
Note: The #12 orifice is not used on some models. For these
models, all of the exhausting 3rd accumulator fluid is routed
to the 3-2 control valve when the #2 checkball seats.
3-2 Control Solenoid and 3-2 Control Valve: These com-
ponents are used to increase the exhaust rate of 3rd
accumulator fluid; as needed depending on vehicle speed.
The normally closed 3-2 control solenoid is Pulse Width
Modulated (PWM) and controlled by the PCM through a
duty cycle operation. The PCM decreases the solenoid's duty
cycle during a 3-2 downshift from approximately 90% to as
low as 10%. Once the shift is complete the solenoid returns
to a 90% duty cycle. The duty cycle value during the shift
controls the 2-4 band apply rate.
• At lower vehicle speed the PCM operates the 3-2 control
solenoid at a lower duty cycle during the shift.
• At a lower duty cycle the solenoid regulates 3-2 signal
fluid to a lower pressure.
• With lower 3-2 signal fluid pressure, 3-2 control valve
spring force opens the valve farther to regulate a faster
exhaust of 3rd accumulator fluid into the 3-4 clutch
fluid circuit (as shown).
• A faster exhaust of 3rd accumulator exhaust provides a
faster apply of the 2-4 band, as needed at lower speeds.
3rd Accumulator Exhaust Check ball (#7): After the down-
shift is completed, the #7 checkball unseats and allows residual
fluid in the 3rd accumulator fluid circuit to exhaust.
Pressure Control Solenoid: Remember that the pressure
control solenoid continually adjusts torque signal fluid in
relation to the various PCM input signals (mainly throttle
position).
SUMMARY
SHIFT SOLENOID 2-4 REVERSE OVERRUN FORWARD FORWARD 3-4 LO/ROLLER LO/REV.
,.2 I 2·3
BAND INPUT
CLUTCH
CLUTCH CLUTCH SPRAG CL Q.UTCH
ASSEMBLY
CLUTCH CLUTCH
OFF I ON APPLIED APPLIED HOLDING
RH0047-4L60-E
7A-14A-70 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

il"'.:.I INTAKE & DECREASE

MANUAL THIRD ~ CONVERTER & LUBE
MAINLINE
• soLENOIO SIG.
- ACCUMULATOR
D ACTUATOR FEED
D TORQUE SIGNAL

PR

...,
..., u
z
...
u
M
:::,
a:
a:
w c,
>
0

Figure 60 Manual Third

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-71

DRIVE RANGE - MANUAL THIRD

(from Overdrive Range - Fourth Gear)

A manual 4-3 downshift is available to increase vehicle performance when the use of only three gear ratios is desired. Manual
Third gear range also provides engine braking in Third gear when the throttle is released. A manual 4-3 downshift is
accomplished by moving the selector lever into the Manual Third (D) position. This moves the manual valve and immediately
downshifts the transmission into Third gear. Refer to Overdrive Range: 4-3 Downshift for a complete description of a 4-3
downshift. In Manual Third, the transmission is prevented, both hydraulically and electronically, from shifting into Fourth gear.
The following information explains the additional changes during a manual 4-3 downshift as compared to a forced 4-3
downshift.

Manual Valve: The selector lever moves the manual shaft
and manual valve into the Manual Third position (D). This
allows line pressure to enter the D3 fluid circuit.
Pressure Switch Assembly (PSA): D3 fluid is routed to the
PSA and opens the normally closed D3 fluid pressure switch.
The combination of the opened D3 switch and the closed D4
switch signals the PCM that the transmission is operating in
Manual Third.
FOURTH GEAR PREVENTED
1-2 Shift Solenoid: When Manual Third is selected, the PCM
de-energizes the 1-2 shift solenoid to immediately downshift
the transmission into Third gear. This electronically prevents
Fourth gear.
3-4 Shift Valve: D3 fluid pressure assists spring force to keep
the valve in the downshifted position against the signal "A"
fluid circuit. In this position the valve blocks 3-4 signal fluid
and the 4th signal fluid circuit is open to an exhaust port past
the valve. Therefore, with D3 fluid pressure assisting spring
force, Fourth gear is hydraulically prevented.
OVERRUN CLUTCH APPLIED
2-3 Shift Valve Train: With the 2-3 shift solenoid de-ener-
gized and open, actuator feed limit (AFL) fluid acting on the
2-3 shuttle valve holds both valves in the upshifted position.
This allows D3 fluid to feed the overrun fluid circuit through
the 2-3 shuttle valve.
Overrun Clutch Feed Checkball (#5): Overrun fluid pres-
sure seats the ball against the empty D2 fluid circuit.
Overrun Clutch Control Checkball (#6): Overrun fluid
pressure seats the #6 checkball and is orificed (#20) to fill the
overrun clutch feed fluid circuit. This orifice controls the
overrun clutch apply rate.
3-4 Relay Valve and 4-3 Sequence Valve: 4th signal fluid
pressure is exhausted from the end of the 3-4 relay valve.
Overrun clutch feed fluid pressure assists spring force and
closes both valves. This allows overrun clutch feed fluid to
clutch plates provide engine compression braking in Manual
Third - Third Gear.
Overrun Clutch Air Bleed Checkball: This ball and cap-
sule is located in the overrun clutch fluid circuit in the oil
pump. It allows air to exhaust from the circuit as fluid pres-
sure increases and also allows air into the circuit to displace
the fluid when the clutch releases.
Torque Converter Clutch: The PCM de-energizes the TCC
solenoid to release the converter clutch prior to downshifting
(assuming the converter clutch is applied in Overdrive Range
- Fourth Gear when Manual Third is selected). The PCM will
re-apply the converter clutch in Manual Third - Third Gear
only when vehicle speed is above approximately 121 km/h
(75 mph).
Pressure Control Solenoid: The pressure control solenoid
operates in the same manner as Overdrive Range, regulating
in response to throttle position and other vehicle operating
conditions.
MANUAL THIRD - FIRST and SECOND GEARS:
OVERRUN CLUTCH RELEASED
In Manual Third the transmission upshifts and downshifts
normally between First, Second and Third gears. However,
in First and Second gears, the 2-3 shift solenoid is energized
and the 2-3 shift valve train is in the downshifted position.
The 2-3 shuttle valve blocks D3 fluid from entering the
overrun fluid circuit and opens the overrun fluid circuit to an
exhaust port at the valve. This prevents overrun clutch apply
and engine compression braking in Manual Third - First and
Second Gears.
SUMMARY
SHIFT SOLENOID REVERSE OVERRUN FORWARD FORWARD
2-4 3-4 LO/ROll.ER LO/REV.
,.2 I 2-3 BAND INPUT CLUTCH CLUTCH SPRAGCL. CLUTCH CLUTCH CLUTCH
CLUTCH ASSEMBLY
OFF I OFF APPLIED APPLIED HOLDING APPLIED

flow through the 4-3 sequence valve and fill the overrun
clutch fluid circuit.
Overrun Clutch Piston: Overrun clutch fluid pressure moves
the piston to apply the overrun clutch plates. The overrun
RH0049-4L60-E

Figure 61 Manual Third (Legend)

7A-14A-72 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

~ INTAKE & DECREASE

MANUAL SECOND l!:!I CONVERTER & LUBE
I!!!!! MAINLINE
SOLENOID SIG.
ACCUMULATOR
D AC TUATOR FEED
D TORQUE SIGNAL

t::===;-i ~
cc
;'5
cc

...,
...
0
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a.
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'-' cc
cc
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LU
>
cc 0

Figure 62 Manual Second

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-73

MANUAL SECOND - SECOND GEAR

(from Manual Third - Third Gear)

A manual 3-2 downshift can be accomplished by moving the gear selector lever into the Manual Second (2) position when the
transmission is operating in Third gear., This causes the transmission to shift immediately into Second gear regardless of vehicle
operating conditions. Refer to Overdrive Range: 3-2 Downshift for a complete description of a 3-2 downshift. Also, the
transmission is prevented from operating in any other gear, First, Third or Fourth. The following information explains the
additional changes during a manual 3-2 downshift as compared to a forced 3-2 downshift.

Manual Valve: The selector lever moves the manual shaft FIRST GEAR PREVENTED
and manual valve into the Manual Second (2) position. This The prevention of First gear in controlled electronically by
allows line pressure to enter the 02 fluid circuit. the PCM through the 1-2 shift solenoid. The PCM keeps the
1-2 shift solenoid de-energized regardless of vehicle operat-
Pressure Switch Assembly (PSA): 02 fluid is routed to the
ing conditions when the PSA signals Manual Second gear
PSA where it opens the normally closed 02 fluid pressure
range. This keeps signal "A" fluid exhausted and spring force
switch. With the 02, and 03 pressure switches closed and the
holds the 1-2 shift valve in the upshifted position.
04 pressure switch open, the PSA signals the PCM that the
transmission is operating in Manual Second.
OVERRUN CLUTCH REMAINS APPLIED
Overrun Clutch Feed Checkball (#5): Orificed 02 fluid
THIRD and FOURTH GEARS PREVENTED
pressure seats the #5 checkball against the empty overrun
2-3 Shift Solenoid: The PCM energizes the 2-3 shift sole-
clutch fluid circuit. This is done simultaneously with overrun
noid and AFL fluid pressure holds the 2-3 shift valve in the
clutch fluid exhausting such that there is a continuous fluid
downshifted position. This electronically prevents Third and
supply to the overrun clutch feed fluid circuit.
Fourth gears.
Overrun Clutch Piston: A continuous supply of fluid pres-
2-3 Shift Valve Train: 02 fluid is routed between the 2-3
sure is routed to the piston to keep the overrun clutch plates
shuttle and 2-3 shift valves and causes the following:
applied.
• Regardless of operating conditions, 02 fluid pressure
Torque Converter Clutch: The converter clutch is released
holds the 2-3 shuttle valve in the downshifted position
prior to downshifting into Manual Second - Second Gear.
against AFL fluid pressure.
Under normal operating conditions the TCC will not apply in
• 2nd fluid is blocked from entering the 3-4 signal fluid Second gear.
circuit and the 3-4 signal fluid circuit is open to an
Pressure Control Solenoid: The PCM output signal to the
exhaust port at the valve.
force motor increases the operating range of torque signal
• The 3-4 clutch cannot apply with 3-4 signal fluid ex- fluid pressure in Manual Second. This provides increased
hausted. Therefore, Third and Fourth gears are line pressur~ for the additional torque requirements during
hydraulically prevented. engine compression braking and increased engine loads.
e1 2nd fluid feeds the servo feed fluid circuit but has no
function in Manual Second.
SUMMARY
• AFL fluid is blocked by the 2-3 shift valve and the 0432
SHIFT SOLENOID REVERSE FORWARD
fluid circuit is exhausted through the valve. 2-4 OVERRUN FOflWARD 3-4 LO/ROLLER LO/REV.

• Overrun fluid is exhausted through the 2-3 shuttle valve.

,.2 I 2-3 BAND INPUT
CLUTCH
ctUTCH CLUTCM SPRAGCL ctUTCH ctUTCH
ASSEMBLY
CLUTCM

OFF I ON APPLIED APPLIED APPLIED HOLDING

1-2 Shift Valve: The 1-2 solenoid is OFF, signal "A" fluid
exhausts through the solenoid and spring force holds the
valve in the upshifted position.

RH0051-4L60-E

Figure 63 Manual Second (Legend)

7A-14A-74 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

~ INTAKE & DECREASE

MANUAL FIRST l!:!I CONVERTER & LUBE
- MAINLINE
- SOLENOID SIG.
- ACCUMULATOR
CJ ACTUATOR FEED
CJ TORQUE SIGNAL

w
a,
3
er
;l5
er
3

PR
LINE
LINE
N@ PRESSURE
TAP
I I

a:;
er
a--'

u
--'
u z
:::,
;!; er ..,.
ffi Cl
>
0

er f2
--'
Q._

"'
Cl
..,. u
Cl Cl
a:

..,. .... --'

u
2
Cl :::,
Q._ u--' :::,
;;; ..,. er
a:; cl, ffi
>
er 0

2ND & 4TH

SERVO

Figure 64 Manual First

 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A·75

MANUAL FIRST - FIRST GEAR

(from Manual Second - Second Gear)

A manual 2-1 downshift can be accomplished by moving the gear selector lever into the Manual First (1) position when the
transmission is operating in Second ~ar. The downshift to First gear is controlled electronically by the PCM. The PCM will not
energize the 1-2 shift solenoid to initiate the downshift until vehicle speed is below approximately 48 to 56 km/h (30 to 35 mph).
Above this speed, the transmission will operate in a Manual First - Second Gear state. The following text explains the manual 2-1
downshift. · ·

Manual Valve: The selector lever moves the manual shaft
and manual valve into the Manual First (1) position. This
allows line pressure to enter the lo fluid circuit.
Pressure Switch Assembly (PSA): Lo fluid is routed to the
PSA where it closes the normally open lo pressure switch.
The addition of the lo pressure switch being closed signals
the PCM that Manual First is selected.
2-3 Shift Solenoid: In both First and Second gears this sole-
noid is energized and maintaining actuator feed limit (AFL)
fluid pressure at the solenoid end of the 2-3 shift valve train.
2-3 Shift Valve Train: Held in the downshifted position by
AFL fluid pressure from the solenoid, the valve train blocks
AFL fluid from entering the 0432 fluid circuit. The 0432
fluid circuit is open to an exhaust past the valve.
1-2 Shift Solenoid: Below approximately 48 to 56 km/h (30
to 35 mph) the PCM energizes the normally open solenoid.
This blocks signal "A" fluid pressure from exhausting through
the solenoid and creates pressure in the signal "A" fluid
circuit. Above this speed, the PCM keeps the solenoid de-
energized and the transmission operates in Manual First -
Second Gear.
1-2 Shift Valve: Signal "A" fluid pressure moves the valve
against spring force and into the downshifted position. In this
position, lo fluid from the manual valve is routed into the lo-
lst fluid circuit and 04 fluid is blocked from entering the 2nd
fluid circuit. 2nd fluid exhausts through an orifice and an
annulus exhaust port past the valve. This orifice (#26) helps
control the 2-4 band release during a 2-1 downshift.
2-4 BAND RELEASES
2-4 Servo Assembly: 2nd clutch fluid, which was fed by 2nd
fluid, exhausts from the servo. This allows spring force from
the servo cushion and servo return springs to move the 2nd
apply piston and apply pin to release the 2-4 band. These
spring forces help control the 2-4 band release.
control the movement of the 1-2 accumulator piston, 2nd
clutch fluid exhaust and the 2-4 band release.
1-2 Upshift Check ball (#8): Exhausting 2nd clutch fluid
pressure unseats the ball and is rouied through the 2nd fluid
circuit.
Converter Clutch Signal Valve: 2nd fluid exhausts from
the converter clutch signal valve. Refer to Park range on for a
description of the TCC signal valve operation in First gear.
LO and REVERSE CLUTCH APPLIES
Lo Overrun Valve: Lo 1st fluid is regulated through the lo
overrun valve and into the lo/reverse fluid circuit to control
the lo/reverse clutch apply.
Lo/Reverse Piston: Lo/reverse fluid pressure acts on the
inner area of the piston to move the piston and apply the lo/
reverse clutch plates.
OVERRUN CLUTCH APPLIED
The overrun clutch remains applied in Manual First to pro-
vide engine compression braking.
Pressure Control Solenoid: Similar to Manual Second, the
PCM output signal to the force motor increases the operating
range of torque signal fluid pressure. This provides increased
line pressure for the additional torque requirements during
engine compression braking and increased engine loads.
3-2 Downshift Control Solenoid and 3-2 Control Valve: In
First gear the solenoid is OFF, AFL fluid is blocked by the
solenoid, 3-2 signal fluid exhausts through the solenoid and
spring force opens the 3-2 control valve.
SUMMARY
SHIFT SOLENOID 2-4 REVERSE OVERRUN FORWARD FORWARD 3-4 LO/ROLi.ER LO/REV.

1-2 Accumulator Assembly: 2nd clutch fluid also exhausts ,.2 I z.3 BAND INPllT
CLllTCH
CLUTCH CLUTCH SPRAGCL. CLUTCH CLUTClt
ASSEMBLY
CLUTClt

from the 1-2 accumulator assembly. Spring force and accu- ON I ON APPLIED APPLIED HOLDING HOLDING APPLIED

mulator fluid pressure move the accumulator piston to assist

2nd clutch fluid exhaust.
Accumulator Valve: As accumulator fluid is filling the 1-2
accumulator assembly, the accumulator valve regulates 04
fluid into the accumulator fluid circuit. This regulation,
biased by torque signal fluid pressure and spring force, helps
RH0053-4L60-E

Figure 65 Manual First (Legend)

7A-14A-76 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

•
#8

#4

#3

FORWARD
CLUTCH
ACCUMULATOR
PASSAGES BORE

1 SUCTION (INTAKE) 18 FORWARD CLUTCH FEED 35 OVERRUN

2 DECREASE 19 REAR LUBE 36 OVERRUN CLUTCH FEED
3 LINE 20 ACCUMULATOR 37 OVERRUN CLUTCH
4 CONVERTER FEED 21 ORIFICIED ACCUMULATOR 38 D2
5 RELEASE 22 SIGNAL A 39 ORIFICED D2
6 APPLY (REG APPLY) 23 SIGNAL B 40 3-2 SIGNAL
7 TO COOLER 24 2ND 41 LO
8 LUBE FROM COOLER 25 2ND CLUTCH 42 L0/1ST
9 ACTUATOR FEED LIMIT 26 C.C. SIGNAL 43 EXHAUST
10 FILTERED ACTUATOR FEED 27 3-4 SIGNAL 44 ORIFICED EXHAUST
11 TORQUE SIGNAL 28 3RDACCUM 45 VENT
12 PR 29 3-4 CLUTCH 46 SEAL DRAIN
13 04-3-2 30 4TH SIGNAL 47 VOID
14 LO/REVERSE 31 SERVO FEED
15 REVERSE 32 4TH
16 REVERSE INPUT (REV. CL.) 33 3-4 ACCUM
17 D4 34 D3

RH0054-4L60-E

Figure 66 Valve Body Passages and Checkball Locations

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-77

374 375 395 376 364 378

380

395

381

384

381 379
395
385
367
386
395
379
381
389 367
390
381
395 362
363
394
379 364

381
393
392
391

340 353 354 355 356

340 VALVE, MANUAL
353 SEAL, FORWARD ACCUMULATOR OIL 374 VALVE, ACTUATOR FEED LIMIT
354 PISTON, FORWARD ACCUMULATOR 375 SPRING, ACTUATOR FEED LIMIT VALVE
355 PIN, FORWARD ACCUMULATOR 376 PLUG, BORE
356 SPRING, FORWARD ACCUMULATOR 377 PRESSURE CONTROL SOLENOID
357 VALVE, FORWARD ABUSE 378 RETAINER, PRESSURE CONTROL SOLENOID
358 SPRING, FORWARD ABUSE VALVE 379 RETAINER, SOLENOID
359 PLUG, BORE 380 VALVE, CONVERTER CLUTCH SIGNAL
360 PIN, COILED SPRING 381 PLUG, BORE
361 VALVE, LOW OVERRUN 382 SPRING, 4-3 SEQUENCE VALVE
362 SPRING, LOW OVERRUN VALVE 383 VALVE, 4-3 SEQUENCE
363 COVER, FORWARD ACCUMULATOR 384 VALVE, 3-4 RELAY
364 BOLT, FORWARD ACCUMULATOR COVER 385 VALVE, 3-4 SHIFT
365 SPRING, 1-2 SHIFT VALVE 386 SPRING, 3-4 SHIFT VALVE
366 VALVE, 1-2 SHIFT 387 VALVE, REVERSE ABUSE
367-A 1-2 SHIFT SOLENOID (A) 388 SPRING, REVERSE ABUSE VALVE
367-B 2-3 SHIFT SOLENOID (8) 389 VALVE, 3-2 DOWNSHIFT
368 VALVE, 2-3 SHIFT 390 SPRING, 3-2 DOWNSHIFT VALVE
369 VALVE, 2-3 SHUTTLE 391 VALVE, 3-2 CONTROL
370 SPRING, 1-2 ACCUMULATOR VALVE 392 SPRING, 3-2 CONTROL VALVE
371 VALVE, 1-2 ACCUMULATOR 393 SPRING, BORE PLUG
372 SLEEVE, 1-2 ACCUMULATOR VALVE 394 3-2 CONTROL SOLENOID
373 PLUG, BORE 395 RETAINER, BORE PLUG PH0055-4L60-E

Figure 67 Valve Trains

7A-14A-78 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

0 912 3 Q41
3NO
00 0 012 340 41

•
29
15/16 • 29/28 / 17/18
15/160 0 q9/28 38 • Q34 0 0. 011 0 \4

10
D
C)
40
4
J> 29
0 2°9
0
15

18
OO12 11118 v~/)42
11 012 14 •

0 6 0 380 0 011 (/0 ~4

29
029 ~9
0 9/10
15

0
41
0 41 43/44 0
9 012

220 01 4
042

•
•
18
1 24 24
1a
30
•
27/290
27/290
0
34
DO. 13 0 0
•
010/22

0 34
300 0 21
340
CJ
22
035
0 a
27
CJ CJ
24
O24 0
13 10
0
250
24/25
oo
Q24 24/25

310 43
024

C]33 310
34

330
~ 24

835/3600CJ Q35 ~·o

38/39

35/39
9
010/23

•
35/36
• D Do
25 43/44 (/ 36 • 330 8 0 020 020

26 37 0 17
0
026 28 Q32 90. 200•
•
0
25 0
25
0
0025
09
110
SHIFT
SOLENOIDS
SCREEN
25
0 020/21
020121
11 03 (49)
o9 eo21
0 250
9/10.
25 ~

- - - - - -• - 6
-eCD -!~
PRESSURE CONTROL
SOLENOID SCREEN
(50)

PASSAGES
1 SUCTION (INTAKE) 18 FORWARD CLUTCH FEED 35 OVERRUN
2 DECREASE 19 REAR LUBE 36 OVERRUN CLUTCH FEED
3 LINE 20 ACCUMULATOR 37 OVERRUN CLUTCH
4 CONVERTER FEED 21 ORIFICIED ACCUMULATOR 38 02
5 RELEASE 22 SIGNALA 39 ORIFICED D2
6 APPLY (REG APPLY) 23 SIGNAL B 40 3-2 SIGNAL
7 TO COOLER 24 2ND 41 LO
8 LUBE FROM COOLER 25 2ND CLUTCH 42 L0/1ST
9 ACTUATOR FEED LIMIT 26 C.C. SIGNAL 43 EXHAUST
10 FILTERED ACTUATOR FEED 27 3-4 SIGNAL 44 ORIFICED EXHAUST
11 TORQUE SIGNAL 28 3RDACCUM 45 VENT
12 PR 29 3-4 CLUTCH 46 SEAL DRAIN
13 04-3-2 30 4TH SIGNAL 47 VOID
14 LO/REVERSE 31 SERVO FEED
15 REVERSE 32 4TH
16 REVERSE INPUT (REV. CL.) 33 3-4ACCUM
17 04 34 D3

RH0056-4L60-E

Figure 68 Spacer Plate Passages

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-79

•
•
•
•~ 300 021 c3 27 24 013
034 D 038 024 10 0
0 25 ~024
24 24
310 CJ /1
0
0
0 •

024
031
~
~
o
03~
33
G
35
(/35/39 • L:J B 23

"VI 8
• D
25 44
/)37
U @ 32 • D@o~ ~
•
17
~ @ 28 0
• 0 025
250 t5 Os
[ill
0
90

eCIJ
•

PASSAGES
1 SUCTION (INTAKE) 18 FORWARD CLUTCH FEED 35 OVERRUN
2 DECREASE 19 REAR LUBE 36 OVERRUN CLUTCH FEED
3 LINE 20 ACCUMULATOR 37 OVERRUN CLUTCH
4 CONVERTER FEED 21 ORIFICIED ACCUMULATOR 38 D2
5 RELEASE 22 SIGNAL A 39 ORIFICED 02
6 APPLY (REG APPLY) 23 SIGNAL B 40 3-2 SIGNAL
7 TO COOLER 24 2ND 41 LO
8 LUBE FROM COOLER 25 2ND CLUTCH 42 L0/1ST
9 ACTUATOR FEED LIMIT 26 C.C. SIGNAL 43 EXHAUST
10 FILTERED ACTUATOR FEED 27 3-4 SIGNAL 44 ORIFICED EXHAUST
11 TORQUE SIGNAL 28 3RDACCUM 45 VENT
12 PR 29 3-4 CLUTCH 46 SEAL DRAIN
13 04-3-2 30 4TH SIGNAL 47 VOID
14 LO/REVERSE 31 SERVO FEED
15 REVERSE 32 4TH
16 REVERSE INPUT (REV. CL.) 33 3-4ACCUM
17 D4 34 D3
RH0057-4L60-E

Figure 69 Spacer Plate to Valve Body Gasket

7A-14A-80 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

@ c=:]38 ~38
410 34 0

• 1600
040
16

c:=)29
•

~
15
@ ~ 0 038

~
29

0
29
016

~
0
•034

,so
012

0,2

0
@)
Sa
@eu
/)17
0

c.//)42
'12'
41

l!.=.J
~o. •
r:;-:;i 14

•
042
c=i 380 0,1 (/044
41 Q41 044
(]]
012
029 0~9
o,s 014
•
220
110 • 24 24
34 13 0 0 010

30
0
Q34
300 Q21 022
G o3400•
c::::::::J35 27
09
[]13 10
•
0 010
•
25 25 Q34 024
Q25 °0 ~ 24 24 039

•
024

25
031 33CJ
cm 43o
'A
u 330
~o Cl
36a 035
039
•8
D ~ • 330~020 020
036
26
0 @ 28 0
32
c:S• 200•
• 0 (2ID
fn\ 250 250 09
v 025 0 IT!]
90

•ITJ •
PASSAGES

1 SUCTION (INTAKE) 18 FORWARD CLUTCH FEED 35 OVERRUN

2 DECREASE 19 REAR LUBE 36 OVERRUN CLUTCH FEED
3 LINE 20 ACCUMULATOR 37 OVERRUN CLUTCH
4 CONVERTER FEED 21 ORIFICIED ACCUMULATOR 38 D2
5 RELEASE 22 SIGNALA 39 ORIFICED D2
6 APPLY (REG APPLY) 23 SIGNAL B 40 3-2 SIGNAL
7 TO COOLER 24 2ND 41 LO
8 LUBE FROM COOLER 25 2ND CLUTCH 42 L0/1ST
9 ACTUATOR FEED LIMIT 26 C.C. SIGNAL 43 EXHAUST
10 FILTERED ACTUATOR FEED 27 3-4 SIGNAL 44 ORIFICED EXHAUST
11 TORQUE SIGNAL 28 3RDACCUM 45 VENT
12 PR 29 3-4 CLUTCH 46 SEAL DRAIN
13 D4-3-2 30 4TH SIGNAL 47 VOID
14 LO/REVERSE 31 SERVO FEED
15 REVERSE 32 4TH
16 REVERSE INPUT (REV. CL.) 33 3-4 ACCUM
17 D4 34 D3

RH0058-4L60-E

Figure 70 Spacer Plate to Case Gasket

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-81

16

29
11

18

TO
LO/REVERSE
CLUTCH

•
SERVO BORE

40(#7)

PASSAGES
1 SUCTION (INTAKE) 19 REAR LUBE 37 OVERRUN CLUTCH
2 DECREASE 20 ACCUMULATOR 38 D2
3 LINE 21 ORIFICIED ACCUMULATOR 39 ORIFICED D2
4 CONVERTER FEED 22 SIGNALA 40 3-2 SIGNAL
5 RELEASE 23 SIGNAL B 41 LO
6 APPLY (REG APPLY) 24 2ND 42 L0/1ST
7 TO COOLER 25 2ND CLUTCH 43 EXHAUST
8 LUBE FROM COOLER 26 C.C. SIGNAL 44 ORIFICED EXHAUST
9 ACTUATOR FEED LIMIT 27 3-4 SIGNAL 45 VENT
10 FILTERED ACTUATOR FEED 28 3RDACCUM 46 SEAL DRAIN
11 TORQUE SIGNAL 29 3-4 CLUTCH 47 VOID
12 PR 30 4TH SIGNAL
13 04-3-2 31 SERVO FEED COMPONENTS I
14 LO/REVERSE 32 4TH
15 REVERSE 33 3-4 ACCUM (38) ACCUMULATOR BLEED PLUG
16 REVERSE INPUT (REV. CL.) 34 D3 (40) 3RD ACCUM. RETAINER AND
17 D4 35 OVERRUN (92) TCC SCREEN
18 FORWARD CLUTCH FEED 36 OVERRUN CLUTCH FEED
RH0059-4L60-E

Figure 71 Case Passages and Checkball Locations

7A-14A-82 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS

I
I
I
I
I
<Il,,11
I
I
I
I ~(40)
I
I I
\ I/ I
43
\
25
\
28 32

28
#7/(40)

PASSAGES

25 2ND CLUTCH
28 3RD ACCUMUL:ATOR
32 4TH
43 EXHAUST
44 ORIFICED EXHAUST

COMPONENTS (

(11) CASE SERVO ORIFICED PLUG

(40) 3RD ACCUM. RETAINER AND BALL ASSEMBLY (#7)

RH0062-4L60-E

Figure 72 2-4 Servo Passages

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-83

PASSAGES 7

3 LINE
7 TO COOLER
8 LUBE FROM COOLER
11 TORQUE SIGNAL
16 REVERSE INPUT
18 FORWARD CLUTCH FEED
26 C. C. SIGNAL
29 3-4 CLUTCH
37 OVERRUN CLUTCH
45 VENT

COMPONENTS (

(10) OIL COOLER PIPE CONNECTOR

(39) LINE PRESSURE TAP 26 37 18 11 29 16 3
RH0060-4L60-E

Figure 73 Pump to Case Passages

45

PASSAGES

1 SUCTION (INTAKE)
2 DECREASE
3 LINE
5 RELEASE
7 TOCOOLER
8 LUBE FROM COOLER
11 TORQUE SIGNAL
16 REVERSE INPUT
18 FORWARD CLUTCH FEED
26 C. C. SIGNAL
29 3-4 CLUTCH
37 OVERRUN CLUTCH
43 EXHAUST
45 VENT
46 SEAL DRAIN
47 VOID

COMPONENTS (

(232) OIL PUMP COVER SCREEN

(237) CHECK VALVE RETAINER AND BALL
ASSEMBLY
(240) ORIFICED CUP PLUG
18 RH0238-4L60-E

Figure 74 Pump Cover Passages (Case Side)

7A-14A-84 4L60·E AUTOMATIC TRANSMISSION DIAGNOSIS

PASSAGES
1 SUCTION (INTAKE)
2 DECREASE
3 LINE
4 CONVERTER FEED
5 RELEASE
6 APPLY
7 TO COOLER
8 LUBE FROM COOLER
11 TORQUE SIGNAL
16 REVERSE INPUT
18 FORWARD CLUTCH FEED
26 C. C. SIGNAL
29 3-4 CLUTCH
37 OVERRUN CLUTCH
43 EXHAUST
45 VENT (237)
47 VOID

COMPONENTS (
(232)
(237)
(238) 16
(239)
(240)
RH0063-4L60-E

Figure 75 Pump Cover Passages

PASSAGES
1 SUCTION (INTAKE)
2 DECREASE
3 LINE
4 CONVERTER FEED
5 RELEASE
7 TO COOLER
11 TORQUE SIGNAL
16 REVERSE INPUT
26 C. C. SIGNAL
29 3-4 CLUTCH
37 OVERRUN CLUTCH
43 EXHAUST
45 VENT
46 SEAL DRAIN
47 VOID

RH0064-4L60-E

Figure 76 Pump Body Passages

 4L60-E AUTOMATIC TRANSMISSION DIAGNOSIS 7A-14A-85

VOLTMETER - Voltage position measures magnitude of voltage when connected in

parallel to an existing circuit. A digital voltmeter with a 10 meg ohm input impedance is
used because this type of meter will not load down the circuit and result in faulty
readings. Some circuits require accurate low voltage readings because they have a very
high resistance.

- E:i) ( 3 E3
O GDG0GJ AMMETER - When used as an ammeter, this meter accurately measures extremely
ftAµltlNAMX
low current flow. Refer to meter instructions for more information.

Selector must be set properly for both function and range. DC is used for most
automotive measurements.

OHMMETER - Measures resistance of circuit directly in ohms. Refer to meter

instructions for more information.

OL display in all ranges indicates open circuit.

Zero display in all ranges indicates a short circuit.

An intermittent connection in a circuit may be indicated by a digital reading that
will not stabilize on the circuit.
FLUKE 87 TRUE RMS
MUTIMETER Autoranges to the 400 n, 4 kn, 40 kn, 400 kn, 4 Mn, or 40 Mn resistance range.
J 39200

CONNECTOR TEST ADAPTER KIT

Assortment of flexible connectors to adapt a multimeter or
jumper cords to connectors.

J 35616-A

CIRCUIT TESTER
Used for checking all relays and solenoids before connecting them to a
new ECM. Measures the circuit resistance and indicates pass or fail via
green or red LED. Amber LED indicates current polarity. Can also be
used as a non-powered continuity checker.

UNPOWERED TEST LIGHT

Used for checking wiring for complete circuit, short to ground,
J 34142-A or voltage.

TECH1 TESTER
Used to check solenoids and other electronic components. Can record
vehicle data during dynamic testing, and turn some electronic
components on and off.

UNIVERSAL PRESSURE GAUGE SET

(9 Ft. Hose; 0-300 PSI)
Used for checking line pressure, pump output (min., max.) in all gear
J 21867 ranges.
RH0239-4L60-E

Figure 77 Electrical Diagnosis Tools

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-1

SECTION 7A-14B
HVDRA-MATIC 4L60-E
AUTOMATIC TRANSMISSION UNIT REPAIR
RPO M30
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out The correct torque value
must be used when installing fasteners that require it. If the above conditions are not followed, parts or system
damage could result.

CONTENTS
Transmission Disassembly .......................... 7A-14B-2
General Service Information .................... 7A-14B-2
2-4 Servo Assembly ................................. 7A-14B-2
Servo Pin Length ...................................... 7A-14B-3
Speed Sensor and Case Extension ........... 7A-14B-5
Pan and Filter Assembly .......................... 7A-14B-6
Valve Body and Wiring Harness ........•..... 7A-14B-6
Transmission End Play Check ................. 7A-14B-9
Oil Pump Assembly ................................. 7A-14B-9
2-4 Band, Reverse Input Clutch,
Input Clutch and Input Gear Set ........ 7 A-14 B-10
Reaction Gear Set ................................... 7 A-14B-11
Lo and Reverse Clutch Parts .................. 7 A-14B-12
Inner Manual Linkage ............................ 7 A-14B-13
Manual Shaft Seal Replacement ............ 7 A-14 B-13
Component Repair and
Transmission Reassembly ...................... 7 A-14B-14
CaseAssembly ....................................... 7A-14B-14
Case ........................................................ 7 A-14B-14
Third Accumulator Retainer and
Ball Assembly .................................... 7A-14B-15
Retainer and Ball Assembly Leak
Check Procedure ................................ 7A-14B-15
Replacement Procedure - Third Accumulator
Retainer and Ball Assembly ............... 7A-14B-15
Lo and Reverse Clutch Piston ................ 7A-14 B-16
Parking Pawl .......................................... 7A-14B-17
Reaction Internal Gear and
Carrier Assembly ............................... 7A-14B-17
Reaction Internal Gear and Support ....... 7A-14B-18
Lo and Reverse Clutch Spacer Plate
Selection ............................................. 7 A-14B-18
Lo and Reverse Clutch Support
Assembly ............................................ 7 A-14B-21
Reaction Sun Gear and Shell ................. 7A-14B-22
Input Internal Gear and
Reaction Shaft .................................... 7A-14B-22
Internal Transmission Speed Sensor
Rotor .................................................. 7A-14B-23
Input Internal Gear and Output Shaft.. ... 7 A-14B-23
Input Carrier and Sun Gear .................... 7A-14B-24
Input Clutch Assembly ........................... 7 A-14B-25
Check Valve Retainer and Ball Assembly -
Replacement Procedures .................... 7 A-14B-26
Forward Clutch Sprag Assembly ........... 7 A-14B-32
Forward Clutch Piston Travel
Check ................................................. 7A-14B-34
3-4 Clutch Assembly .............................. 7A-14B-35
3-4 Clutch Piston Travel Check ............. 7A-14B-35
Clutch Air Check .................................... 7A-14B-35
Turbine Shaft Seals ................................ 7A-14B-36
Reverse Input Clutch Assembly ............. 7A-14B-37
Reverse Input Clutch Backing Plate
Selection ............................................. 7A-14B-39
Reverse Input and Input Clutches .......... 7 A-14B-40
2-4 Band Assembly ................................ 7A-14B-41
Oil Pump Assembly ............................... 7A-14B-41
Oil Pump Body ....................................... 7A-14B-41
Oil Pump Cover (Disassemble) .............. 7A-14B-42
Oil Pump Body (Assemble) ................... 7A-14B-44
Oil Pump Cover (Assemble) .................. 7A-14B-44
Oil Pump Cover and Body ..................... 7A-14B-45
Transmission End Play Check ............... 7A-14B-46
Valve Body and Associated Parts ........... 7A-14B-49
Control Valve Assembly ......................... 7 A-14B-50
2-4 Servo Assembly ............................... 7A-14B-55
Speed Sensor and Case Extension ......... 7A-14B-58
Torque Converter Assembly ................... 7 A-14B-59
Cross Section .......................................... 7A-14B-61
Disassembled Views .................................. 7 A-14B-62
Seal and Bearing Locations ....................... 7A-14B-71
Bushing Locations ..................................... 7A-14B-72
Torque Specifications ................................ 7A-14B-73
Bushing Replacement
Procedure ................................................ 7A-14B-74
Special Tools ............................................. 7A-14B-78
7A-14B-2 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

TRANSMISSION DISASSEMBLY 2-4 Servo Assembly

General Service Information Figures 2 and 3

Figure 1 Tool Required:

J 29714 Servo Cover Compressor
Tool Required:
J 8763-02 Holding Fixture and Base l+-..1 Remove or Disconnect

NOTICE: It is not recommended to use air 1. Install J 29714.

powered tools to disassemble or assemble 2. Servo cover retaining ring (29).
transmissions/transaxles. Improper bolt torques 3. Servo cover and 0-ring seal (28 and 27).
can contribute to transmission repair conditions • If the servo cover seems to be hung up on
and this information, vital to diagnosis, can only the seal, cut and remove the 0-ring seal
be detected when using hand tools. before removing the cover.
• Teflon Oil Seal Rings 4. 2-4 servo assembly (12-26).
If any seal rings are damaged, cut, or do not
rotate freely in their groove be certain to check
the ring groove for debris, burrs, or damage.
• Thrust Washer Surfaces J 29714
The thrust washer and thrust bearing surfaces
may appear to be polished. This is a normal
condition and should not be considered damage.

~ Clean
• Thoroughly clean the exterior of the trans-
mission.
l+..I Remove or Disconnect
• Torque Converter (1).
l..+I Install or Connect
12
1. J 8763-02 onto the transmission case.
2. Holding fixture into the base.

~
13 - 24
l+..I Remove or Disconnect
• Drain the transmission fluid out case extension
by rotating transmission so bell housing is up.
()~
~ 28
25

~29 20 HOUSING, SERVO PISTON

(INNER)
12 SPRING, SERVO RETURN 21 SEAL, 0-RING
13 PIN, 2ND APPLY PISTON 22 SPRING, SERVO APPLY PIN
14 RING, RETAINER (2ND 23 WASHER SERVO APPLY
APPLY PISTON) PIN '
15 RETAINER, SERVO 24 RING, RETAINER (APPLY
CUSHION SPRING PIN)
16 SPRING, SERVO CUSHION 25 PISTON, 4TH APPLY
17 PISTON, 2ND APPLY 28 COVER, 2-4 SERVO
18 RING, OIL SEAL (2ND 29 RING, SERVO COVER
APPLY PISTON - OUTER) RETAINING
19 RING, OIL SEAL (2ND
APPLY PISTON - INNER) RH0101-4L60-E

Figure 2 Servo Cover Removal

Figure 1 Holding Fixture
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-3

Servo Pin Length

Figures 3, 4 and 5
Tools Required:
J 33037 Band Apply Pin Tool
J 22269-01 Piston Compressor
As a diagnostic aid, the servo pin length should
now be checked. If the pin length is too short or too
long, be certain to inspect the 2-4 band and reverse
input drum for damage or wear when disassembled.
J 33037
l@I Measure A WHITE LINE
8 GAGE SLOT
Figure3
1. Install J 33037 as shown with apply pin (13). PIN IS PRESET AT FACTORY AND MUST NOT BE
READJUSTED
2. Install servo cover retaining ring (29) to secure
tool. 2-4 SERVO PIN SELECTION
3. Apply 11 N•m (98 lb. in.) torque.
PIN LENGTH PIN I.D.
4. If white line "A" appears in gage slot "B" pin
length is correct. MM INCH
5. Use pin selection chart to determine correct pin 65.82-66.12 2.59-2.60 1 GROOVE
length if new pin is needed. 67.23-67.53 2.65-2.66 2 GROOVES
68.64-68.94 2.70-2.71 NO GROOVE

RH0102-4l60-E

Figure 3 Servo Pin Length

7A-14B-4 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

1.. -+I Remove or Disconnect

Figures 4 and 5
1. 4th apply piston (25).
2. Servo return spring (12).
3. Servo pin retainer ring (24), washer (23) and
apply pin spring (22).
4. 2nd apply piston pin (13).
5. Install J 22269-01.
6. Retainer ring (14).
7. Cushion spring retainer (15) and cushion spring
(16).

14 RING, RETAINER (2ND APPLY PISTON)

17 SECOND APPLY PISTON RH0103-4L60-E

Figure 4 Second Servo Piston Retaining Ring Removal

e------12

ILL.
NO. DESCRIPTION
12 SPRING, SERVO RETURN
13 PIN, 2ND APPLY PISTON
14 RING, RETAINER (2ND APPLY PISTON)
15 RETAINER, SERVO CUSHION SPRING
16 SPRING, SERVO CUSHION
17 PISTON, 2ND APPLY
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER)
20 HOUSING, SERVO PISTON (INNER)
21 SEAL, 0-RING
22 SPRING, SERVO APPLY PIN
23 WASHER, SERVO APPLY PIN
24 RING, RETAINER (APPLY PIN)
25 PISTON, 4TH APPLY
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER)
27 SEAL, 0-RING (2-4 SERVO COVER)
28 COVER, 2-4 SERVO
29 RING, SERVO COVER RETAINING

RH0104-4L60-E

Figure 5 Servo Assembly

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-5

Speed Sensor and Case Extension

Figures 6 and 7
Tool Required:
J 38417 Speed Sensor Remover and
Installer
1. Speed sensor retaining bolt (35).
2. Speed sensor assembly (36) and 0-ring seal
(37) with J 38417. ·
3. Case extension bolts (32), case extension (31)
and extension seal ring (30).
4. Output shaft sleeve (690) and output shaft
0-ring seal (691).
• Not all models use an output shaft sleeve
ILL.
and seal. NO. DESCRIPTION
8 CASE, TRANSMISSION
30 SEAL, CASE EXTENSION TO CASE
31 EXTENSION, CASE
32 BOLT, CASE EXTENSION TO CASE
33 BUSHING, CASE EXTENSION
34 SEAL ASSEMBLY, CASE EXTENSION OIL
35 BOLT, SPEED SENSOR RETAINING
36 SPEED SENSOR, INTERNAL TRANSMISSION
37 SEAL, 0-RING (ITSS TO CASE EXTENSION)
687 SHAFT, OUTPUT
RH0106-4L60-E

Figure 7 Extension and Associated Parts

35 BOLT, SPEED SENSOR RETAINING
36 SPEED SENSOR, INTERNAL
TRANSMISSION RH0105-4L60-E

Figure 6 Speed Sensor Removal

7A·14B·6 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

Pan And Filter Assembly

Figures
(m Clean
• Exposed ends of bottom pan screws and spray
with penetrating oil.
,...., Remove or Disconnect
1'. Screws (76), oil pan (75) and gasket (73).
2. Oil filter (72) and filter seal (71).
• Filter seal may be stuck in the pump.
ll'S'! Inspect
• Filter (72), open filter by prying the metal
crimping away from the top of the filter
(black) and pull apart. The filter may
contain evidence for root cause diagnosis.
- Clutch material.
- Bronze slivers indicating bushing wear.
- Steel particles. 8 CASE, TRANSMISSION
71 SEAL, FILTER
72 FILTER ASSEMBLY, TRANSMISSION OIL
Valve Body And Wiring Harness 73 GASKET, TRANSMISSION OIL PAN
75 PAN, TRANSMISSION OIL
Figures 9 through 14 76 SCREW, TRANSMISSION OIL PAN RH0107-4L60-E

,...., Remove or Disconnect Figure 8 Pan, Filter and Seal Removal

Figures 9 and 10
1. Electrical connections from components.
2. TCC Solenoid bolts (68) and solenoid assembly
(66) with 0-ring seal (65) and wiring harness.
3. Pressure switch assembly bolts (70) and pressure
switch assembly (69).
4. Accumulator cover bolts (58 and 59) and 1-2
accumulator cover and pin assembly (57).
5. 1-2 accumulator piston (56) and seal (55).
6. Spring (54).
7. Dipstick stop bracket (93).

93 62 364 59

58 BOLT, ACCUMULATOR COVER

59 BOLT, ACCUMULATOR COVER
62 BOLT, VALVE BODY
64 BOLT, MANUAL DETENT SPRING
68 BOLT, HEX WASHER HEAD (SOLENOID)
70 BOLT, PRESSURE SWITCH ASSEMBLY
93 BRACKET, DIPSTICK STOP
364 BOLT, FORWARD ACCUMULATOR COVER
RH0108-4L60-E-R1

Figure 9 Valve Body Bolt Locations

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-7

88 340 63
63 SPRING ASSEMBLY, MANUAL DETENT
88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE
340 VALVE, MANUAL
RH0110-4L60-E

Figure 11 Manual Valve Link

8 CASE, TRANSMISSION
60 VALVE ASSEMBLY, CONTROL BODY
62 BOLT, VALVE BODY
63 SPRING ASSEMBLY, MANUAL DETENT
64 BOLT, MANUAL DETENT SPRING
66 SOLENOID ASSEMBLY, WIRING HARNESS AND
69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE
70 BOLT, PRESSURE SWITCH ASSEMBLY
93 BRACKET, DIPSTICK STOP RH0109-4L60-E-R1

Figure 10 Control Valve and Pressure Switch Assembly

E3 Remove or Disconnect

Figures 9, 11 and 12
1. Bolt (64) and manual detent spring assembly
(63).
2. Wiring harness retaining bolts.

l••I Remove or Disconnect

Figures 11 through 14
1. Remaining valve body bolts (62).
2. Manual valve link (89).
3. Control valve assembly (60).
4. Bolts (58 and 59), accumulator cover (57), 43 PIN, ACCUMULATOR PISTON
44 PISTON, 3-4 ACCUMULATOR
piston (56) and spring (54). 46 SPRING, 3-4 ACCUMULATOR
5. Bolts (77) and plate (53). 47 GASKET, SPACER PLATE TO CASE
48 PLATE, VALVE BODY SPACER
6. Spacer plate (48) and spacer plate gaskets (47 52 GASKET, SPACER PLATE TO VALVE BODY
and 52). 53 PLATE, SPACER PLATE SUPPORT
7. Spring (46), piston (44), and pin (43). 54 SPRING, 1-2 ACCUMULATOR
56 PISTON, 1-2 ACCUMULATOR
• Seven checkballs are located under the 57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR
valve body and one is located in the case. 58 BOLT, ACCUMULATOR COVER
The large copper flash colored ball is #1 59 BOLT, ACCUMULATOR COVER
checkball (91). 77 BOLT, SPACER PLATE SUPPORT RH0111-4L60-E

Figure 12 Accumulator Assembly, Spacer Plate

and Gaskets
7A-14B-8 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

#8 #4

#3 #2 #12
2 3RD ACCUMULATOR 38 PLUG, TRANSMISSION CASE (ACCUM. BLEED)
3 REVERSE INPUT 40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM.
4 3-4 CLUTCH EXHAUST 91 NO. 1 CHECKBALL
5 OVERRUN CLUTCH FEED 92 SCREEN, TCC
6 OVERRUN CLUTCH CONTROL
8 1-2 UPSHIFT
12 FORWARD CLUTCH ACCUM. RH0112-4L60-E RH0113-4L60-E-R1

Figure 13 Valve Body Checkballs Figure 14 Case Checkballs and Filters

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-9

Transmission End Play Check

A DIAL INDICATOR
Figures 15 and 16 B 278mm(11")BOLT
C LOCK NUT
Tools Required:
J 24773-A Oil Pump Remover
J 25022-A End Play Adaptor (245 mm)
J 34725 End Play Adaptor (298 mm)
J 25025-7 A Post
Dial indicator
J 24773-A
As a diagnostic aid, transmission end play should
be checked prior to removing the internal parts. If the
end play is not within specifications, you should watch
for possible worn or misassembled parts during
disassembly.

l@I Measure
Figure 16 End Play Check
RH0115-4L60-E

1. Remove an oil pump bolt (2) and install a 278

mm ( 11 inch) bolt and locknut or J 25025-7 A. Oil Pump Assembly
2. Install J 25022-A or J 34725 as shown.
3. Install J 24773-A as shown. Figures 17 and 18
4. Install dial indicator. Tools Required:
A. Set to zero. J 37789-A Oil Pump Remover and Installer
B. Pull up on J 24773-A. J 39119 Adapter
C. End play should be 0.13 to 0.92 mm (0.005
to 0.036 inch). I+-+! Remove or Disconnect
1. 0-ring seal (618).
2. All oil pump bolts (2) and 0-rings (3).
3. Slide J 39119 over stator shaft until it locks
under splines.
4. Oil pump assembly (4) with J 37789-A.
5. Oil pump to case seal (5) and gasket (6).
6. Reverse input clutch to oil pump thrust washer
(601).

A 298mm TURBINE SHAFT

B 245mm TURBINE SHAFT =:51- 0

THE SOLENOID ASM. AND OIL FILTER MUST BE REMOVED

BEFORE OIL PUMP REMOVAL RH0116-4L60-E
RH0114-4L60-E
Figure 17 Oil Pump Removal
Figure 15 End Play Tool
7A-14B-10 4L60~E AUTOMATIC TRANSMISSION UNIT REPAIR

2-4 Band, Reverse Input Clutch, Input Clutch

And Input Gear Set
Figures 18 through 20
Tools Required:
J 29837 Output Shaft Support Fixture
J 34627 Snap Ring Pliers

,...., Remove or Disconnect

Figures 18 and 20
1. Reverse input clutch (605) and input clutch
(621) together.
• Grasp the turbine shaft and lift.
2. Band anchor pin (41 ).
3. The 2-4 band assembly (602).
4. Input sun gear (658).

E3 Install or Connect
Figures 19 and 20

• J 29837 as shown .
[I] Important
• Output shaft (687) may fall free when
retaining ring (661) is removed if J 29837
is not used.

8 CASE, TRANSMISSION
687 SHAFT, OUTPUT RH0118-4L60-E
2 BOLT, PUMP TO CASE
3 0-RING, PUMP TO CASE BOLT
4 PUMP ASSEMBLY, OIL Figure 19 Output Shaft Support Fixture
5 SEAL, OIL (PUMP TO CASE)
6 GASKET, PUMP COVER TO CASE
8 CASE, TRANSMISSION ,...., Remove or Disconnect
41 PIN, BAND ANCHOR
601 WASHER, THRUST (PUMP TO DRUM) Figure20
602 BAND ASSEMBLY, 2-4
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT 1. Retaining ring (661) with J 34627. Do not
CLUTCH
621 HOUSING AND SHAFT ASSEMBLY, INPUT
overexpand the ring.
658 GEAR, INPUT SUN RH0117-4L60-E 2. Input carrier assembly (662).
Figure 18 Input Clutch Removal
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-11

3. J 29837 and output shaft (687). Reaction Gear Set

[I] Important Figure21
• The manufacturer assembles the output l+-..1 Remove or Disconnect
shaft and reaction internal gear with
adhesive for ease of assembly. If these parts 1. Input internal gear (664) and reaction carrier
have not become separated during use, the (666).
output shaft will come out later along with 2. Reaction sun shell (670) and thrust washer
the reaction internal gear. (669).
4. Thrust bearing assembly (663). 3. Reaction sun shell to inner race thrust washer
(674).
4. Lo and reverse support to case retainer ring
,. -----661 (676).
C,)----- 5. Lo and reverse clutch support retainer spring
662
(680).
6. Reaction sun gear (673).
7. Lo and reverse inner race (675), roller assembly
~~663
(678), support assembly (679) and reaction
~ 8 carrier assembly (681).
8. Lo and reverse clutch plates (682).
9. Reaction internal gear (684) and thrust bearing
assembly (683).
10. Reaction gear support to case bearing (692).

8 CASE, TRANSMISSION
661 RET., OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT)
RH0119-4L60-E

Figure 20 Input Carrier Removal

7A-14B-12 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

Lo And Reverse Clutch Parts

664
666 Figures 22, 23 and 25
669 Tools Required:
J 34627 Snap Ring Remover/Installer
J 23327 Clutch Spring Compressor
670
,...., Remove or Disconnect
673 1. Bolts (715) and parking lock bracket (710).

674 [I] Important

675 • Due to interference, the parking pawl may

have to be removed before removing or
installing the low and reverse piston.
676
A. Parking pawl shaft plug (78) with a #4
678 screw extractor.
679 B. Parking pawl pivot shaft (79) with a
J
680 681
magnet.
C. Parking pawl (81) and return spring
(80).
697
2. Install tool J 23327.
3. Lo and reverse clutch retainer ring (693) with
J 34627.
4. Lo and reverse clutch spring assembly (694).
5. Lo and reverse clutch piston (695).
• Apply air pressure in the case apply
passage.

8 CASE, TRANSMISSION
664 GEAR, INPUT INTERNAL
J 23327
666 SHAFT, REACTION CARRIER
669 WASHER, THRUST (REACTION SHAFT/SHELL)
670 SHELL, REACTION SUN
673 GEAR, REACTION SUN
674 WASHER, THRUST (RACE/REACTION SHELL) 693
675 RACE, LO AND REVERSE ROLLER CLUTCH
676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
679 SUPPORT ASM., LO AND REVERSE CLUTCH
680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
SUPPORT RETAINER)
681 CARRIER ASSEMBLY, REACTION
682A PLATE, LO AND REVERSE CLUTCH (WAVED)
8 CASE, TRANSMISSION
6828 PLATE, SPACER LO AND REVERSE CLUTCH (SELECTIVE) 693 RING, LO AND REVERSE CLUTCH RETAINER
682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER) 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
6820 PLATE, LO AND REVERSE CLUTCH (STEEL) 695 PISTON, LO AND REVERSE CLUTCH RH0121-4L60-E
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
SUPPORT)
Figure 22 Lo and Reverse Snap Ring Removal
684 GEAR, INTERNAL REACTION
685 SUPPORT, INTERNAL REACTION GEAR
692 BRG., REACTION GEAR SUPPORT TO CASE
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH
697 DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
RH0120-4L60-E

Figure 21 Reaction Gear Set Removal

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-13

A
A APPLY AIR PRESSURE HERE TO REMOVE LO AND
REVERSE PISTON FROM THE CASE
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH 78 PLUG, STEEL CUP
695 PISTON, LO AND REVERSE CLUTCH 79 SHAFT, PARKING BRAKE PAWL
RH0122-4L60-E 80 SPRING, PARKING PAWL RETURN
81 PAWL, PARKING BRAKE
Figure 23 Lo and Reverse Piston Removal 82 SEAL, MANUAL SHAFT
83 RETAINER, MANUAL SHAFT
84 SHAFT, MANUAL
85 ACTUATOR ASSEMBLY, PARKING LOCK
Inner Manual Linkage 86 BRACKET, PARKING LOCK
87 BOLT, PARKING LOCK BRACKET
Figure24 88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE
I+--+! Remove or Disconnect 90 NUT, HEX HEAD
RH0123-4L60-E
1. Inside manual shaft nut (90).
2. Manual shaft (84) and manual shaft retainer Figure 24 Parking Linkage
(83).
3. Parking lock actuator assembly (85) and inside
detent lever (88). Manual Shaft Seal Replacement
Figure25
l+--+I Remove or Disconnect
• Manual shaft seal (82).
- Pry out with a screwdriver.

1-++-I Install or Connect

• New manual shaft seal (82).
- Tap into place using a 14 mm socket.
7A-148-14 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

82
84

8 CASE, TRANSMISSION
82 SEAL, MANUAL SHAFT 8 CASE, TRANSMISSION
84 SHAFT, MANUAL RHO 124-4L60-E 9 VENT ASSEMBLY, TRANSMISSION RH0125-4L60-E

Figure 25 Manual Shaft Seal Figure 26 Case Vent Assembly

IL•! Inspect Case

Figure24 Figures 26, 27 and 28
• Actuator rod (85) for damage.
• Inside detent lever (88) for damage or cracks. !l•! Inspect
• Manual shaft (84) for damage or burrs. • Case (8) exterior for cracks or porosity.
• Manual detent 'spring assembly (63) for roller • Case to valve body face for damage,
freeness or damage. interconnected oil passages and flatness.
E3 Install or Connect - Face flatness can be checked by inspecting
the spacer plate to case ·gasket for proper
Figure24 land impressions.
• Parking lock actuator (85) onto inside detent • Vent assembly (9) for damage.
lever (88).
• Air check all oil passages.
• Manual shaft (84) into case (8) and inside detent
lever (88). - See diagnosis section for oil passage
• Inside manual shaft nut (90) onto manual shaft identification.
(84). • 2-4 servo bore for:
~ lighten - Damage, porosity, or burrs.
- Any sharp edges (i.e. - oil passages, slots
• Nut (90) to 31 N•m (23 lb. ft.) for retaining ring removal - remove if
• Manual shaft retainer (83) onto manual shaft found).
(84).
• Orifice cup plug (11) in servo bore for debris
COMPONENT REPAIR AND or damage.
TRANSMISSION REASSEMBLY • Third accumulator bore for:
- Porosity, damage, or burrs.
The assembly of some components will require
use of an assembly lube. It is recommended that - Pin damage (43).
Transjel™ J 36850 or equivalent be used during - Orifice cup plug (42) damaged or plugged.
assembly. • Speed sensor bore for:
NOTICE: Do not use any type of grease to retain - Damage.
parts during assembly of this unit. Greases other
than the recommended assembly lube will change - Sharp edges.
transmission fluid characteristics and cause - Porosity.
undesirable shift conditions and/or filter clogging. • All bolt holes for thread damage
Case Assembly - Heli-coil to repair.
• Cooler connectors (10) for:
(!ll Clean
- Damage.
• Thoroughly with solvent. - Proper torque 38 N•m (28 lb. ft.).
• Airdry.
- Do not wipe with cloth.

• Case interior for:
- Damaged ring grooves or casting flash.
- Clutch plate lugs worn or damaged.
- Bushing (33) scored, worn, or damaged (see
Bushing Replacement).
A 2-4 SERVO BORE
B SERVO EXHAUST HOLE
C 2ND 7 4TH BAND APPLY PASSAGE
D 3RD ACCUM. PRESSURE TAP PASSAGE
11 PLUG, CASE SERVO
40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM.
Figure 27 2-4 Servo Bore
A 3-4 ACCUMULATOR BORE
38 PLUG, TRANSMISSION CASE
(ACCUM. BLEED)
Figure 28 Third Accumulator Bore
4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-15
Third Accumulator Retainer and Ball Assembly
Figure29
IL1t! Inspect
• Ball for:
- Presence.
- Sticking or leaking.
• Retainer for:
- Presence.
- Loose.
- Incorrect seating.
- Restricted feed slots.
Retainer and Ball Assembly Leak Check
Procedure
Figure29
1. Install the servo assembly (12-26) into the servo
bore.
2. Install the servo cover (28) and retainer (29).
3. Pour a suitable solvent into the accumulator
bore.
IL1t! Inspect
• Watch for leakage inside the case.
• If leakage is observed, replace the third
accumulator retainer and ball assembly.
Replacement Procedure-Third Accumulator
Retainer and Ball Assembly
RH0061-4L60-E Figures 29 and 30
Tools Required:
6.3 mm (#4) Screw Extractor
9.5 mm (3/8 inch) diameter metal rod
,...., Remove or Disconnect
• Third accumulator retainer and ball assembly
(40). '
- Use 6.3 mm (#4) screw extractor.
E3 Install or Connect
Figures 29 and 30
• A new third accumulator retainer and ball
RHO 126·4L60-E assembly.
Oil feed slots in the retainer must line up
with oil passage in the servo bore. To be
certain of correct··installation depth, scribe
a mark at 42.0 mm (l.653 inch)on the 9.5
mm (3/8 inch) diameter metal rod. Use. it
to seat the third accumulator and ball
assembly as shown. When the scribed line
is flush with the case face, installation depth
is correct.
 7A-14B-16 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

l·H·I Install or Connect

Figure32
1. Piston seals (696) onto the piston (695).
• Lubricate with Transjel™ J 36850 or
equivalent.
D~
2. Piston (695) into the case.
• Index the piston with the notch in the
bottom of the case.
3. Spring assembly (694) onto the piston.
• Flat side of the retainer upward.
A 3RD ACCUMULATOR BORE 4. J 23327 over the spring assembly.
C CASE INTERIOR • Compress the spring assembly past the ring
D 2-4 SERVO BORE
groove in the case hub.
40 RETAINER & BALL ASSEMBLY, 3RD ACCUM.
RH0127-4L60-E 5. Retainer ring (693) into the case hub ring groove
with J 34627.
Figure 29 Leak Check - 3rd Accumulator

DRIVE UNTIL SCRIBE MARK

IS FLUSH WITH CASE RH0128-4L60-E

Figure 30 Third Accumulator Retainer and. Ball Asm. -

Installation

Lo and Reverse Clutch Piston

Figures 31 and 32
Tools Required:
J 34627 Snap Ring Remover/Installer 8 CASE, TRANSMISSION
693 RING, LO AND REVERSE CLUTCH RETAINER
J 23327 Clutch Spring Compressor 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH
696 SEAL, TRANSMISSION (LO AND REVERSE CLUTCH -
IL'S'I Inspect OUTER, CENTER, INNER) RH0129-4L60-E
Figure31
Figure 31 Lo and Reverse Piston
• Lo and reverse piston (695) for:
- Porosity or damage.
- Ring groove damage.
• Piston seals (696) for nicks or cuts.
• Spring assembly (694) for damage.
• Retainer ring (693) overstressed.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A~14B-17

Parking Pawl
Figure33
IL'l'I Inspect
• Parking pawl (81) for cracks, burrs, or damage.
• Parking pawl return spring (80) for distortion
or damage.
• Parking pawl pivot shaft (79) for damage and
freeness of fit with the parking pawl.
l·u·I Install or Connect
Figure33
8 CASE, TRANSMISSION 1. Parking pawl (81) and parking pawl return
693 RING, LO AND REVERSE CLUTCH RETAINER spring (80) into the case.
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH 2. Parking pawl pivot shaft (79) into the parking
RH0121-4L60-E
pawl (81) and the case.
Figure 32 Installing Lo and Reverse Snap Ring • Check for proper operation.
3. Retaining plug (78) into the case.
• Coat the plug with Loctite® sealant or
equivalent and install it with a hammer and
86 85
punch.

Reaction Internal Gear and Carrier Assembly

Figures 34, 35 and 36
IL'l'I Inspect
• Reaction internal gear (684) and support (685)
for:
- Proper assembly.
- Stripped splines.
- Cracks.
- Teeth or lug damage.
- Thrust bearing assemblies (683 and 692)
for drunage.
• Lo and reverse clutch plates (682) for:
81 82 - Composition material wear, heat damage,
80 or delamination.
- Heat damage or surface finish damage to
steel plates.
• Reaction carrier assembly (681) for:
78 PLUG, STEEL CUP
79 SHAFT, PARKING BRAKE PAWL - Pinion gear damage.
80 SPRING, PARKING PAWL RETURN - Excessive pinion washer wear.
81 PAWL, .PARKING BRAKE
82 SEAL, MANUAL SHAFT - End play exceeding 0.61 mm (0.024 inch).
83 RETAINER, MANUAL SHAFT - Proper pinion staking.
84 SHAFT, MANUAL
85 ACTUATOR ASSEMBLY, PARKING LOCK - Keystoned pinion gears (pinions must tum
86 BRACKET, PARKING LOCK freely).
87 BOLT, PARKING LOCK BRACKET - Damaged or worn thrust bearing.
88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE - To check the captive thrust bearing in the
90 NUT, HEX HEAD carrier for wear, place a bushing or an
RHO 123-4L60-E output shaft sleeve on the bearing race (do
Figure 33 Parking Pawl Installation
not contact the pinion gears) and tum it
with the palm of your hand. Any
imperfections will be felt through the
bushing.
7A-14B-18 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

• Retain with Transjel™ J 36850 or

equivalent.
2. Reaction internal gear and support (684 and
685) onto the bearing as shown.
3. Reaction carrier to support thrust bearing
assembly (683) onto the support (685).
A • Outer bearing race goes toward the support.
4. Reaction carrier (681) onto the thrust bearing.

A PINION GEAR END PLAY -

.20mm/.60mm (.008"/.024")
RH0131-4L60-E
I
Figure 34 Pinion End Play Check

681 683 685 692

8 CASE, TRANSMISSION
681 CARRIER ASSEMBLY, REACTION
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
SUPPORT)
685 SUPPORT, INTERNAL REACTION GEAR
692 BRG., REACTION GEAR SUPPORT TO CASE
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
690 SLEEVE, OUTPUT SHAFT RH0133-4L60-E
RH0132-4L60-E

Figure 36 Reaction Internal Gear and Carrier Bearing

Figure 35 Captive Thrust Bearing Check
Locations

Reaction Internal Gear and Support Lo and Reverse Clutch Spacer Plate Selection
Figure 41
Figures 37 through 40
E3 Install or Connect Tools Required:
1. Reaction gear support to case bearing (692) onto Scale
the case hub as shown. Straight edge
• Outside bearing race goes toward case hub.
 4L60·E AUTOMATIC TRANSMISSION UNIT REPAIR 7A·14B-19

679

INSTALL THE APPROPRIATE SELECTIVE

SPACER PLATE TO THE FINAL
6828 ASSEMBLY AFTER DIMENSION "D"
IS OBTAINED. IDENTIFICATION SIDE UP.

679 SUPPORT ASM., LO AND REVERSE CLUTCH

682A PLATE, LO AND REVERSE CLUTCH (WAVED)
6828 PLATE, SPACER LO AND REVERSE CLUTCH (SELECTIVE)
682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER)
6820 PLATE, LO AND REVERSE CLUTCH (STEEL)
STACK UP FOR
MEASURING
RHO 134-4L60-E

Figure 37 Measuring For Spacer Plate Selection

3. Measure the height of the clutch pack from the

II) Measure
work surface to the top of the lo and reverse
Figures 37, 38 and 39 clutch support (dimension D).
1. To measure for proper selective spacer plate, 4. Use dimension D to select the proper thickness
stack the lo and reverse assembly on a flat of the selective spacer plate for assembly.
surface in the following order: 5. Install the proper selective spacer plate between
A. One waved plate (682B). the wave plate and the first composition clutch
B. Five composition and four steel plates plate with the identification side up.
(682), starting with one composition plate 6. The overall height for dimension D with the
and alternating with steel. selective spacer plate included should be 29.22
C. Lo and reverse clutch support (679). to 29.90 mm (1.20 to 1.24 inch).
2. Apply an evenly distributed load to the top of
the lo and reverse support assembly (679). Light LO AND REVERSE CLUTCH
pressure (approximately 22 Nor 5 lbs.) on the QTY. THICKNESS
lo and reverse support assembly (679) will
provide the correct dimension for measurement. PLATE - WAVED 1
2.42mm
(.096")
NOTICE: Excessive pressure will start to flatten
PLATE - SELECTIVE 1 SEE FIG. 39
the wave plate resulting in an inaccurate
measurement. PLATE - COMP. FACED 5
2.25mm
(.088")

1.75mm
PLATE - FLAT STEEL 5
(.069")

RH0135-4L60-E

Figure 38 Lo and Reverse Clutch Plate Chart

7A-14B-20 4Lu0-E AUTOMATIC TRANSMISSION UNIT REPAIR

LO AND REVERSE CLUTCH SPACER PLATE SELECTION CHART

IF GAGE DIMENSION uDu 1$ USE THIS SELECTIVE PLATE

FROM TO IDENTIFICATION PLATE THICKNESS

28.065mm 27.545mm 1.684mm 1.829mm

NONE
(1.102") (1.081") (.066") (.072")

28.586mm 28.066mm 1.314mm 1.168mm

0
(1.122") (1.102") (.052") (.046")

27.544mm 27.026mm 2.198mm 2.344mm

1
(1.081") (1.061") (.087") (.092")

RH0136·4L60-E

Figure 39 Lo and Reverse Spacer Plate Selection Chart

1.. +I Install or Connect

Figures 38 and 40
1. Waved plate (682A).
2. Correct selective spacer plate (6828), from
selection procedurv.
3. Lo and reverse clutch plates (682) into case
lugs.
• Start with a composition plate and alternate
with steel.
• Index with the splines of the reaction carrier
and the case as shown.

8 CASE, TRANSMISSION
682 PLATE ASSEMBLY,
LO AND REVERSE CLUTCH

, 8 CASE, TRANSMISSION
8 681 CARRIER ASSEMBLY, REACTION
682 PLATE ASSEMBLY, LO AND REVERSE CLUTCH
682A PLATE, LO AND REVERSE CLUTCH (WAVED)
6828 PLATE, SPACER LO AND REVERSE CLUTCH
(SELECTIVE)
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
SUPPORT)
RH0137-4L60-E
684 GEAR, INTERNAL REACTION
685 SUPPORT, INTERNAL REACTION GEAR
Figure 40 Lo and Reverse Clutch Plates Properly 692 BRG., REACTION GEAR SUPPORT TO CASE
Installed 697 DEFLECTOR, OIL (HIGH OUTPUT
MODELS ONLY) RH0138·4L60-E

Figure 41 Reaction Internal Gear and Carrier Assembly

Installation
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A~14B-21

Lo and Reverse Clutch Support Assembly • Support assembly for:

- Cracks or damaged lugs.
Figures 42, 43 and 44
,...., Install or Connect
l+-..1 Remove or Disconnect
Figure42 Figures 42, 43 and 44

1. Inner race (675) from the support assembly. 1. Roller clutch assembly (678) into the cam and
support assembly (679).
2. One retainer ring (677).
2. Support and roller assembly into the case with
3. Roller clutch assembly (678). the hub down.
3. Inner race (675) into the roller assembly.
• Tum inner race (675) while inserting.
-------677 A. Push down for full engagement.
B. Bottom tangs will be flush with carrier
hub when properly installed.
C. Check for proper operation by rotating
the inner race as shown in Figure 42.
4. Support retainer spring (680) into the case.
• Insert between the case lug and the one
open notch in the support.

680
~--- 679

RH0140-4L60-E

Figure 43 Lo and Reverse Support and Roller Asm.

Installation
A LOCKED UP
B FREE WHEELS
675 RACE, LO AND REVERSE ROLLER CLUTCH
677 RING, LO AND REVERSE RETAINER (ROLLER 680
ASSEMBLY/CAM)
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
679 SUPPORT ASM., LO AND REVERSE CLUTCH
680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
SUPPORT RETAINER) 679
RH0139-4L60-E

Figure 42 Lo and Reverse Clutch Support Assembly

IL•I Inspect
Figure 42
• Inner race (675) for damage and surface finish. 8 CASE, TRANSMISSION
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
• Roller clutch assembly (678) for: 679 SUPPORT ASM., LO AND REVERSE CLUTCH
- Damaged rollers. 680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
- Broken springs. SUPPORT RETAINER) RH0141-4L60-E

• Cam for: Figure 44 Support Spring - Installed

- Loose cam.
- Surface finish.
 7A·14B-22 4L60·E AUTOMATIC TRANSMISSION UNIT REPAIR

Reaction Sun Gear and Shell

Figure45

IL•I Inspect
• Reaction sun gear (673) for:
- Nicked, scored, or worn bushing (See
Bushing Replacement).
- Damaged spline or teeth.
- Loose or weak retaining ring (do not
remove this ring, except to replace it.).
• Reaction sun shell (670) for:
- Stripped or worn splines.
- Broken hub.
- Bent tangs.
• Lo and reverse inner race to reaction sun gear
shell thrust washer (674) for wear or damage.
• Reaction shaft to reaction sun gear shell bronze
thrust washer (669) for wear or damage.

E3 Install or Connect
Figure45
1. Reaction sun gear retainer ring (671) onto the
reaction sun gear, if previously removed.
2. Reaction sun gear (673) into the reaction carrier. 8 CAST, TRANSMISSION
• Index the teeth with the pinion gears. 669 WASHER, THRUST (REACTION SHAFT/SHELL)
670 SHELL, REACTION SUN
3. Thrust washer (674) onto the lo and reverse 671 RING, REACTION SUN GEAR RETAINER
support inner race. 673 GEAR, REACTION SUN
674 WASHER, THRUST (RACE/REACTION SHELL)
• Index the four locating ears into the inner 675 RACE, LO AND REVERSE ROLLER CLUTCH
race. 676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
4. Reaction sun gear shell (670) onto the reaction
sun gear. RH0142-4L60-E

5. Bronze thrust washer (669) onto the reaction Figure 45 Reaction Sun Gear and Shell Installation
sun gear shell.
• Index tangs into the shell.
ll•I Inspect
Figures 46 and 47
Input Internal Gear and Reaction Shaft • Reaction carrier shaft (666) for:
Figures 46 and 47 - Scored, damaged, or worn bushings (see
Bushing Replacement).
J+..I Remove or Disconnect - Cracked shaft.
Figure46 - Damaged spline or gear teeth.
1. Retainer ring (668) from input internal gear
- Under cut around the shaft from
(664). interference with the sun gear.
2. Reaction carrier shaft (666) from the input
internal gear.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-23

• Input internal gear (664) for:

- Cracks.
E3 Install or Connect
Figure 47
- Damaged spline or gear teeth.
• Input carrier to reaction shaft thrust bearing 1. Place new rotor over output shaft.
(663) for wear or damage. 2. Place J 36352-4 in groove on output shaft.
• Output shaft (687) for: 3. Place J 36352-6 on shaft and press to make
- Plugged or restricted lube passages. contact with J 36352-4.
- Damaged splines or ring groove.
- Damaged governor drive gear teeth. REMOVAL INSTALLATION

- Burrs or damage to the front of the shaft at

PRESS
seal area. (Polish with crocus cloth if
necessary).
- Burrs or damage to bearing journals.
J 36352-4

664 666 668 J 36352-6

699
687

687 SHAFT, OUTPUT

699 ROTOR, INTERNAL TRANSMISSION SPEED SENSOR

664 GEAR, INPUT INTERNAL RH0144-4L60-E

666 SHAFT, REACTION CARRIER
668 RING, REACTION SHAFT/INTERNAL.GEAR RETAINER Figure 47 Transmission Output Speed Sensor Rotor
RH0143-4L60-E

Figure 46 Input Internal Gear and Reaction Shaft Input Internal Gear and Output Shaft
Figures 48 and 49
Transmission Output Speed Sensor Rotor
Tool Required:
Figure47
J 29837·0utput Shaft Support Fixture
Tools Required:
J 21427-01 Speedometer Gear Puller E3 Install or Connect
Adapter 1. Reaction shaft (666) into the input internal gear
J 8433 Speedometer Gear Puller (664).
J 36352-6 "C" Washer 2. Retainer ring (668) into the input internal gear.
J 36352-4 Rotor Installer 3. Input internal gear and shaft assembly into the
Mechanical press sun gear shell.
• Index the shaft spline into the reaction
IL11'1 Inspect carrier.
4. Thrust bearing (663) onto the reaction carrier
Figure47
shaft.
• Speed sensor rotor on output shaft for tooth • Outer race goes toward the reaction carrier
damage. shaft.
[I) Important 5. Output shaft (687) into the transmission.
• Index the splines with the mating parts.
• If rotor is damaged, replace it. Do not reuse a 6. J 29837 onto the case.
rotor that has been removed.
• Position upwards as far as possible to
l~•I Remove or Disconnect support the output shaft.
Figure47
• Install J 21427 with J 8433 and remove rotor.
7A-14B-24 4L60·E AUTOMATIC TRANSMISSION UNIT REPAIR

Input Carrier and Sun Gear

664~ Figure50
v663
Tool Required:
666 J 34627 Snap Ring Pliers

ll•I Inspect
• Input carrier assembly (662) for:
668 - Pinion gear damage.
- Excessive pinion washer wear - end play
should be 0.20 to 0.61 mm (0.008 to 0.024
inch).
- Proper pin stake.
- Keystoned pinion gears (pinion gears must
rotate freely).
- Damaged or worn thrust bearing.
• To check the captive thrust bearing in
the carrier for wear, place a bushing or
an output shaft sleeve on the bearing
8 CASE, TRANSMISSION race (do not contact the pinion gears)
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT) and tum it with the palm of your hand.
664 GEAR, INPUT INTERNAL Any imperfections will be felt through
666 SHAFT, REACTION CARRIER the bushing.
668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER
RH0145·4L60·E
• Input sun gear (658) for:
- Bushing damage or wear (see Bushing
Figure 48 Input Internal Gear Installation Replacement Procedure).
- Cracks.
- Damaged spline or gear teeth.

E3 Install or Connect
Figure50
1. Input carrier assembly (662) onto the output
shaft.
2. Retainer ring (661) into the output shaft ring
groove.
• Use care not to overexpand the ring during
installation.
• Do not reuse the old retainer ring if it has
been overexpanded.
3. Remove J 29837.
8 CASE, TRANSMISSION
4. Input sun gear (658) into the input carrier.
687 SHAFT, OUTPUT RH0118·4L60·E • Rotate the sun gear teeth into the pinion
gear teeth.
Figure 49 Output Shaft - Installation
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-25

3. The 3-4 clutch plates (654).

4. Five 3-4 clutch boost spring assemblies (600).
5. The 3-4 clutch apply plate (653).
6. The 3-4 clutch ring retainer plate (652).
7. Forward clutch backing plate retainer ring (651)
and backing plate (650).
8. Forward clutch sprag assembly (638-648).

605

~615
~ 616

621

8 CASE, TRANSMISSION
658 GEAR, INPUT SUN
661 RET., OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
RH0146-4L60-E

Figure 50 Input Carrier and Sun Gear - Installation

Input Clutch Assembly

Figures 51 through 55
Tools Required:
J 23456 Clutch Spring Compressor Press
J 23327-1 Clutch Spring Compressor
J 25018-A Clutch Spring Compressor
Adaptor
605 HOUSING AND DRUM ASSEMBLY, REVERSE
INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT/
SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
621 HOUSING AND SHAFT ASSEMBLY, INPUT
RH0147-4L60-E
Figure 51 Reverse Input and Input Clutches

El Remove or Disconnect
I+! Disassemble
Figure53
Figures 51 and 53
1. Input sun gear bearing assembly (637).
• Reverse. input clutch assembly (605) from the 2. Input housing to output shaft lip seal (636).
input clutch assembly (621).
3. Forward clutch plates (649).
• Oil pump to selective washer thrust bearing
(615). 4. Forward wave plate (648).
• Selective washer (616) .. 5. Forward clutch apply plate (646).
6. Overrun clutch plates (645).
1±1 Disassemble
I+! Disassemble
Figures 52 and 53
Figure53
1. Place the input clutch assembly (621) on the
bench with the turbine shaft through the bench 1. Install J 23456 and J 23327-1 with J 25018-A.
hole. • Compress overrun clutch spring assembly
2. The 3-4 clutch plate retainer ring (656) and the (634).
backing plate (655). 2. Overrun clutch retainer ring (635).
7A-14B-26 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

3. Overrun clutch spring assembly (634). • Check valve retainer and ball assembly (617)
4. Overrun clutch piston (632). for:
• Inner and outer lip seals (631). - Damage.
5. Forward clutch piston assembly (630). - The ball must move freely in the retainer.
• Inner and outer lip seals (629). - The retainer must be tight in the turbine
6. Forward clutch housing (628). shaft.
7. The 3-4 clutch spring assembly (626). • Feed passages for:
8. The 3-4 clutch apply ring (625) and piston (623). - Obstructions - blow air through passages.
• Inner and outer lip seals (624) from piston.
9. Forward clutch to input housing 0-ring seal Check Valve Retainer and Ball Assembly -
(622). Replacement Procedures
10. Four turbine shaft oil seal rings (619). Figures 53 through 64
Tools Required:
6.3 mm (#4) Screw extractor
9.5 mm (3/8 inch) diameter metal rod
6.35 mm (1/4 inch) diameter rod or drift
hammer
J 23456 Clutch Spring Compressor Press
J 23327-1 Clutch Spring Compressor
J 25018-A Clutch Spring Compressor
Adaptor
621 HOUSING AND SHAFT J 29882 Overrun Clutch Inner Seal
ASSEMBLY, INPUT RH0148·4L60-E Protector
Figure 52 Overrun Clutch Retainer Ring - Removal J 29883 Forward Clutch Inner Seal
Protector
lL!J Inspect
l••I Remove or Disconnect
Figures 54 and 55
Figure55
• Input housing for porosity or damage
1. Straighten the tangs of the retainer and remove
• Input housing and shaft assembly (621) for:
the ball.
- Spline wear or damage.
2. Check valve retainer.
- Three turbine shaft checkballs. • Use 6.3 mm (#4) Screw extractor.
A. The balls must not be loose or leaking.
B. The open hole is the lube oil passage
which feeds the output shaft.
l••I Install or Connect
Figure55
• Presence of orificed cup plug (698).
• Cracks at lube holes. • New check valve retainer and ball assembly
(617).
• Four turbine shaft oil seal ring grooves for
damage or burrs. A. Use the 9.5 mm (3/8 inch) metal rod.
- Seals must fit freely into the ring grooves. B. Seat the retainer 3.0 mm (1/8 inch) below
top surface of the turbine shaft.
C. Be certain the ball is loose.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-27

615 616 617 621 623 625 632 634 635 636

645A 6458 637 638 639 643 642 643 644 641 646 648 649A 6498 650 651

ILL. ILL.
NO. DESCRIPTION NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5) 646 PLATE, FORWARD CLUTCH (APPLY)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE 648 PLATE, FORWARD CLUTCH (WAVED)
WASHER 649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL)
616 WASHER, THRUST (SELECTIVE) 6498 PLATE, FORWARD CLUTCH (FIBER)
617 RETAINER AND BALL ASM., CHECK VALVE 650 PLATE, FORWARD CLUTCH BACKING (SEL.)
620 RETAINER AND CHECKBALL ASSEMBLY 651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
621 HOUSING AND SHAFT ASSEMBLY, INPUT 653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
623 PISTON, 3RD AND 4TH CLUTCH 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 6548 PLATE, 3RD AND 4TH CLUTCH (STEEL)
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
627 RETAINER AND BALL ASSEMBLY, FORWARD CLUTCH 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
HOUSING RETAINER
628 HOUSING, FORWARD CLUTCH 698 PLUG, ORIFICED CUP
630 PISTON, FORWARD CLUTCH
632 PISTON, OVERRUN CLUTCH
633 BALL, OVERRUN CLUTCH
634 SPRING ASSEMBLY, OVERRUN CLUTCH
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL)
6458 PLATE, OVERRUN CLUTCH (FIBER)
A FORWARD CLUTCH SPRAG ASSEMBLY
637 BEARING ASSEMBLY, INPUT SUN GEAR
638 SNAP RING, OVERRUN CL. HUB RETAINING
639 HUB, OVERRUN CLUTCH
641 RETAINER AND RACE ASSEMBLY, SPRAG
642 FORWARD SPRAG ASSEMBLY
643 RETAINER RINGS, SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER)
RH0149-4L60-E-R1

Figure 53 Input Clutch Assembly

7A-14B-28 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

ll'l'I Inspect
Figures 54 and 56
• Turbine shaft 0-ring seal (618) for:
- Damage.
- Nicks or cuts.
• Input housing check valve ball (620):
- The ball must move freely.
- Leak check the ball with solvent.

rn Important
• If the 3-4 clutch plates are burned or worn and
a cause is not found during diagnosis or
disassembly, replacement of the retainer and
checkball assembly may be required (Figure
54).

A LUBE PASSAGE
615 BEARING ASSEMBLY, STATOR SHAFT I SELECTIVE
WASHER
616 WASHER, THRUST (SELECTIVE)
620 RETAINER AND CHECKBALL ASSEMBLY USED WITH USED WITH
621 HOUSING AND SHAFT ASSEMBLY, INPUT 298mm CONVERTER 245mm CONVERTER
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT A SHAFT TURBINE
687 SHAFT, OUTPUT 618 SEAL, 0-RING (TURBINE SHAFT I SELECTIVE WASHER)
698 PLUG, ORIFICED CUP 621 HOUSING AND SHAFT ASSEMBLY, INPUT
RHO 150-4L60-E RH0152-4L60-E

Figure 54 Input Housing Check Valve Ball Figure 56 Views of the Input Housing

,~..I Remove or Disconnect

c Figure57
• Tap out retainer and ball assembly.

INSTALL E3 Install or Connect

Figures 55 and 57
• Using same tools, tap in retainer and ball
assembly until shoulder is seated in housing.

REMOVE B

A #4 EASY OFF
B TURBINE SHAFT
C 9.5mm (3/8") METAL ROD
617 RETAINER AND BALL ASM., CHECK VALVE
RH0151-4L60-E

Figure 55 Retainer and Ball Assembly- Replacement

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A~14B-29

1. Inner and outer 3-4 clutch lip seals (624) on the

(A)
5.715mm
3-4 clutch piston.
(1/4") • Seal lips must face away from the piston
DIAMETER hub.
ROD STOCK
• Lubricate the seals with Transjel™ J 36850
620
or equivalent.
2. The 3-4 clutch piston (623) into the input
housing as shown.
• Use care not to damage the seals.

621
624

623

REMOVAL

621 HOUSING AND SHAFT ASSEMBLY, INPUT

623 PISTON, 3RD AND 4TH CLUTCH
624 SEAL, 3RD AND 4TH CL. (INNER AND OUTER)
RHO 154-4L60-E

Figure 58 Input Housing and 3-4 Piston

A
INSTALLATION

ROD STOCK/DRIFT, 5.715mm (1/4") DIA.

ll•I Inspect
620 RETAINER AND CHECKBALL ASSEMBLY
Figures 59 and 60
621 HOUSING AND SHAFT ASSEMBLY, INPUT • Forward clutch housing (628) for:
698 PLUG, ORIFICED CUP
RH0153-4L60-E
- Proper checkball operation.
- Damage or distortion.
Figure 57 Retainer and Checkball Removal/Installation
- Burrs in seal areas.

ll•! Inspect
•
Cracks.
Forward clutch piston (630) and overrun clutch
Figure53 piston (632) for:
• The 3-4 clutch piston (623) for damage or - Porosity or damage.
porosity. - Ring groove damage.
• The 3-4 clutch apply ring (625) for: - Apply leg damage.
- Bent tangs. • Overrun spring assembly (634) for damage or
• The 3-4 clutch spring assembly (626) for distortion.
damage or distortion. • Input housing to output shaft lip seal (636) for
• The 3-4 clutch boost spring assemblies (600) damage or wear.
for damage or distortion.

Et) Assemble
III Assemble
Figures 59 and 60
Figure58
1. Forward clutch housing to input clutch housing
Position the input housing and shaft assembly 0-ring seal (622) as shown.
on the bench with the turbine shaft through a bench • Lubricate with Transjel™ J 36850 or
hole. equivalent.
7A-14B-30 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

631
J 29883
J 29882

632
2
BARS

1
BAR

621 HOUSING AND SHAFT ASSEMBLY, INPUT 621 HOUSING AND SHAFT ASSEMBLY, INPUT
622 SEAL, 0-RING INPUT TO FORWARD HSG. 623 PISTON, 3RD AND 4TH CLUTCH
623 PISTON, 3RD AND 4TH CLUTCH 625 RING, 3RD AND 4TH CLUTCH (APPLY)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 628 HOUSING, FORWARD CLUTCH
628 HOUSING, FORWARD CLUTCH 630 PISTON, FORWARD CLUTCH
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) 631 SEAL, OVERRUN CLUTCH (INNER AND OUTER)
630 PISTON, FORWARD CLUTCH 632 PISTON, OVERRUN CLUTCH

RH0155-4L60-E RH015&4L60-E

Figure 59 Forward Clutch and 3-4 Apply Ring - Figure 60 Overrun Piston - Installed
Installed

2. Inner and outer seals (629) on forward clutch
piston.
• Seal lips must face away from the piston
tangs as shown.
• Lubricate with Transjel™ J 36850 or
equivalent.
3. Forward clutch piston (630) into the forward
clutch housing.
• Use care not to damage the outer lip seal.
4. The 3-4 clutch spring assembly (626) onto the
3-4 clutch apply ring.
5. Forward clutch assembly onto the 3-4 clutch
spring assembly.
• The forward clutch piston apply legs must
be indexed with the 3-4 clutch apply ring
legs.
6. J 29883 on the input housing as shown.
7. Apply ring and forward clutch assembly into
the input housing as shown.
A. Hold the assembly by the apply ring legs
during installation.
B. Do not let the forward clutch piston
separate from the housing.
C. Firmly seat the assembly.
8. J 29882 on the input housing as shown.
9. Overrun clutch piston (632).
• Hub facing upward as shown.
• If all parts are properly seated to this point,
the overrun piston hub will be
approximately 4.7 mm (3/16 in.) below the
top of the snap ring groove in the input
housing hub.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148·31

!+f+! Assemble !l•! Inspect

Figures 61 and 62 • Overrun clutch plates (645) for:
1. Overrun clutch spring assembly (634) onto the - Composition plate damaged tangs,
overrun clutch piston. delamination, or excessive wear.
• Locate the springs on the piston tabs. - Steel plate damaged tangs, wear, or heat
damage.
2. J 23456 and J 23327-1 with J 25018-A onto the
overrun spring assembly. • Input sun gear bearing assembly (637) for:
• Compress springs (Do not over-compress). - Wear.
3. Retainer snap ring (635) into the snap ring - Flatness.
groove. - Damaged.
4. Input housing to output shaft lip seal (636). III Assemble
Figures 63 and 64
J 23456 1. Overrun clutch plates (645) into the input
housing.
• Overrun clutch plates are the smallest of
the three sets of plates in the input
housing.
• Index the plates as shown starting with a
steel plate and alternate with composition.
2. Thrust bearing assembly (637) onto the input
clutch hub. ·
621 HOUSING AND SHAFT • The inside race must face the input housing
ASSEMBLY, INPUT RH0148-4L60-E hub.
Figure 61 Overrun Clutch Retaining Ring - Installed • Retain with Transjel™ J 36850 or
equivalent.
3. Align the tangs on the two.composition overrun
clutch plates.

* ALIGN WIDE NOTCHES TO CASE LUGS

OVERRUN CLUTCH

621 636 637 687 MODEL FLAT STEEL COMP. FACED

621 HOUSING AND SHAFT ASSEMBLY, INPUT THICK- THICK-

636 SEAL, INPUT HOUSING TO OUTPUT SHAFT NO. NO.
N"ESS NESS
637 BEARING ASSEMBLY, INPUT SUN GEAR
687 SHAFT, OUTPUT .
ALL 2.248mm - 2.400mm 2.03mm
RH0157-4L60-E 2 2
MODELS (.089" - .094") (.079")
Figure 62 Input Hsg. to Output Shaft Lip Seal
RH0158-4L60-E

Figure 63 Overrun Clutch Plate Chart

7A-14B-32 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

• Forward sprag outer race (644) for:

- Spline damage.
- Surface finish damage.
- Plugged lubrication holes.

637 638 639 643 642 643 644 641

THE NOTCHES
SPRAG ABOVE.EACH
MUST POINT UP AS
SHOWN WHEN ASSEMBLED
INTO THE OUTER RACE
-w~~1
I rr:=J
c::::J

637 BEARING ASSEMBLY, INPUT SUN GEAR

638 SNAP RING, OVERRUN CL. H!..IB RETAINING
639 HUB, OVERRUN CLUTCH
641 RETAINER AND RACE ASSEMBLY, SPRAG
642 FORWARD SPRAG ASSEMBLY
643 RETAINER RINGS, SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER) RH0160-4L60-E
621 637 658
Figure 65 Forward Clutch Sprag Assembly
621 HOUSING AND SHAFT ASSEMBLY, INPUT
637 BEARING ASSEMBLY, INPUT SUN GEAR
658 GEAR, INPUT SUN
RH0159-4L60-E
1±1 Assemble
Figures 66, 67 and 68
Figure 64 Input Sun Gear Thrust Bearing
1. Forward clutch sprag assembly (642) into the
outer race.
Forward Clutch Sprag Assembly
• To correctly install, the notches in the sprag
Figures 65 through 71 cage must face upward as shown.
l+I Disassemble
2. One sprag retainer ring (643) onto the race and
retainer assembly.
Figure 65 • The flange on the retainer ring must face
1. Forward sprag outer race (644). away from the retainer.
2. Overrun clutch hub retaining snap ring (638) 3. Race and retainer assembly into the sprag
and clutch hub (639). assembly.
3. Forward clutch retainer and race assembly (641). A. To assemble, hold the outer race in your
left hand with your fingers supporting the
IL•I Inspect sprag at the recessed side of the outer race.
• Forward clutch sprag assembly (642) for: B. Insert the race and retainer assembly by
- Wear or damage. pushing in and turning to the left.
- Weak or broken springs. 4. The remaining retainer ring onto the sprag
- Damaged or missing retainer caps (brass). assembly.
• Overrun clutch hub (639) for: 5. Overrun clutch hub (639).
- Spline damage. 6. Overrun clutch hub retaining snap ring (638)
- Plugged lubrication holes. into the snap ring groove of the race and retainer
assembly.
- Damaged tangs.
7. Test the assembly for proper operation as shown
- Cracks. (Figure 68).
• Forward clutch retainer and race assembly (641)
for: II] Important
- Spline damage.
• If the assembly operates backwards, you
- Ring groove damage. have installed the sprag backwards.
- Surface finish damage. Reassemble correctly.
- Loose retainer.
 4L60-E AUTOMATIC TRANSMISSION UI\IIT REPAIR 7A·148-33

H+I Assemble
A
• Forward clutch sprag assembly into the input
clutch housing.
c 644
- Index the overrun clutch hub into the
overrun clutch plates.

!l'I'! Inspect
Figures 69 and 70
• Forward (649) and 3-4 clutch plates (654) for:
- Composition plate damaged tangs,
A RECESSED FACE
delamination, or wear.
B NOTCHES POINT UPWARD AS SHOWN - Steel plate damaged tangs, wear, or heat
C LIPPED EDGE damage.
642 FORWARD SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER) • Forward (650) and 3-4 clutch backing plates
RH0161-4L60-E
(655) for: ·
Figure 66 Sprag Assembly Procedure - Flatness.
- Surface finish damage.
- Burrs or nicks.
• Forward clutch apply plate (646) and spacer
plate (647) for:
- Flatness.
- Surface finish damage.
- Burrs or nicks.

643

644 FORWARD CLUTCH PACK

A PUSH IN AND TURN COUNTERCLOCKWISE TO INSTALL

641 RETAINER AND RACE ASSEMBLY; SPRAG
642 FORWARD SPRAG ASSEMBLY '
643 RETAINER RINGS, SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER) RH0162-4L60-E
ALIGN WIDE NOTCHES
Figure 67 Sprag Race and Retainer Assembly TO CASE LUGS
Procedure

600 3-4 CLUTCH PACK

~ LOCATE IN FIVE
PLACES AROUND
CLUTCH PACK

600

THE OVERRUN CLUTCH HUB MUST TURN

600
CLOCKWISE, BUT NOT COUNTERCLOCKWISE.
600 SPRING ASM., 3-4 CLUTCH BOOST (5)
639 HUB, OVERRUN CLUTCH RH0164-4L60-E
644 RACE, FORWARD CLUTCH (OUTER)
RH0163-4L60-E Figure 69 Forward and 3-4 Clutch Plates - Installed
Figure 68 Sprag Operation Check
7A-14B-34 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

• The 3-4 clutch apply plate (653) for:

- Flatness.

~:1
656 Bent tangs.
- Surface finish damage.

655 1-.!+1 Assemble

Figures 69 through 72
1. Forward clutch apply plate (646) into the input
clutch housing.
649A • Index as shown.
2. Waved steel forward clutch plate (648) into the
648 input clutch housing.
6548 • Index as shown.
646
3. The remaining forward clutch plates (649) into
654A
the input clutch housing.
• Start with a steel plate and alternate with
composition.
@ s;,i 653 4. Forward clutch selective backing plate (650).
621
5. Forward clutch retaining ring (651).

651 Forward Clutch Piston Travel Check

Figure 72
650 l@I Measure
1. With the overrun clutch and forward clutch fully
assembled in the Input Housing, check the end
clearance between the backing plate (650) and
the retaining ring (651) with two feeler gages.
2. Proper forward clutch backing plate travel
should be 0.75 to 1.60 mm (0.030 to 0.063
inch).
3. Select the proper backing plate from the chart
ILL. to obtain the correct clearance.
NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5)
FORWARD CLUTCH INFORMATION CHART
621 HOUSING AND SHAFT ASSEMBLY, INPUT
646 PLATE, FORWARD CLUTCH (APPLY) QUANTITY REQUIRED
648 PLATE, FORWARD CLUTCH (WAVED) PLATE TYPE THICKNESS
649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL) ALL MODELS
6498 PLAT!;, FORWARD CLUTCH (FIBER)
650 PLATE, FORWARD CLUTCH BACKING (SEL.) 4.30mm
APPLY PLATE 1
(.169")
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
WAVED STEEL 1.79mm
654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER) 1
CLUTCH PLATE (.070")
6548 PLATE, 3RD AND 4TH CLUTCH (STEEL)
655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.) FLAT STEEL 2.29mm
656 RING, 3RD AND 4TH CLUTCH BACKING PLATE 5
CLUTCH PLATE (.090")
RETAINER
COMPOSITION
1.78mm
FACED CLUTCH 5
(0.70")
PLATES

BACKING PLATE SELECTIVE 1

RH0166-4L60-E
RH0165-4L60-E-R1
Figure 71 Forward Clutch Plate Chart
Figure 70 Input Housing with Forward and 3-4 Clutch
Plates
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-35

FORWARD CLUTCH 3-4 CLUTCH

BACKING PLATE SELECTION INFORMATION CHART
ALL MODELS QUANTITY REQUIRED
PLATE TYPE THICKNESS
.75mm - 1.60mm ALL MODELS
BACKl NG PLATE JR AVEL = (. 030 .. _.063 .. )

PLATE THICKNESS IDENTIFICATION STEPPED 5.60mm

1
APPLY PLATE (.220")
6.97mm - 7.07mm
A
(.274" - .278")
tFLAT STEEL 1.78mm
1
6.38mm - 6.48mm CLUTCH PLATES (.070")
B
(.250" - .255")
FLAT STEEL 2.71mm
5.79mm - 5.89mm 5
(.227" - .232")
c CLUTCH PLATE (.107")

5.20mm - 5.30mm COMPOSITION

D 2.03mm
(.205" - .208") FACED CLUTCH 6
(0.79")
4.61mm - 4.71mm PLATES
E
(.180" - .185")
BACKING PLATE SELECTIVE 1

t SAME SPLINE CONFIGURATION AS APPLY PLATE

RH0168-4L60-E-R 1

Figure 73 3-4 Clutch Plate Chart

3-4 Clutch Piston Travel Check

621 HOUSING AND SHAFT ASSEMBLY, INPUT Figure 74
650 PLATE, FORWARD CLUTCH BACKING (SEL.)
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
RH0167-4L60-E
!@! Measure
• Check the end clearance between the backing
Figure 72 Forward Clutch Backing Plate Travel plate (655) and the first composition plate with
a feeler gage.
• Select the proper backing plate from the chart
3-4 Clutch Assembly to obtain the correct clearance for model you
are working on.
Figures 73 and 77
~ Assemble Clutch Air Check
1. The 3-4 clutch apply plate (653). Figure 75
• Index each leg into the apply ring legs. Air check the 3-4, forward and overrun clutches
2. The 3-4 clutch plates (654). by applying air pressure at the feed holes in the turbine
• Start with steel and alternate with shaft.· (When the overrun clutch is checked, the air
composition as shown in (Figure 77). will blow by the forward clutch piston lip seals and
• First steel plate has the same spline exit out the forward clutch feed hole in the turbine
configuration as apply plate. shaft.)
3. The 3-4 boost springs (600).
4. The 3-4 clutch backing plate (655) and retainer
ring (656).
• Chamfered side up.
7A-14B-36 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

3-4 BACKING PLATE SELECTION

MODEL BACKING PLATE *BACKING

TRAVEL PLATE

Use Backing Plate

Which Gives Correct Travel

DIM. I.D.

5.88mm - 5.68mm
A
(.231" - .224")

2.10mm - .90mm 4.99mm - 4.76mm

ALL B
(.083" - .035") (.196" - .187")

4.1 Omm - 3.90mm

(.161" - .154")
c

654

1 CONVERTER RELEASE 4 3-4 CLUTCH

2 OVERRUN CLUTCH 5 LUBE
3 FORWARD CLUTCH

RH0170-4L60-E

Figure 75 Turbine Shaft Fluid Passages

J 36418-1
621 HOUSING AND SHAFT ASSEMBLY, INPUT 619 J 36418-2A
654 PLATE ASSEMBLY, 3RD AND 4TH CLUTCH
655 PLATE, 3RD AND 4TH CLUTCH
BACKING (SEL.)
RH0169-4L60-E-R1
621
Figure 74 3-4 Backing Plate Selection Chart

Turbine Shaft Seals

Figure 76
Tools Required:
J 36418-1 Seal Installer
619 RING, OIL SEAL (SOLID)
J 36418-2A Seal Sizer 621 HOUSING AND SHAFT ASSEMBLY, INPUT
RH0171-4L60-E
l+f.,I Assemble
Figure 76 Turbine Shaft Oil Seal Rings
1. Install four turbine shaft oil seal rings (619)
using J-36418-1.

~ Adjust
• Adjust screw to obtain proper height.
2. Use J 36418-2A to size the seals after
installation.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-37

626 629 630 6458 648 6498

600

621

619

600 SPRING ASM., 3-4 CLUTCH BOOST (5) 641 RETAINER AND RACE ASSEMBLY, SPRAG
619 RING, OIL SEAL (SOLID) 642 FORWARD SPRAG ASSEMBLY
620 RETAINER AND CHECKBALL ASSEMBLY 643 RETAINER RINGS, SPRAG ASSEMBLY
621 HOUSING AND SHAFT ASSEMBLY, INPUT 644 RACE, FORWARD CLUTCH (OUTER)
622 SEAL, 0-RING INPUT TO FORWARD HSG. 645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL)
623 PISTON, 3RD AND 4TH CLUTCH 6458 PLATE, OVERRUN CLUTCH (FIBER)
624 SEAL, 3RD AND 4TH CL. (INNER AND OUTER) 646 PLATE, FORWARD CLUTCH (APPLY)
625 RING, 3RD AND 4TH CLUTCH (APPLY) 648 PLATE, FORWARD CLUTCH (WAVED)
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH 649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL)
628 HOUSING, FORWARD CLUTCH 6498 PLATE, FORWARD CLUTCH (FIBER)
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) 650 PLATE, FORWARD CLUTCH BACKING (SEL.)
630 PISTON, FORWARD CLUTCH 651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
631 SEAL, OVERRUN CLUTCH (INNER AND OUTER) 653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
632 PISTON, OVERRUN CLUTCH 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
634 SPRING ASSEMBLY, OVERRUN CLUTCH 6548 PLATE, 3RD AND 4TH CLUTCH (STEEL)
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
637 BEARING ASSEMBLY, INPUT SUN GEAR RETAINER
638 SNAP RING, OVERRUN CL. HUB RETAINING
639 HUB, OVERRUN CLUTCH RH0172-4L60-E-R1

Figure 77 Input Clutch Assembly

Reverse Input Clutch Assembly 2. Backing plate (613).

3. Clutch plates (612) and Belleville steel plate
Figures 78 through 83 (611).
Tools Required: 4. Install J 23327-1 and J 25018-A.
J 23327-1 Clutch Spring Compressor • Compress the spring assembly.
J 25018-A Clutch Spring Compressor 5. Spring assembly retainer ring (610) and spring
Adaptor assembly (609).
6. Reverse input clutch piston (607).
l+I Disassemble • Inner and outer lip seals (608).
Figures 78 and 79
1. Retaining ring (614) from reverse input
housing.
7A-14B-38 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

614

613

J 25018-A
6128 UNDER
J 23327-1

605 HOUSING AND DRUM ASSEMBLY,

REVERSE INPUT CLUTCH RH0174·4L60-E

Figure 79 Reverse Input Retainer Ring - Removal

612A
ll'l'I Inspect
Figures 78 and 80
611 • Backing plate (613) for:
610
- Damage.
- Distortion or flatness.
- Burrs or surface finish damage.
609
• Clutch Plates (612) for:
- Composition plate tang damage,
608 delamination, or wear.
Steel plate tang damage, wear, or heat
608
damage.
• Spring assembly (609) for distortion or damage.
• Piston (607) for:
607
- Damage or porosity.
- Ring groove damage.
• Housing and drum assembly (605) for:
- Damaged or worn bushings ( 603 and 606).
- Surface on the hub and outer housing.
605 - Leak at the weld.

ILL.
NO. DESCRIPTION
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT
CLUTCH .
607 PISTON ASM., REVERSE INPUT CLUTCH
608 SEALS, REVERSE INPUT CLUTCH
(INNER AND OUTER)
609 SPRING ASM., REVERSE INPUT CLUTCH
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE)
612A PLATE ASM., REVERSE INPUT CLUTCH (STEEL)
6128 PLATE, REVERSE INPUT CLUTCH (FIBER)
613 PLATE, REVERSE INPUT CLUTCH BACKING (SELECTIVE)
614 RING, REVERSE INPUT CL. RETAINING A CHECK FOR DISHING AT THIS POINT
605 HOUSING AND DRUM ASSEMBLY,
REVERSE INPUT CLUTCH RH0175-4L60-E

RH0173-4L60-E Figure 80 Check Reverse Input Housing For Dishing

Figure 78 Reverse Input Clutch Assembly
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-39

1±1 Assemble
Figures 78, 79, 81, 82 and 83
1. Inner and outer seals (608) on the piston.
• Lips must face away from the hub as
shown.
• Lubricate with transmission fluid.
2. Piston (607) into the housing and drum
assembly.
• Use an 8 mm feeler gage to position the lip
seals.
• Use care not to damage the seals.
3. Spring assembly (609).
• Large opening in the assembly goes
towards the piston.
4. Install J 23327-1 and J 25018-A.
A. Compress the spring assembly.
B. Install the retainer ring (610).
5. Belleville steel clutch plate (611).
6. Clutch plates (612). (4 steel and 4 composition
plates required).
• Start with a steel and alternate with
composition.
7. Backing plate (613).
• Chamfered side up ·
8. Retaining ring (614).
Reverse Input Clutch Backing Plate Selection
Figures 81, 82 and 83
l@I Measure
1. With the reverse input clutch fully assembled,
apply an evenly distributed load to the clutch
pack in the direction shown in Figure 81.
Medium pressure (approximately 89 N or 20
lbs.) on the backing plate applied by hand on
five evenly distributed points will obtain the
backing plate travel for measurement.
NOTICE: Excessive pressure will distort the
Belleville plate resulting in an inaccurate
measurement.
2. Using a feeler gage, measure between the snap
ring and the backing plate. Backing plate travel
should be 1.02 to 1.94 mm (0.040 to 0.076
inch).
3. Select the proper backing plate to obtain the
specified travel.

REVERSE INPUT CLUTCH

CHECK FOR
NO. THICKNESS
(.040"-.075")
BACKING PLATE 2.311 mm (.091 ")
TRAVEL BELLEVILLE PLATE 1
2.210mm (.087")

FLAT STEEL 2.045mm (0.81")

4
CLUTCH PLATE 1.892mm (0.75")

COMPOSITION FACED 1.880mm (.074")

4
CLUTCH PLATE 1.730mm (.068")

BACKING PLATE 1 SELECTIVE

RH0177-4L60-E

Figure 82 Reverse Input Clutch Plate Chart

REVERSE INPUT CLUTCH

BACKING PLATE SELECTION

ALL MODELS

1.02mm - 1.94mm
BACKING PLATE TRAVEL = (0. .. __ .. )
40 076

PLATE THICKNESS IDENTIFICATION

7.249mm - 7.409mm
2
(.285" - .292")

RH0176-4L60-E 6.678mm - 6.519mm

3
(.263" - .257")
Figure 81 Reverse Input Backing Plate Selection
5.947mm - 5.787mm
4
(.234" - .228")

RH0178-4L60-E

Figure 83 Reverse Input Backing Plate Selection Chart

7A-14B-40 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

605
CORRECTLY
INSTALLED
615-----e:t:)

616----$>

613

----------- 609

610

605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT

CLUTCH
607 PISTON ASM., REVERSE INPUT CLUTCH
609 SPRING ASM., REVERSE INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT I
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER
SELECTIVE WASHER
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE)
616 WASHER, THRUST (SELECTIVE)
612A PLATE ASM., REVERSE INPUT CLUTCH (FIBER)
621 HOUSING AND SHAFT ASSEMBLY, INPUT
6128 PLATE, REVERSE INPUT CLUTCH (STEEL)
613 PLATE, REVERSE INPUT CLUTCH BACKING (SELECTIVE)
614 RING, REVERSE INPUT CL. RETAINING
RHO 179-4L60-E RH0180-4L60-E

Figure 84 Reverse Input Clutch Figure 85 Thrust Bearing and Selective Washer
Location

Reverse Input and Input Clutches

Figures 85, 86 and 87 605

F~3 Assemble
Figures 85 and 86
~615
1. Selective thrust washer (616) onto the input ~ 616
housing.
2. Bearing assembly (615).
• Inside (black race) goes toward the oil
pump. 621
3. Reverse input clutch assembly (605) onto the
input clutch assembly.
• Index the reverse input clutch plates with
the input clutch hub.
• Make certain all clutch plates are fully
engaged.

605 HOUSING AND DRUM ASSEMBLY, REVERSE

INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT I
SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
621 HOUSING AND SHAFT ASSEMBLY, INPUT
RH0147-4L60-E

Figure 86 Reverse Input and Input Clutches

 4L60·E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-41

III Assemble
Figure87
• Reverse input and input clutch assembly into
the transmission case.
A. Index the 3-4 clutch plates with the input
internal gear.
B. Make sure all clutch plates are fully
engaged.
C. When properly assembled, the reverse input
clutch housing will be located just below
the case oil pump face.
8 CASE, TRANSMISSION
602 BAND ASSEMBLY, 2-4
605 HOUSING AND DRUM ASSEMBLY, REVERSE
INPUT CLUTCH RH0182-4L60-E
621
Figure 88 2-4 Band Assembly - Installed

605 Oil Pump Assembly

Figures 89 and 91

I+--+! Remove or Disconnect

1. Thrust washer (601).
2. Pump cover to case gasket (6).
3. Pump to case oil seal (5).
4. Pump cover bolts (233).
5. Pump cover (215) from pump body (200).

Oil Pump Body

Figure91
A
8
BAND ANCHOR PIN LOCATION
CASE, TRANSMISSION
I+! Disassemble
41 PIN, BAND ANCHOR 1. Pump slide springs (206 and 207).
605 HOUSING AND DRUM ASSEMBLY, REVERSE
INPUT CLUTCH CAUTION: Springs are under very high
621 HOUSING AND SHAFT ASSEMBLY, INPUT
pressure. Place covering over spring to
RH0181-4L60-E prevent possible injury.
Figure 87 Installing Input Clutch A. Compress with needle nose pliers.
B. Pull straight out.
2-4 Band Assembly
4 PUMP ASSEMBLY, OIL
Figures 87 and 88 601 WASHER, THRUST
(PUMP TO DRUM)
IL1tl Inspect
601

• 2-4 band assembly (602) for damage or wear.

4
III Assemble
Figures 87 and 88
1. Align the band anchor pin end with the case
pin hole.
2. Band anchor pin (41) into the case. RH0183-4L60-E
• Index the pin into the 2-4 band.
Figure 89 Oil Pump Thrust Washer Location
7A-14B-42 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

2. From the pump pocket: • Pump cover (215) and pump body (200) for:
• Pump guide rings (210) - Worn or damaged bushings (see Bushing
• Pump vanes (213) Replacement Procedure).
• Pump rotor (212) - Foreign material or debris.
• Pump guide (211) - Porosity.
• Slide (209) - Scored or irregular mating faces.
• Slide seal (201) - Cross channel leaks.
• Seal support (208) - Ring groove damage.
• Pivot slide pin (205) and spring (204) • Rotor (212) and slide (203) for cracks.
• Slide seal ring (201) and slide back up seal • Oil seal assembly for damage or wear.
(202)
~ Clean
3. Retainer (94), oil seal assembly (2).
• Pry out with a screwdriver. • Wash and air dry all parts.
[I] Important
Oil Pump Cover • Do not wipe dry with a cloth.
Figures 90, 91 and 94
Tool Required:
One inch micrometer OIL PUMP ROTOR SELECTION CHART

l+I Disassemble
THICKNESS (mm)

17.948- 17.961
THICKNESS (in.)

0.7066 - 0.7071
Figures 91 and 94 17.961 - 17.974 0.7071 - 0.7076
17.974- 17.987 0.7076 - 0.7081
1. Converter clutch apply valve train.
17.987 - 18.000 0.7081 - 0.7086
A. Compress converter clutch stop valve (223)
18.000 - 18.013 0.7086, 0.7091
with a screwdriver.
B. Remove retaining ring (222). OIL PUMP SU.DE SELECTION CHART
C. Slowly release the spring tension.
THICKNESS (mm) THICKNESS (in.)
D. Stop valve (223), converter clutch apply
valve (224) and two converter clutch valve 17.948 - 17.961 0.7066 - 0.7071
springs. 17.961 - 17.974 0. 7071 - 0. 7076
17.974- 17.987 0.7076 - 0.7081
2. Pressure relief ball (228).
17.987 - 18.000 0.7081 - 0.7086
• Ball is under strong spring pressure. 18.000 - 18.013 0.7086 - 0.7,091
• Cover the ball with a cloth when removed.
3. Pressure regulator assembly (216-221).
• Follow the same procedure used to remove
the converter clutch valve.

ll•I Inspect
Figure91 212

• Pressure regulator valve assembly (216-221) and

converter clutch apply valve assembly (222-
226) for:
- Chips, burrs, distortion, plugged oil passage
and free movement in bore.
- Remove burrs with lapping compound.
203 SLIDE, PUMP
• Pressure relief assembly (227-229) for damage 212 ROTOR, Oil PUMP
or distortion.
RH0184-4L60·E

Figure 90 Oil Pump Rotor and Slide Selection

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148-43

ILL.
NO. DESCRIPTION
200 BODY, PUMP
241
201 RING, OIL SEAL (SLIDE TO WEAR PLATE)
230 202 SEAL, 0-RING (SLIDE SEAL BACK-UP)
233 236 203 SLIDE, PUMP

/ 204
205
206
207
SPRING, PIVOT PIN
PIN, PIVOT SLIDE
SPRING, PUMP SLIDE (OUTER)
SPRING, PUMP SLIDE (INNER)
208 SUPPORT, PUMP SLIDE SEAL
236 209 SEAL, PUMP SLIDE
210 RING, PUMP VANE
236 211 GUIDE, ROTOR
23 212 ROTOR, OIL PUMP
239 213 VANE, PUMP
236 214 SHAFT, STATOR
238 215 COVER, PUMP
216 VALVE, PRESSURE REGULATOR
226 217 SPRING, PRESSURE REGULATOR VALVE
218 SPRING, PRESSURE REGULATOR ISOLATOR
219 VALVE, REVERSE BOOST
220 SLEEVE, REVERSE BOOST VALVE
221 RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
223 VALVE, STOP
224
224 VALVE, CONVERTER CLUTCH
225 SPRING, CONVERTER CLUTCH VALVE (INNER)
226 SPRING, CONVERTER CLUTCH VALVE (OUTER)
227 RIVET, PRESSURE RELIEF BOLT
228 BALL, PRESSURE RELIEF
223 229 SPRING PRESSURE RELIEF
230 RING, OIL SEAL (STATOR SHAFT)
222 231 SEAL, OIL PUMP COVER SCREEN
232 SCREEN, OIL PUMP COVER
233 BOLT, MS X 1.25 X 40 (COVER TO BODY)
234 BUSHING, STATOR SHAFT (FRONT)
235 PLUG, OIL PUMP COVER (FWD CLUTCH FEED)
236 PLUG, OIL PUMP COVER
237 RETAINER AND BALL ASSEMBLY, CHECK VALVE
238 ORIFICE, CONVERTER CLUTCH SIGNAL
(CUP PLUG)
239 ORIFICE, OIL COOLER (CUP PLUG)
240 PLUG, CUP ORIFICE
241 BUSHING, STATOR SHAFT (REAR)
242 BUSHING, PUMP BODY
243 SEAL ASSEMBLY, OIL
244 RETAINER, FRONT HELIX

RHO 185-4L60-E

Figure 91 Oil Pump Assembly

7A-14B-44 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

II] Measure
8.
9.
Vanes (213).
Vane guide ring (210).
Figure 90 10. Pump slide spring (206 and 207).
• Oil pump rotor (212) thickness. 11. Oil seal assembly (2), retainer (94).
• Oil pump slide (203) thickness. • Use J 25016.
[Il Important
• Measurement of rotor/slide must be made on
undamaged surfaces. Select similar size
replacements. Lightly hone both sides of
replacement rotor or slide to remove any nicks
or burrs.

Oil Pump Body

Figures 91, 92 and 93
Tool Required:
J 25016 Seal Installer

1±1 Assemble
1. 0-ring seal (202) and oil seal ring (201) into
the groove on the back side of the slide.
• Retain with Transjel™ J 36850 or
equivalent.
2. Pivot pin spring (204) and pivot pin (205) into
the pump body. 201 RING, OIL SEAL (SLIDE TO WEAR PLATE)
3. Slide (203). 202 SEAL, 0-RING (SLIDE SEAL BACK-UP)
204 SPRING, PIVOT PIN
• Index the notch in the slide with the pivot 205 PIN, PIVOT SLIDE
pin. 208 SUPPORT, PUMP SLIDE SEAL
209 SEAL, PUMP SLIDE
• The oil seal ring must face downward into
RH0187-4L60-E
the pump pocket.
4. Slide seal (209) and support (208). Figure 93 Slide Back Up and Slide Seal
5. Vane guide ring (210).
6. Rotor guide (211) onto the rotor. Oil Pump Cover
• Retain with Transjel™ J 36850 or Figure91
equivalent.
7. Rotor (212). lf:I Assemble
• With guide toward the pump pocket. 1. Pressure relief ball (228), spring (229) and rivet
(227).
2. Inner (225) and outer (226) converter clutch
valve springs into the converter clutch valve
bore.
3. Converter clutch valve (224).
4. Stop valve (223).
5. Retaining ring (222).
6. Pressure regulator valve (216) into the pressure
regulator bore.
7. Pressure regulator valve spring (217).

Figure 92 HYDRA-MATIC 4L60-E - Oil Pump Seal

 4L60-E.AUTOMATIC TRANSMISSION UNIT.REPAIR 7A-14B-45

8. Reverse boost valve (219) into the reverse boost

valve sleeve.
• Small end of the valve first
• Retain with Transjel™ J 36850 or
equivalent.
9. Reverse boost valve sleeve (220) into the
pressure regulator bore.
10. Retainer ring (221).

Oil Pump Cover and Body

Figures 91 and 95 through 98
Tools Required:
J 21368 Oil Pump Body and Cover
Alignment Band
J 25025-1 Alignment Pins

(ti Assemble
Figures 91, 95, 96 and 97
1. Oil pump cover (215) onto oil pump body.
• Stator shaft through a bench hole
2. Pump cover bolts (233).
• Leave finger tight.
3. Align pump cover and pump body with J 21368.
• Place a screwdriver through a bolt hole
and into a hole in the bench.

~ lighten €)----223

• Attaching bolts to 24 N•m (18 lb. ft.).

0---222
• Retain with Transjel™ J 36850 or
equivalent.
4. Install two oil seal rings (233) using 138735-3
and J 39855-1.
It] Adjust ~221

• Adjust screw to obtain proper height.

5. Use J 39855-2 to size seals after installation.

216 VALVE, PRESSURE REGULATOR

217 SPRING, PRESSURE REGULATOR VALVE
218 SPRING, PRESSURE REGULATOR ISOLATOR
219 VALVE, REVERSE BOOST
220 SLEEVE, REVERSE BOOST VALVE
221 RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE RETAINING
223 VALVE, STOP
224 VALVE, CONVERTER CLUTCH
225 SPRING, CONVERTER CLUTCH VALVE (INNER)
226 SPRING, CONVERTER CLUTCH VALVE (OUTER)

RH0188-4L60-E

Figure 94 Pressure Regulator and Converter Clutch

Apply Valve Trains
7A-14B-46 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
Figure 95 Oil Pump Alignment Band
4 PUMP ASSEMBLY, OIL
230 RING, OIL SEAL (STATOR SHAFT)
Figure 96 Install and Size Oil Seal Rings
I.. +-I Install or Connect
Figure98
1. Thrust washer (601).
2. J 25025-1 into the case as shown.
3. Oil pump assembly into the case.
• Align all holes properly.
4. Bolts and 0-rings (2 and 3).
~ lighten
• Bolts to 24 N•m (18 lb. ft.).
4 PUMP ASSEMBLY, OIL
601 WASHER, THRUST (PUMP TO DRUM)
4 • End play should be 0.13 to 0.92 mm (0.005
Figure 97 Oil Pump Thrust Washer
II] Important
• Rotate the transmission to a horizontal position.
If the transmission is assembled properly the
turbine shaft should turn by hand. If not identify
and correct the misassembly now.
A ALIGNMENT PINS
4 PUMP ASSEMBLY, OIL
RH0189-4L60-E
J 39855-2
RH0191-4L60-E
Figure 98 Oil Pump and Case
Transmission End Play Check
Figures 99 through 103 and 106, 107 and 108
Tools Required:
RH0237-4L60-E J 24773-A End Play Checking Fixture
J 25022 End Play Checking Fixture Adaptor
(245 mm)
J 34725 End Play Checking Fixture Adaptor
(298 mm)
J 25025-7A Post or 278 mm ( 11 inch) Bolt
and Nut
Dial indicator
[I] Measure
Figures 99 through 102
1. Remove an oil pump to case bolt and install a
278 mm (11 inch) bolt and lock nut or J 25025-
7A.
2. Install J 25022-A or J 34725 as shown.
3. Install J 24773-A as shown.
4. Install a dial indicator.
• Set to zero.
5. Pull up on J 24773-A.
to 0.036 inch).
The selective washer which controls end play is
located between the input housing and the thrust
bearing on the oil pump hub. If more or less end play
is required, select the proper washer from the chart
RH0183-4L60-E and install. If dial indicator shows no end play, the
selective washer and thrust bearing have been
misassembled.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-47

TRANSMISSION END PLAY

WASHER SELECTION CHART
WASHER THICKNESS 1.0.

1.87 - 1.97 mm (.074" - .078") 67

2.04- 2.14 mm (.080" - .084") 68
2.21 - 2.31 mm (.087'' - .091") 69
2.38 - 2.48 mm (.094" - .098") 70
2.55 - 2.65 mm (.100" - .104") 71
2.72 - 2.82 mm (.107" - .111 ") 72
2.89 - 2.99 mm (.113" - .118") 73
3.06 - 3.16 mm (.120" - .124") 74

RH0192-4L60-E

Figure 101 End Play Chart

A 298mm TURBINE SHAFT CORRECTLY

B 245mm TURBINE SHAFT INSTALLED
615--d)

616---$>
RH0114-4L60-E

Figure 99 End Play Tool

A DIAL INDICATOR
B 278mm(11")BOLT
CLOCK NUT

J 25022

615 BEARING ASSEMBLY, STATOR SHAFT I

SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
621 HOUSING AND SHAFT ASSEMBLY, INPUT

RH0115-4L60-E RH0180-4L60-E

Figure 100 J 25022-A Installed Figure 102 Selective Washer and Thrust Bearing
Properly Installed
JA-148-48 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

l..!•I Assemble ll1tl Inspect

Figure 103 Figures 105, 106 and 107
• 0-ring seal (618) into the groove in the end of • The 1-2 accumulator cover and pin assembly
the turbine shaft. (57) for:
- Porosity or damage.
[I] Important
- Scored piston wall.
• There should be clearance between the reverse - Plugged oil passage.
input clutch and the reaction sun gear shell. • 1-2 accumulator piston (56) and the 3-4
This clearance can be observed at the point accumulator piston (44) for:
shown in Figure 105. Do not try to shim the
internal parts because of this clearance (Figure - Porosity.
104). - Ring groove damage.
- Pin hole damage.
• 1-2 accumulator spring (54) and 3-4
accumulator spring (46) for distortion or
damage.
• Spacer plate (48) and gaskets (47 and 52) for
damage.
• Checkballs (61) for damage.
• Manual detent spring (63) for damage.
• Oil filter (72) for:
- Cut or damaged filter seal (71 ).
- Cracks in the neck or body.
USED WITH USED WITH - Casting flash in the neck.
298mm CONVERTER 245mm CONVERTER
• Solenoid assembly (66) for:
A SHAFT, TURBINE
618 SEAL, 0-RING (TURBINE SHAFT/ SELECTIVE WASHER)
- Damage.
621 HOUSING AND SHAFT ASSEMBLY, INPUT - Cut or pinched wires.
RH0152-4L60-E
- Damaged connectors.
Figure 103 Turbine Shaft 0-Ring Seal - Cut or damaged 0-ring (65).

A AS INSTALLED THESE TWO PARTS HAVE A NORMAL

END CLEARANCE OF APPROX. 3.Bmm (.150")
8 CASE TRANSMISSION
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT
CLUTCH
670 SHELL, REACTION SUN RH0193-4L60-E

Figure 104 Clearance Between Reverse Input Clutch

and Sun Gear Shell
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148-49

58
1993 1-2 ACCUMULATOR 3-4 ACCUMULATOR
MODELS SPRING COLOR SPRING . COLOR

ORANGE, LT. GREEN,

CHO, .CJD, KCD VIOLET
WHITE OR PLAIN

CAD, CBD, KAO, ORANGE, LT. GREEN,

DK. GREEN
MJD, MND WHITE OR PLAIN

ORANGE, LT. GREEN,

CCD,CFD,KBD RED
WHITE OR PLAIN

SHD, TLD DK. GREEN LT. BLUE

CKD, CLO, KOO, ORANGE, LT. GREEN,

YELLOW
MOD, MSD, TAD, TBD WHITE OR PLAIN

RH0194-4L60-E

46 SPRING, 3-4 ACCUMULATOR Figure 106 1-2 and 3-4 Accumulator Spring Chart
47 GASKET, SPACER PLATE TO CASE
48 PLATE, VALVE BODY SPACER
52 GASKET, SPACER PLATE TO VALVE BODY !-++-! Install or Connect
53 PLATE, SPACER PLATE SUPPORT
54 SPRING, 1-2 ACCUMULATOR 1. The wiring harness pass-thru connector into the
57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR case.
58 BOLT, ACCUMULATOR COVER
59 BOLT, ACCUMULATOR COVER 2. The 3-4 accumulator pin (43) into the case.
77 BOLT, SPACER PLATE SUPPORT
RH0233-4L60-E
3. The 3-4 accumulator piston seal (45) onto the
3-4 accumulator piston.
Figure 105 Accumulator Assembly, Spacer Plate 4. The 3-4 accumulator piston (44) onto the pin.
and Gaskets
• The end with three legs must face the valve
body.
Valve Body and Associated Parts
5. The 3-4 accumulator piston spring (46).
Figures 105 and 107
!-++-! Install or Connect
Tool Required:
1. Torque converter clutch oil screen (92).
J 25025-5 Guide Pins
2. Checkball (91) into case as shown.
NOTICE: The use of a honing stone, fine • Retain with Transjel™ J 36850 or
sandpaper or crocus cloth is not recommended equivalent.
for servicing stuck valves. All valve lands have 3. J 25025-5 into the case.
sharply machined comers that are necessary for 4. Screens onto spacer plate as shown.
"cleaning" the bore. If these comers are rounded, 5. Spacer plate to case gasket (47) and spacer plate
foreign material could wedge between the valve to valve body gasket (52) onto the spacer plate
and bore causing the valve to stick. (48).
If it is found necessary to clean a valve, "micro • Gasket (47) identified by a "C".
fine" lapping compound 900 grit or finer should Gasket (52) identified by a "V".
be used.
• Retain with Transjel™ J 36850 or
Too much "lapping" of a valve will cause equivalent.
excessive clearances and increase the chance of a
valve not operating.
7A~14B-5P 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR
6. Spacer plate and gaskets onto the case.
[I) Important
• Be careful not to damage screens when
installing the spacer plate and gaskets.
7. Spacer plate support (53) and bolts (77).
~ Tighten
• Bolts to 11 N•m (8 lb. ft.)
Control Valve Body
~ Clean
• Control valve assembly thoroughly in clean
solvent.
A. Move the valves with a pick or small
screwdriver to dislodge any dirt or debris
that may have accumulated.
B. Air dry
l+--+I Remove or Disconnect
[I) Important
• Some valves are under pressure - cover the
bores while removing roll pins and retainer
clips.
• Valves, springs and bushings must be laid
out on a clean surface in the exact sequence
they are removed.
1. Pressure control solenoid retainer bolt (364)
retainer (378) and solenoid.
2. Bore plug retainer clip (395), bore plug (376)
and valve train (374 and 375).
3. 2-3 shift solenoid retainer (379), solenoid (367)
and valve train (368 and 369).
4. 1-2 shift solenoid retainer (379), solenoid (367)
and valve train (365 and 366).
5. Accumulator valve train retainer pin (360), bore
plug (373) and valve train (370 and 371).
6. Forward accumulator cover bolts (364) and
cover (363).
7. Forward accumulator spring (356), piston (354)
and pin (355).
8. Lo overrun valve spring (362) and valve (361).
9. Retainer pin (360), bore plug (359) and forward
abuse valve train (357 and 358).
10. Manual valve (340).
11. 3-2 control solenoid retainer clip (379) and
solenoid (394).
12. Bore plug retainer (395), bore plug (381) and
3-2 control valve train (391 - 393).
13. 3-2 downshift bore plug retainer (395), bore
plug (381) and valve train (389 - 390).
14. Reverse abuse bore plug retainer pin (360), bore
plug (359) and valve train (387 - 388).
15. 3-4 shift valve bore plug retainer (395), bore
plug (381) and valve train (385 - 386).
16. 3-4 relay bore plug retainer (395), bore plug
(381) and valve train (382 - 384).
17. Torque converter clutch signal valve bore plug
retainer (395), bore plug (381) and valve (380).
~ Clean
• All valves, springs, bushings and control valve
body in clean solvent.
• Dry using compressed air
IL1tl Inspect
• All valves and bushings for:
- Porosity
- Scoring
- Nicks
- Scratches
• Springs for damaged or distorted coils.
• Valve body casting for:
- Porosity
- Cracks
- Interconnected oil passages
- Damaged machined surfaces
If:) Assemble
• Control valve assembly (350) exactly as shown.
- Notice the position of the valve lands and
bushing passages.
- Position the pressure control solenoid so
the connector tabs face outward.
!-++-! Install or Connect
1. Checkballs into the valve body assembly (350):
• Retain with Transjel™ J 36850 or
equivalent.
2. Valve body assembly (350).
• Connect the manual valve link (89) to the
inside detent lever (88).
• Be careful not to damage screens when
installing the valve body assembly.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B·51

3. Wiring harness (66), manual spring assembly

(63), pressure switch assembly (69), dipstick
stop bracket (93) and all remaining valve body
bolts.
NOTICE: Torque valve body bolts in a spiral
pattern starting from the center. If bolts are torqued
at random, valve bores may be distorted and
inhibit valve operation.

4. rec solenoid (66) and bolts (68).

l~I lighten
• Bolts to 11 N•m (8 lb. ft.)

E3 Install or Connect
• Wiring harness connections to electrical
components.

To correctly hook up the wires, see the wiring

diagram in the HYDRA-MATIC 4L60-E Diagnosis
Section. 38 PLUG, TRANSMISSION CASE (ACCUM. BLEED)
40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM.
The pressure control solenoid (377) has two 91 NO. 1 CHECKBALL
different colored connectors. The black connector 92 SCREEN, TCC
should be installed on the tab farthest from the valve
body. RH0113-4L60-E

B Install or Connect
Figure 107 Case Checkballs and Oil Screens - Location

1. Parking bracket (86).

49
~ lighten
• Bolts to 31 N•m (23 lb. ft.) o=
Do o
2. The 1-2 accumulator piston seal (55) onto the
1-2 accumulator piston (56). • DC)
00•0'00
0
•D oOe 0
'
'
0' DO O D
3. The 1-2 accumulator piston (56) into the 1-2 0 = DODO ;??,
accumulator cover and pin assembly (57). o o\J C"l
0

OD
vo
•
• The three legs on the piston must face • , • o O DD•
D
•
toward the case when installed. 0
oD = o
o= D
D
0
4. The 1-2 accumulator spring (54) onto the piston
(56).
Do oo o
D
0
0
o
0
CJ
00 0
0

O • 0 11111149)
0

l!llh<110 •
eo
O
O,
CJ
()
• Doo o '
0
5. The 1-2 accumulator cover and pin assembly 0 0 0
(57) onto the case. • OD
o •O Oo
~ lighten 0 0 D O eo
0
D
•=1
9d/10.
• Torque to 11 N•m (8 lb. ft.) O (50)

eD

50

49 SHIFT SOLENOIDS SCREEN

50 PRESSURE CONTROL SOLENOID SCREEN

RH0234-4L60-E

Figure 108 Filter Screen - Locations

7A-14B-52 4L60-E AUTOMATIC TRANSIVIISSION UNIT REPAIR

373
360~@)
~ u39,
3 7 7378
~
364

RH0195-4L60-E

Figure 109 Control Valve Assembly

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-53

340 VALVE, MANUAL

350 VALVE ASSEMBLY, CONTROL BODY
· 353 S£Al; FORWAiIDACCUMUlAT-0-FI 01L •..
354 PISTON, FORWARD ACCUMULATOR
355 PIN, FORWARD ACCUMULATOR
356 SPRING, FORWARD ACCUMULATOR
357 VALVE, FORWARD ABUSE
358 SPRING, FORWARD ABUSE VALVE
359 PLUG, BORE
360 PIN, COILED SPRING
361 VALVE, LOW OVERRUN
362 SPRING, LOW OVERRUN VALVE
363 COVER, FORWARD ACCUMULATOR
364 BOLT, FORWARD ACCUMULATOR COVER
365 SPRING, 1-2 SHIFT VALVE
366 VALVE, 1-2 SHIFT
367A 1-2 SHIFT SOLENOID (A)
3678 2-3 SHIFT SOLENOID (B)
368 VALVE, 2-3 SHIFT
369 VALVE, 2-3 SHUTILE
370 SPRING, 1-2 ACCUMULATOR VALVE
371 VALVE, 1-2 ACCUMULATOR
372 SLEEVE, 1-2 ACCUMULATOR VALVE
373 PLUG, BORE
374 VALVE, ACTUATOR FEED LIMIT
375 SPRING, ACTUATOR FEED LIMIT VALVE
376 PLUG, BORE
377 PRESSURE CONTROL SOLENOID
378 RETAINER, PRESSURE CONTROL SOLENOID
379 RETAINER, SOLENOID
380 VALVE, CONVERTER CLUTCH SIGNAL
381 PLUG, BORE
382 SPRING, 4-3 SEQUENCE VALVE
383 VALVE, 4-3 SEQUENCE
384 VALVE, 3-4 RELAY
385 VALVE, 3-4 SHIFT
386 SPRING, 3-4 SHIFT VALVE
387 VALVE, REVERSE ABUSE
388 SPRING, REVERSE ABUSE VALVE
389 VALVE, 3-2 DOWNSHIFT
390 SPRING, 3-2 DOWNSHIFT VALVE
391 VALVE, 3-2 CONTROL
392 SPRING, 3-2 CONTROL VALVE
393 SPRING, BORE PLUG
394 3-2 CONTROL SOLENOID
395 RETAINER, BORE PLUG

RHO 196-4L60-E

Figure 110 Control Valve Assembly- Legend

7A-.148-54 4L&o.:E AUTOMATIC TRANSMISSION UNIT REPAIR

#8 #4

88 89 340 63

63 SPRING ASSEMBLY, MANUAL DETl;NT

88 LEVER, INSIDE DETENT
89 LINK, MANUAL VALVE
340 VALVE, MANUAL RH0110-4L60-E

Figure 112 Manual Valve Link

#3 #2 #12
2 3RD ACCUMULATOR
3 REVERSE INPUT
4 3-4 CLUTCH EXHAUST
5 OVERRUN CLUTCH FEED
6 OVERRUN CLUTCH CONTROL
8 1-2 UPSHIFT
12 FORWARD CLUTCH ACCUM. RH0112-4L60-E

Figure 111 Valve Body Checkball Locations

A M6 X 1.0 X 65.0
B M6 X 1.0 X 54.4
C M6 X 1.0 X 47.5
D M6X 1.0X 18.0
E M6 X 1.0 X 35.0
F MS X 1.25 X 20.0
G M6 X 1.0 X 12.0
RH0197-4L60-E-R1

Figure 113 Valve Body Boltlocations

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-55

66
8 CASE, TRANSMISSION
71 SEAL, FILTER
66 SOLENOID ASSEMBLY, WIRING HARNESS 72 FILTER ASSEMBLY, TRANSMISSION OIL
73 GASKET, TRANSMISSION OJL PAN
75 PAN, TRANSMISSION OIL
RH0198-4L60-E-R1 76 SCREW, TRANSMISSION OIL PAN RH0107-4L60-E

Figure 114 Outside Electrical Connector Figure 115 Case, Pan and Filter Assembly

E3 Install or Connect 2-4 Servo Assembly

Figure 115 Figures 116 through 120
1. Filter seal (71) onto the oil filter. Tools Required:
• Lubricate with Transjel™ J 36850 or J 33037 Band Apply Pin Tool
equivalent. Vernier calipers
2. Oil filter (72). Scale
3. Oil pan gasket (73).
J 22269-01 Piston Compressor
4. Chip magnet (74) onto oil pan (75).
J 29714 Servo Cover Compressor
5. Oil pan (75) and bolts (76).
~ lighten !@! Measure
• Torque to 12 N•m (9 lb. ft.) Figure 116
1. Install J 33037 as shown with apply pin (13).
2. Install servo cover retaining ring (29) to secure
tool.
3. Apply 11 N•m (98 lb. in.) torque.
4. If white line "A" appears in the gage slot "B",
pin length is correct.
5. Use pin selection chart to determine the correct
pin length if new pin is needed.
7A-148-56 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

IL•I Inspect l@I Measure

• Pistons for: Figure 117
- Porosity or damage. 1. Measure piston (17) dimension *A.
- Ring groove damage. 2. Measure housing (20) dimension **B.
3. Check model application.

· 2ND APPLY PISTON AND HOUSING APPLICATION

PISTON HOUSING
MODEL DIMENSION DIMENSION
*A **B
CHO, CJD, CKD, CLO, 44.64mm 45.54mm
KCD,KDD (1.78") (1.79")

CAD,CBD,CCD,CFD,KAD,KBD,
57.85mm 58.74mm
MJD, MOD, MND, MSD, SHD,
(2.28") (2.31")
TAM, TBM, TLD
J 33037
A WHITE LINE
8 GAGE SLOT

PIN IS PRESET AT FACTORY AND MUST NOT BE

READJUSTED

2-4 SERVO PIN SELECTION

17 20
PIN LENGTH PIN 1.0.

MM INCH

65.82-66.12 2.59-2.60 1 GROOVE

67.23-67.53 2.65-2.66 2 GROOVES
68.64-68.94 2.70-2.71 NO GROOVE

RH0102-4L60-E

Figure 116 Servo Pin Length

• Cover (28) for porosity or damage.

• Seals for:
- Nicks or cuts.
- Freeness in the seal groove.
• Springs for distortion.
• Pin for wear or burrs. 17 PISTON, 2ND APPLY
20 HOUSING, SERVO PISTON (INNER) RH0199-4L60-E

[I] Important Figure 117 2nd Apply Piston and Housing

• Check servo bore in the case for any wear which Measurement
may cut the servo seals.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148-57

f!..I Assemble
Figures 118 through 120
29 1. Cushion spring (16) into the 2nd apply piston
(17).
2. Cushion spring retainer (15) on the cushion
spring.
3. Install J 22269-01.
A. Compress the retainer past the snap ring
groove in the 2nd apply piston.
B. Install the retainer ring (14).
4. The 2nd apply piston (17) onto the apply pin
(13)
• Retainer goes toward the shoulder of the
pin.
5. Servo apply pin spring (22) on the pin.

::~_J 16
6. Servo apply pin washer (23) and retaining clip
(24).
7. Inner (19) and outer (18) seals on the 2nd apply
piston (17).
• Retain with Transjel™ J 36850 or
equivalent.
8. 0-ring seal (21) on servo piston housing.
9. Servo piston inner housing (20) on the 2nd apply
piston.
10. Seal ring (26) onto the 4th apply piston.
11. The 4th apply piston (25) onto the apply pin.
12. Return spring (12) on the pin.
13. Servo piston assembly into the servo bore.
14. 0-ring seal (21) on the servo cover.
-------12 • Lubricate the seal with Transjel™
J 36850 or equivalent.
15. Servo cover (28) into the servo bore.
ILL. 16. Install J 29714.
NO. DESCRIPTION
A. Compress the servo cover.
12 SPRING, SERVO RETURN
13 PIN, 2ND APPLY PISTON B. Install the retainer ring (29).
14 RING, RETAINER (2ND APPLY PISTON)
15 RETAINER, SERVO CUSHION SPRING
16 SPRING, SERVO CUSHION
17 PISTON, 2ND APPLY
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER)
20 HOUSING, SERVO PISTON (INNER)
21 SEAL, 0-RING
22 SPRING, SERVO APPLY PIN
23 WASHER, SERVO APPLY PIN
24 RING, RETAINER (APPLY PIN)
25 PISTON, 4TH APPLY
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER)
27 SEAL, 0-RING (2-4 SERVO COVER)
28 COVER, 2-4 SERVO
29 RING, SERVO COVER RETAINING 14 RING, RETAINER (2ND APPLY PISTON)
17 SECOND APPLY PISTON RHO 103-4L60-E

Figure 119 2nd Servo Piston -Assembly

RH0104-4L60-E

Figure 118 2-4 Servo Assembly

7A-14B-58 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

3. Seal ring (37) on the case extension.

4. Case extension (31) and bolts (32).
• Position extension so the speed sensor bore
J 29714 is on the gear selector lever side of the
case.
~ lighten
• Torque to 35 N•m (26 lb. ft.).
5. Remove case extension oil seal (34).
A. Pry out with a screwdriver.
B. Install new seal with J 21426.
28 6. Speed sensor (36) with J 38417.
7. Retainer, bolt and washer (34).
8. Outside electrical connector, gear selector lever
12 and nut.

~
13- 24

~
~
25

28
29 20 HOUSING, SERVO PISTON
(INNER)
12 SPRING, SERVO RETURN 21 SEAL, 0-RING
13 PIN, 2ND APPLY PISTON 22 SPRING, SERVO APPLY PIN
14 RING, RETAINER (2ND 23 WASHER, SERVO APPLY
APPLY PISTON) PIN
15 RETAINER, SERVO 24 RING, RETAINER (APPLY
CUSHION SPRING PIN)
16 SPRING, SERVO CUSHION 25 PISTON, 4TH APPLY
17 PISTON, 2ND APPLY 28 COVER, 2-4 SERVO
18 RING, OIL SEAL (2ND 29 RING, SERVO COVER
APPLY PISTON - OUTER) RETAINING RH0200-4L60-E
19 RING, OIL SEAL (2ND
APPLY PISTON - INNER) RH0101-4L60-E
Figure 121 Output Shaft Sleeve and Seal
Figure 120 2-4 Servo Bore

J 21426
Speed Sensor and Case Extension
Figures 123
690
Tools Required:
J 23103 or J 25016 Seal Installer
J 21426 Seal Installer
J 38417 Speed Sensor Remover and
Installer
E3 Install or Connect
690 SLEEVE, OUTPUT SHAFT RH0201-4L60-E

1. 0-ring seal (691) on the output shaft sleeve. Figure 122 Output Shaft Sleeve - Installation
2. Output shaft sleeve (690) on the output shaft.
• Use J 25016 or J 23103.
• Do not push the sleeve past the machined
surface on the output shaft.
 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-59

\r
30 SEAL, CASE EXTENSION TO CASE
31 EXTENSION, CASE
32 BOLT, CASE EXTENSION TO CASE RH0202-4L60-E RH0203-4L60-E

Figure 123 Case Extension and Seal Figure 125 Case Extension Oil Seal Assembly

Torque Converter Assembly

Figure 126
Tool Required:
J 3513 8 Torque Converter End Play
Checking Tool

ll"'! Inspect
The torque converter assembly must be replaced
for any of the following conditions:
• Evidence of damage to the pump assembly.
• Metal particles are found after flushing the
cooler and cooler lines.
ILL • External leaks in hub weld area.
NO. DESCRIPTION • Converter pilot is broken, damaged or poor fit
8 CASE, TRANSMISSION into crankshaft.
30 SEAL, CASE EXTENSION TO CASE
31 EXTENSION, CASE
• Converter hub is scored or damaged.
32 BOLT, CASE EXTENSION TO CASE • Internal damage to stator.
33 BUSHING, CASE EXTENSION • Contamination from engine coolant.
34 SEAL ASSEMBLY, CASE EXTENSION OIL
35 BOLT, SPEED SENSOR RETAINING • Excess end play.
36 SPEED SENSOR, INTERNAL TRANSMISSION
37
687
SEAL, 0-RING (ITSS TO CASE EXTENSION)
SHAFT, OUTPUT
I@! Measure
RH0106-4L60-E
Figure 126
Figure 124 Case Extension and Associated Parts • Install J 35138 and measure end play.
- 0 to 0.5 mm (0.000 to 0.020 inch) for
245 mm torque converters.
- 0 to 0.6 mm (0.000 to 0.024 inch) for
298 mm torque converters.
7A·14B-60 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

The Torque Converter should not be replaced If:

• The fluid has an odor, discoloration or no
evidence of metal or clutch plate material.
A. Drain out as much, fluid as possible.
B. Replace the oil filter and pan gasket.
C. Fill to proper level (Refer to Section 7 A).
• The converter bolt hole threads are damaged.
- Correct with thread insert (Refer to Section
6A).
[I] Important
• Flushing the torque converter is not
recommended.

E3 Install or Connect
1. Torque converter.
2. J 21366 converter holding strap.
3. R~move transmission from holding fixture.

RH0204-4L60-E

Figure 126 Checking Torque Converter End Play

 HYDRA-MATIC 4L60-E
CASE REVERSE INPUT CLUTCH OVERRUN FORWARD LO AND OUTPUT
ASSEMBLY INPUT CLUTCH HOUSING CLUTCH CLUTCH REVERSE SHAFT
CLUTCH

.,,
cc·
c:
ro
.....
N
-..J
:::c
-< .,..
0
:IJ ~
Q
)> .I
m
~ CJ J>
~ ----== c:
n d
.i,.
r
a>
s:
0I !j
m
::;"
n
-t
D>
::,
Cl) ~
3 z
Cl)
Cl)
Cl)
a·::, s:
0Cl)
0
z
c:
z
=i
~
J
:a
::0
::c
8 2-4 .......
0
TURBINE PUMP BAND INSIDE MANUAL CONTROL VALVE PARKING LOCK PARKING SPEED J>
.,..
I
.;.. SHAFT ASSEMBLY ASSEMBLY DETENT LEVER SHAFT ASSEMBLY ACTUATOR ASSEMBLY PAWL SENSOR ...a
~
r\,
m
0)
·...&
7A-14B-62 4L60-E. Al)TOMATIC TRANSMISSION UNIT REPAIR

29

33 34

7
3

58

59

68

74
73

75
76

RH0205-4L60-E-R1

Figure 128 Case and External Parts

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148-63

ILL. ILL.
NO. DESCRIPTION NO. DESCRIPTION
1 TORQUE CONVERTER ASSEMBLY 48 PLATE, VALVE BODY SPACER
2 BOLT, PUMP TO CASE 49 SCREEN, SHIFT SOLENOIDS
3 0-RING, PUMP TO CASE BOLT 50 SCREEN, PRESSURE CONTROL SOLENOID
4 PUMP ASSEMBLY, OIL 51 SCREEN, 3-2 CONTROL SOLENOID
5 SEAL, OIL (PUMP TO CASE) 52 GASKET, SPACER PLATE TO VALVE BODY
6 GASKET, PUMP COVER TO CASE 53 PLATE, SPACER PLATE SUPPORT
7 BUSHING, CASE 54 SPRING, 1-2 ACCUMULATOR
8 CASE, TRANSMISSION 55 RING, OIL SEAL (1-2 ACCUMULATOR)
9 VENT ASSEMBLY, TRANSMISSION 56 PISTON, 1-2 ACCUMULATOR
10 CONNECTOR, OIL COOLER PIPE 57 COVER AND PIN ASSEMBLY, 1-2 ACCUMULATOR
11.PLUG, CASE SERVO 58 BOLT, ACCUMULATOR COVER
12 SPRING, SERVO RETURN 59 BOLT, ACCUMULATOR COVER
13 PIN, 2ND APPLY PISTON 60 VALVE ASSEMBLY, CONTROL BODY
14 RING, RETAINER (2ND APPLY PISTON) 61 CHECKBALL
15 RETAINER, SERVO CUSHION SPRING 62 BOLT, VALVE BODY
16 SPRING, SERVO CUSHION 63 SPRING ASSEMBLY, MANUAL DETENT
17 PISTON, 2ND APPLY 64 BOLT, MANUAL DETENT SPRING
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER) 65 SEAL, WIRING HARNESS PASS-THAU CONNECTOR
19 RING, OIL SEAL (2ND APPLY PISTON - INNER) 0-RING
20 HOUSING, SERVO PISTON (INNER) 66 SOLENOID ASSEMBLY, WIRING HARNESS
21 SEAL, 0-RING 67 SEAL 0-RING (SOLENOID)
22 SPRING, SERVO APPLY PIN 68 BOLT, HEX WASHER HEAD (SOLENOID)
23 WASHER, SERVO APPLY PIN 69 SWITCH ASSEMBLY, TRANSMISSION PRESSURE
24 RING, RETAINER (APPLY PIN) 70 BOLT, PRESSURE SWITCH ASSEMBLY
25 PISTON, 4TH APPLY 71 SEAL, FILTER
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER) 72 FILTER ASSEMBLY, TRANSMISSION OIL
27 SEAL, 0-RING (2-4 SERVO COVER) 73 GASKET, TRANSMISSION OIL PAN
28 COVER, 2-4 SERVO 74 MAGNET, CHIP COLLECTOR
29 RING, SERVO COVER RETAINING 75 PAN, TRANSMISSION OIL
30. SEAL, CASE EXTENSION TO CASE 76 SCREW, TRANSMISSION OIL PAN
31 EXTENSION, CASE 77 BOLT, SPACER PLATE SUPPORT
32 BOLT, CASE EXTENSION TO CASE 78 PLUG, STEEL CUP
33 BUSHING, CASE EXTENSION 79 SHAFT, PARKING BRAKE PAWL
34 SEAL ASSEMBLY, CASE EXTENSION OIL 80 SPRING, PARKING PAWL RETURN
35 BOLT, SPEED SENSOR RETAINING 81 PAWL, PARKING BRAKE
36 SPEED SENSOR, INTERNAL TRANSMISSION 82 SEAL, MANUAL SHAFT
37 SEAL, 0-RING (ITSS TO CASE EXTENSION) 83 RETAINER, MANUAL SHAFT
38 PLUG, TRANSMISSION CASE (ACCUM. BLEED) 84 SHAFT, MANUAL
39 PLUG, PRESSURE 85 ACTUATOR ASSEMBLY, PARKING LOCK
40 RETAINER AND BALL ASSEMBLY, 3RD ACCUM. 86 BRACKET, PARKING LOCK
41 PIN, BAND ANCHOR 87 BOLT, PARKING LOCK BRACKET
42 RETAINER AND BALL ASM. (DOUBLE ORIFICE) 88 LEVER, INSIDE DETENT
43 PIN, ACCUMULATOR PISTON 89 LINK, MANUAL VALVE
44 PISTON, 3-4 ACCUMULATOR 90 NUT, HEX HEAD
45 RING, OIL SEAL (3-4 ACCUMULATOR PISTON) 91 NO. 10 C::HECKBALL
46 SPRING, 3-4 ACCUMULATOR 92 SCREEN, TCC
47 GASKET, SPACER PLATE TO CASE 93 BRACKET, DIPSTICK STOP

RH0206-4L60-E-R 1

Figure 129 Case and External Parts - Legend

7A-148-64 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

601 603 612A 6128 613 614

I

•• M __J
I

621 623 624 625 626 630 629 632 631 634 635

646 648 649A 6498 650 651

654A 6548 655 656 658 664 665 666 667

'"!el _ _ _J
I

668 669 670 671 672 673 674

I
____ __J
682C 6820 6828 682A 683 684 685 686 687

w i
IJDm D)ii
I

_ _ _J
690 691 692 693 694 695

r- ----
1
I
I
I I
1SOME I
MODELS J I
Il _______
RH0207-4L60-E-R 1

Figure 130 Transmission Internal Parts

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-65

ILL. ILL.
NO. DESCRIPTION NO. DESCRIPTION
600 SPRING ASM., 3-4 CLUTCH BOOST (5) 654A PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
601 WASHER, THRUST (PUMP TO DRUM) 6548 PLATE, 3RD AND 4TH CLUTCH (STEEL)
602 BAND ASSEMBLY, 2-4 655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEU
603 BUSHING, REVERSE INPUT CL. (FRONT) 656 RING, 3RD AND 4TH CLUTCH BACKING PLATE
605 HOUSING AND DRUM ASSEMBLY, REVERSE INPUT RETAINER
CLUTCH 657 BUSHING, INPUT SUN GEAR (FRONT)
606 BUSHING, REVERSE INPUT CLUTCH (REAR) 658 GEAR, INPUT SUN
607 PISTON ASM., REVERSE INPUT CLUTCH 659 BUSHING, INPUT SUN GEAR (REAR)
608 SEALS, REVERSE INPUT CLUTCH 661 RET., OUTPUT SHAFT TO INPUT CARRIER
(INNER AND OUTEFl) 662 CARRIER ASSEMBLY, INPUT (COMPLETE)
609 SPRING ASM., REVERSE INPUT CLUTCH 663 BEARING ASSEMBLY, THRLJST (INPUT CARRIER TO
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER REACTION SHAFT)
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE) 664 GEAR, INPUT INTERNAL
612A PLATE ASM., REVERSE INPUT CLUTCH (STEEL) 665 BUSHING, REACTION CARRIER SHAFT (FRONT)
6128 PLATE, REVERSE INPUT CLUTCH (FIBER) 666 SHAFT, REACTION CARRIER
613 PLATE, REVERSE INPUT CLUTCH BACKING 667 BUSHING, REACTION CARRIER SHAFT (REAR)
(SELECTIVE) 668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER
614 RING, REVERSE INPUT CL. RETAINING 669 WASHER, THRUST (REACTION SHAFT/SHELL)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE 670 SHELL, REACTION SUN
WASHER 671 RING, REACTION SUN GEAR RETAINER
616 WASHER, THRUST (SELECTIVE) 672 BUSHING, REACTION SUN
617 RETAINER AND BALL ASM., CHECK VALVE 673 GEAR, REACTION SUN
618 SEAL, 0-RING (TURBINE SHAFT/ SELECTIVE WASHER) 674 WASHER, THRUST (RACE/REACTION SHELL)
619 RING, OIL SEAL (SOLID) 675 RACE, LO AND REVERSE ROLLER CLUTCH
620 RETAINER AND CHECKBALL ASSEMBLY 676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
621 HOUSING AND SHAFT ASSEMBLY, INPUT 677 RING, LO AND REVERSE RETAINER (ROLLER
622 SEAL, 0-RING INPUT TO FORWARD HSG. ASSEMBLY/CAM)
623 PISTON, 3RD AND 4TH CLUTCH 678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
624 SEAL, 3RD AND 4TH CL. (INNER AND OUTER) 679 SUPPORT ASM., LO AND REVERSE CLUTCH
625 RING, 3RD AND 4TH CLUTCH (APPLY) 680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH SUPPORT RETAINER)
627 RETAINER AND BALL ASSEMBLY, FORWARD CLUTCH 681 CARRIER ASSEMBLY, REACTION
HOUSING 682A PLATE, LO AND REVERSE CLUTCH (WAVED)
628 HOUSING, FORWARD CLUTCH 6828 PLATE, SPACER LO AND REVERSE CLUTCH
629 SEAL, FORWARD CLUTCH (INNER AND OUTER) (SELECTIVE)
630 PISTON, FORWARD CLUTCH 682C PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER)
631 SEAL, OVERRUN CLUTCH (INNER AND OUTER) 6820 PLATE, LO AND REVERSE CLUTCH (STEEL)
632 PISTON, OVERRUN CLUTCH 683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
633 BALL, OVERRUN CLUTCH SUPPORT)
634 SPRING ASSEMBLY, OVERRUN CLUTCH 684 GEAR, INTERNAL REACTION
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER 685 SUPPORT, INTERNAL REACTION GEAR
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT 686 RING, REACTION GEAR/SUPPORT RETAINER
637 BEARING ASSEMBLY, INPUT SUN GEAR 687 SHAFT, OUTPUT
638 SNAP RING, OVERRUN CL. HUB RETAINING 690 SLEEVE, OUTPUT SHAFT
639 HUB, OVERRUN CLUTCH 691 SEAL, OUTPUT SHAFT
641 RETAINER AND RACE ASSEMBLY, SPRAG 692 BRG., REACTION GEAR SUPPORT TO CASE
642 FORWARD SPRAG ASSEMBLY 693 RING, LO AND REVERSE CLUTCH RETAINER
643 RETAINER RINGS, SPRAG ASSEMBLY 694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
644 RACE, FORWARD CLUTCH (OUTER) 695 PISTON, LO AND REVERSE CLUTCH
645A PLATE ASSEMBLY, OVERRUN CLUTCH (STEEL) 696 SEAL, TRANSMISSION (LO AND REVERSE CLUTCH -
6458 PLATE, OVERRUN CLUTCH (FIBER) OUTER, CENTER, INNER)
646 PLATE, FORWARD CLUTCH (APPLY) 697 DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
648 PLATE, FORWARD CLUTCH (WAVED) 698 PLUG, ORIFICED CUP
649A PLATE ASSEMBLY, FORWARD CLUTCH (STEEL) 699 ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
6498 PLATE, FORWARD CLUTCH (FIBER)
650 PLATE, FORWARD CLUTCH BACKING (SEL.)
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)

RH0208-4L60-E-R1

Figure 131 Transmission Internal Parts - Legend

7A:14B-66 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

373
360~@)
~ ij395

377 ~
378
364

~, ~
3~- ~M

395ij 383

3~
38~~

395ij

RH0195-4L60-E

Figure 132 Control Valve Assembly

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-148-67

340 VALVE, MANUAL

350 VALVE ASSEMBLY, CONTROL BODY
353 SEAL, FORWARD ACCUMULATOR OIL
354 PISTON, FORWARD ACCUMULATOR
355 PIN, FORWARD ACCUMULATOR
356 SPRING, FORWARD ACCUMULATOR
357 VALVE, FORWARD ABUSE
358 SPRING, FORWARD ABUSE VALVE
359 PLUG, BORE
360 PIN, COILED SPRING
361 VALVE, LOW OVERRUN
362 SPRING, LOW OVERRUN VALVE
363 COVER, FORWARD ACCUMULATOR
364 BOLT, FORWARD ACCUMULATOR COVER
365 SPRING, 1-2 SHIFT VALVE
366 VALVE, 1-2 SHIFT
367A 1-2 SHIFT SOLENOID (A)
3678 2-3 SHIFT SOLENOID (B)
368 VALVE, 2-3 SHIFT
369 VALVE, 2-3 SHUTTLE
370 SPRING, 1-2 ACCUMULATOR VALVE
371 VALVE, 1-2 ACCUMULATOR
372 SLEEVE, 1-2 ACCUMULATOR VALVE
373 PLUG, BORE
374 VALVE, ACTUATOR FEED LIMIT
375 SPRING, ACTUATOR FEED LIMIT VALVE
376 PLUG, BORE
377 PRESSURE CONTROL SOLENOID
378 RETAINER, PRESSUijE CONTROL SOLENOID
379 RETAINER, SOLENOID
380 VALVE, CONVERTER CLUTCH SIGNAL
381 PLUG, BORE
382 SPRING, 4-3 SEQUENCE VALVE
383 VALVE, 4-3 SEQUENCE
384 VALVE, 3-4 RELAY
385 VALVE, 3-4 SHIFT
386 SPRING, 3-4 SHIFT VALVE
387 VALVE, REVERSE ABUSE
388 SPRING, REVERSE ABUSE VALVE
389 VALVE, 3-2 DOWNSHIFT
390 SPRING, 3-2 DOWNSHIFT VALVE
391 VALVE, 3-2 CONTROL
392 SPRING, 3-2 CONTROL VALVE
393 SPRING, BORE PLUG
394 3-2 CONTROL SOLENOID
395 RETAINER, BORE PLUG

RH0196-4L60-E

Figure 133 Control Valve Assembly- Legend

7A-14B-68 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

VALVES LOCATED IN THE PUMP VALVES LOCATED IN THE VALVE BODY

RH0209-4L60-E

Figure 134 Control Valve Identification

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-69

SPRINGS LOCATED IN THE PUMP SPRINGS LOCATED IN THE VALVE BODY

PRESSURE · CONVCL 3-4 3·4

REGULATOR VALVE SEQ SHIFT

3-2 ACT 1-2

DOWNSHIFT FD LIMIT SHIFT

BLU PUR

3-2 FWD REV

CONTROL ABUSE ABUSE
RH0210-4L60-E

Figure 135 Control Valve Spring Identification

7A-14B-70 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

ILL.
NO. DESCRIPTION
200 BODY, PUMP
201 RING, OIL SEAL (SLIDE TO WEAR PLATE)
202 SEAL, 0-RING (SLIDE SEAL BACK-UP)
203 SLIDE, PUMP
204 SPRING, PIVOT PIN
205 PIN, PIVOT SLIDE
206 SPRING, PUMP SLIDE (OUTER)
231 207 SPRING, PUMP SLIDE (INNER)
208 SUPPORT, PUMP SLIDE SEAL
236 209 SEAL, PUMP SLIDE
210 RING,. PUMP VANE
~~~~~~:f§,....___.m---236 211 GUIDE, ROTOR
212 ROTOR, OIL PUMP
239 213 VANE, PUMP
236 214 SHAFT, STATOR
238 215 COVER, PUMP
216 VALVE, PRESSURE REGULATOR
217 SPRING, PRESSURE REGULATOR VALVE
226
218 SPRING, PRESSURE REGULATOR ISOLATOR
219 VALVE, REVERSE BOOST
220 SLEEVE, REVERSE BOOST VALVE
221 RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
222 RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
223 VALVE, STOP
224
224 VALVE, CONVERTER CLUTCH
225 SPRING, CONVERTER CLUTCH VALVE (INNER)
226 SPRING, CONVERTER CLUTCH VALVE (OUTER)
227 RIVET, PRESSURE RELIEF BOLT
228 BALL, PRESSURE RELIEF
223 229 SPRING PRESSURE RELIEF
230 RING, OIL SEAL (STATOR SHAFT)
222
231 SEAL, OIL PUMP COVER SCREEN
232 SCREEN, OIL PUMP COVER
233 BOLT, M8 X 1.25 X 40 (COVER TO BODY)
234 BUSHING, STAlOR SHAFT (FRONT)
235 PLUG, OIL PUMP COVER (FWD CLUTCH FEED)
236 PLUG, OIL PUMP .COVER
237 RETAINER AND BALL ASSEMBLY, CHECK VALVE
238 ORIFICE, CONVERTER CLUTCH SIGNAL
(CUP PLUG)
239 ORIFICE, OIL COOLER (CUP PLUG)
240 PLUG, CUP ORIFICE
200 241 BUSHING, STATOR SHAFT (REAR)
242 BUSHING, PUMP BODY
243 SEAL ASSEMBLY, OIL
244 RETAINER, FRONT HELIX

RH0185-4L60-E

Figure 136 Oil Pump Assembly

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-71

608
696
ll I 696 30

608 I
622
•
'
3

I
I
I
I
I
I
I 691
243 : SOME 1
34
:~~_!)J!:~:

3 0-RING, PUMP TO CASE BOLT OUTER)

5 SEAL, OIL (PUMP TO CASE) 618 SEAL, 0-RING (TURBINE SHAFT/ SELECTIVE
18 RING, OIL SEAL (2ND APPLY PISTON - OUTER) WASHER)
19 RING, OIL SEAL (2ND APPLY PISTON - INNER) 619 RING, OIL SEAL (SOLID)
21 SEAL, 0-RING 622 SEAL, 0-RING INPUT TO FORWARD HSG.
26 RING, OIL SEAL (4TH APPLY PISTON - OUTER) 624 SEAL, 3RD AND 4TH CL. (INNER AND OUTER)
27 SEAL, 0-RING (2-4 SERVO COVER) 629 SEAL, FORWARD CLUTCH (INNER AND OUTER)
30 SEAL, CASE EXTENSION TO CASE 631 SEAL, OVERRUN CLUTCH (INNER AND OUTER)
34 SEAL ASSEMBLY, CASE EXTENSION OIL 636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
37 SEAL, 0-RING (ITSS TO CASE EXTENSION) 691 SEAL, OUTPUT SHAFT
230 RING, OIL SEAL (STATOR SHAFT) 696 SEAL, TRANSMISSION (LO AND REVERSE
243 SEAL ASSEMBLY, OIL CLUTCH -OUTER, CENTER, INNER)
608 SEALS, REVERSE INPUT CLUTCH (INNER AND

RH0211-4L60-E

Figure 137 Seal and Bearing Locations

7A-148-72 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

242 603 234

601 674 683

669

7 BUSHING, CASE 657 BUSHING, INPUT SUN GEAR (FRONT)

33 BUSHING, CASE EXTENSION 659 BUSHING, INPUT SUN GEAR (REAR)
234 BUSHING, STATOR SHAFT (FRONT) 663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
241 BUSHING, STATOR SHAFT (REAR) REACTION SHAFT)
242 BUSHING, OIL PUMP BODY 665 BUSHING, REACTION CARRIER SHAFT (FRONT)
601 WASHER, THRUST (PUMP TO DRUM) 667 BUSHING, REACTION CARRIER SHAFT (REAR)
669 WASHER, THRUST (REACTION SHAFT/SHELL)
603 BUSHING, REVERSE INPUT CL. (FRONT)
672 BUSHING, REACTION SUN
606 BUSHING, REVERSE INPUT CLUTCH (REAR)
674 WASHER, THRUST (RACE/REACTION SHELL)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
WASHER
SUPPORT)
616 WASHER, THRUST (SELECTIVE)
692 BEARING., REACTION GEAR SUPPORT TO CASE
637 BEARING ASSEMBLY, INPUT SUN GEAR

RH0212-4L60-E

Figure 138 Bushing Locations

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-73

TORQUE SPECIFICATIONS
LOCATION QTY. SIZE TORQUE LOCATION QTY. SIZE TORQUE
ACCUMULATOR M6 11 N•m PARK BRAKE M8 31 N•m
2 2
COVER TO CASE 1.0 x 35.0 (8 LB.-FT.) BRACKET TO CASE 1.25 X 20.0 (23 LB.-FT.)

ACCUMULATOR M6 11 N•m PUMP COVER TO M8 24 N•m

1 5
COVER TO CASE 1.0 x 65.0 (8 LB.-FT.) BODY 1.25 X 40.0 (18 LB.-FT.)

DETENT SPRING TO M8 24N•m PUMP ASSEMBLY TO M8 24 N•m

1 7
VALVE BODY 1.25 x 20.0 (18 LB.-FT.) CASE 1.25 X 60.0 (18 LB.-FT.)

FWD ACCUM. COVER M6 11 N•m CASE EXTENSION M10 35 N•m

3 4
TO VALVE BODY 1.0 x 17.7 (8 LB.-FT.) TO CASE 1.50 X 30.0 (26 LB.-FT.)

SOLENOID ASSEMBLY M6 11 N•m MANUAL SHAFT TO M10 31 N•fll

2 1
TO CASE 1.0 x 12.0 (8 LB.-FT.) INSIDE DETENT LEVER 1.50 NUT (23 LB.-FT.)

TRANSMISSION OIL M8 11 N•m LINE PRESSURE 11 N•m

16 1 1/8 - 27
PAN TD CASE 1.25 x 19.3 (8 LB.-FT.) PLUG (8 LB.-FT.)

VALVE BODY M6 11 N•m CONNECTOR COOLER 38 N•m

2 2 1/4 - 18
TO CASE 1.0 X 35.0 (8 LB.-FT.) PIPE (28 LB.-FT.)

VALVE BODY M6 11 N•m PRESSURE SWITCH M6 11 N•m

9 2
TO CASE 1.0 x 47.5 (8 LB.-FT.) ASM. TO VALVE BODY 1.0 X 17.7 (8 LB.-FT.)

VALVE BODY M6 11 N•m VEHICLE SPEED M6 11 N•m

3 1
TO CASE 1.0 x 54.4 (8 LB.-FT.) SENSOR RETAINER 1.0X21.7 (8 LB.-FT.)

VALVE BODY M6 11 N•m SPACER PLATE M6 11 N•m

3 3
TO CASE 1.0 x 65.0 (8 LB.-FT.) SUPPORT TO CASE 1.0 X 17.7 (8 LB.-FT.)

PRESSURE CONTROL
M6 11 N•m
SOLENOID TO 1
1.0 X 17.7 (8 LB.-FT.)
VALVE BODY

RH0235-4L60-E

Figure 139 Torque Specifications

7A-14B-74 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

BUSHING REPLACEMENT PROCEDURE

PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY

REMOVE AS SHOWN INSTALL AS SHOWN

J 7004-1

J 25019-14

J 8092

200

J 34196-12
242
200

J 8092

J 25019-9
603

605

605

RH0213-4L60-E

Figure 140 Bushing Replacement Procedure

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-75

BUSHING REPLACEMENT PROCEDURE

PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY

REMOVE AS SHOWN INSTALL AS SHOWN

659

J 23907

J 7004-1

J 25019-14
665

666

J 8092 J 8092

J 34196-1 J 34196-1
672 672

673 673

RH0214-4L60-E

Figure 141 Bushing Replacement Procedure

7A-14B-76 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

BUSHING REPLACEMENT PROCEDURE

PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY

REMOVE AS SHOWN INSTALL AS SHOWN

J 8092 J 8092

J 23062-14
J 34196-4

33

31 31

J 8092

J 34196-10

RH0215-4L60-E

Figure 142 Bushing Replacement Procedure

 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR 7A-14B-77

SPECIAL TOOLS
UNIVERSAL REMOVER DIAL INDICATOR SET REAR SEAL INSTALLER HOLDING FIXTURE AND BASE

J 7004-1 J 8001 J 21426 J 8763-02

OIL PUMP BODY & COVER CLUTCH SPRING COMPRESSOR PUMP OIL SEAL INSTALLER PISTON COMPRESSOR
ALIGNMENT BAND PRESS

J 21368 J 25016 J 22269-01

END PLAY CHECKING FIXTURE END PLAY FIXTURE ADAPTER CLUTCH SPRING CLUTCH SPRING COMPRESSOR
COMPRESSOR ADAPTER

J 25022 J 34725 J 23327 J 25018-A

OIL PUMP REMOVER & END SPEED SENSOR REMOVER UNIVERSAL REMOVER PUMP REMOVER & INSTALLER
PLAY CHECKING FIXTURE

SPEEDOMETER GEAR PULLER TURBINE SHAFT SEAL ADAPTER TURBINE SHAFT SEAL SIZER
&ADAPTER INSTALLER

J 21427-01 & J 8433 J 36418-1 J 39119 J 36418-2A

OUTPUT SHAFT SUPPORT SERVO COVER COMPRESSOR BUSHING & UNIVERSAL REMOVER SET
FIXTURE
J 29369-1

J 29369-1 & J 29369-2

J 29837 J 29714 RH0216-4L60-E

Figure 143 Special Tools

7A-148-78 4L60-E AUTOMATIC TRANSMISSION UNIT REPAIR

SPECIAL TOOLS
SPEED SENSOR ROTER SPEEDOMETER GEAR HANDLE INNER FORWARD CLUTCH
INSTALLER INSTALLER SEAL PROTECTOR

J 36352-4 & J 36352-6 J 5590 J 8092 J 29883

2-4 BAND APPLY PIN TOOL DIAL INDICATOR POST END PLAY CHECKING TOOL INNER OVERRUN CLUTCH
SEAL PROTECTOR

J 29882
STATOR SHAFT SEALS INSTILLATION AND SIZING TOOLS BUSHING INSTALLERS

J 39855-1 J 38735-3 J 39855-2 J 25019-12

Pusher J 25019-9
Protector Sizer

w~ J 39855-1 & J 38735-3 & J 39855-2

® ® J 25019-9 & J 25019-12
BUSHING REMOVER BUSHING REMOVER BUSHING REMOVER BUSHING REMOVER

J 25019-14 J 24036 J 23062-14 J 25019-16

BUSHING SET COOLER FLUSHER

@)JD ell]~
oO)aiDu@@})
J 34196
DIAL INDICATOR STAND & GUIDE PIN SET

.., ;;;;;JWW I w m==mrnm I Ml ;;;;-m@i

w ;;;;;..Hmu I Ml ;;;;;Jf@W I w ;;;;--nam 1
J35944
RH0236-4L60-E
J 25025-B
Figure 144 Special Tools
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78·1

SECTION 78

MANUAL TRANSMISSION
ON-VEHICLE SERVICE
RPO MM6 AND M49
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread Jocking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . .
5-Speed Manual Transmission Assembly
(RPO M49) . . . . . . . . . . . . . . . . . . . . . . . . . .
6-Speed Manual Transmission Assembly
(RPO MM6) ..........................
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . .
Checking Manual Transmission Assembly
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Support and Transmission
Mount Assembly . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Control Lever Boot
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Control Assembly
(5-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Control Lever
Handle Assembly (6-Speed) .............
7B- l Manual Transmission Control Assembly
(6-Speed) ............................ 7B-8
7B-1 Output Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . 7B-9
Backup Lamp Switch Assembly . . . . . . . . . . . 7B-10
7B-1 Speed Sen~or Assembly (5-Speed) ......... 7B-11
7B-2 Electronic Speed Sensor (6-Speed) . . . . . . . . . 7B-11
7B-4 Reverse Lockout Solenoid (6-Speed) ....... 7B-11
Reverse Lockout Assembly (6-Speed) ...... 7B-14
7B-4 Skip Shift Solenoid (6-Speed) ............. 7B-14
5-Speed Manual Transmission Assembly
7B-4 (RPO M49) ......................... 7B-14
6-Speed Manual Transmission Assembly
7B-6 (RPO MM6) . . . . . . . . . . . . . . . . . . . . . . . . . 7B-16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-18
7B-7 Fastener Tightening Specifications . . . . . . . . . 7B-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B- l 8
7B-8

GENERAL DESCRIPTION
The 5-speed manual transmission assembly (RPO
M49) is the only manual transmission assembly available
for the 3.4L L32 V6 engine assembly. The 6-speed
manual transmission assembly (RPO MM6) is available
for the 5. 7L LT! V8 engine assembly. Manual transmis-
sion assemblies are identified by the number of forward
gears and the measured distance between the centerline of
the output shaft and the counter gear.
5-SPEED MANUAL TRANSMISSION
ASSEMBLY (RPO M49)
The 5-speed 77 mm manual transmission assembly
is a fully synchronized unit with blocker ring synchro-
nizers and a sliding mesh reverse gear. First and second
gears have three-piece synchronizer rings, consisting of
steel inner and outer cones and a tapered metal ring that is
lined on both sides with friction material similar to auto-
matic transmission friction plates. The cones are indepen-
dent of the gears and can be replaced separately. Third and
fourth gear blocker rings are more conventional in appear-
ance, but are also lined with friction material. The fifth
gear blocker ring is brass.
NOTICE: No lubricant other than DEXRON®-II
GM P/N 1051855 should be used in this manual
transmission assembly. Other lubricants or additives
may damage the blocker ring friction material or its
adhesive.
The mainshaft and countershaft are supported on
tapered roller bearings and must be shimmed for proper
end play. First through fourth speed mainshaft gears ride
on caged roller bearings. An aluminum transmission case
houses the various gears and bearings. The manual trans-
mission control assembly is mounted on top of the exten-
sion housing. The manual transmission control assembly
cannot be adjusted and can be serviced independently of
the manual transmission assembly.
6-SPEED MANUAL TRANSMISSION
ASSEMBLY (RPO MM6)
The 6-speed 85 mm manual transmission assembly
is a fully synchronized unit with blocker ring synchroniz-
ers and sliding mesh reverse gears.
78·2 MANUAL TRANSMISSION ON-VEHICLE SERVICE
NOTICE: No lubricant other than DEXRON®-II
GM P/N 1051855 should be used in this manual
transmission assembly. Other lubricants or additives
may damage the blocker ring friction material or its
adhesive.
The 6-speed manual transmission assembly has a
reverse lockout solenoid, which · operates a reverse
lockout assembly to prevent the operator from accidently
shifting into reverse when the vehicle is moving forward
at a speed of 5 km/h (3 mph) or more.
The 6-speed manual transmission assembly is
equipped with a. skip shift solenoid. This is to ensure good
fuel economy and compliance with federal fuel economy
standards. When shifting out of first gear, second and
third gears are inhibited by the use of an electric solenoid.
The following conditions must be present for this to
occur:
• Coolant temperature is above 77 °C (162 °F).
• Vehicle speed is between 24 and 29 km/h (15 and 21
mph).
• Throttle is opened 35 percent or less.
The 6-speed manual transmission assembly also uti-
lizes an electronic speed sensor.
Each forward gear synchronizer assembly is made
up of a splined hub with three synchronizer keys, a sleeve,
CONDITION POSSIBLE CAUSE
Transmission Assembly 1. Incorrect clutch travel.
Shifts Hard 2. Misaligned clutch housing bore to
crankshaft pilot.
3. Binding shift rail.
4. Internal bind in transmission assem-
bly caused by shift forks, selector
plates, or synchronizer assemblies.
5. Incorrect lubricant.
and two synchronizer springs. The reverse synchronizer
has a splined hub with three synchronizer keys, a sleeve,
two synchronizer springs, and a reverse synchronizer
retainer.
The mainshaft and countershaft are supported on
tapered roller bearings. All speed gears ride on caged
roller bearings. An aluminum transmission case houses
the various gears and bearings.
Like the 5-speed manual transmission assembly,
the 6-speed manual transmission control assembly is
mounted on top of the extension housing, and can be
serviced independently of the manual transmission
assembly. The manual transmission control assembly
cannot be adjusted. Unlike the 5-speed manual trans-
mission assembly, the manual transmission control lever
handle assembly on the 6-speed manual transmission
assembly can be removed from the manual transmission
control assembly. This allows for removal of the 6-speed
manual transmission assembly with the manual trans-
mission control assembly intact.
DIAGNOSIS
For diagnosis of the 5-speed 77 mm manual trans-
mission assembly or the 6-speed 85 mm manual transmis-
sion assembly refer to the following diagnosis chart.
CORRECTION
1. Refer to SECTION 7C.
2. Check alignment as necessary.
3. 5-Speed Manual Transmission
Assembly - remove transmission
cover and check for mispositioned
selector arm roll pin, loose cover
bolts, worn shift rail bores, worn
shift rail, distorted oil seal, or exten-
sion housing not aligned with case.
Replace worn or damaged compo-
nents as necessary.
6-Speed Manual Transmission
Assembly - remove, disassemble
and inspect transmission. Check for
worn shift bores, worn shift rail or
worn shift rail bushings. Replace
worn or damaged components as
necessary.
4. Remove, disassemble and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
5. Drain and refill manual transmis-
sion assembl .

CONDITION
Manual Transmission 1. No power to reverse lockout
Assembly Shifts Hard Into
Reverse or Does Not Shift
Into Reverse (6-Speed Manual 2. Damaged reverse lockout sol.enoid.
Transmission Assembly)
3. Worn or broken shift linkage
Gear Clash When Shifting
From One Gear to Another
Noisy Transmission
Jumps Out of Gear
Will Not Shift Into One Gear
MANUAL TRANSMISSION ON-VEHICLE SERVICE 78·3
POSSIBLE CAUSE
solenoid.
Worn or broken reverse lockout
mechanism.
components. Worn or damaged
synchronizer sleeve or hub.
I. Incorrect clutch travel.
2. Low lubricant level or incorrect
lubricant.
3. Worn or damaged control or syn-
chronizer assemblies.
I. Low lubricant level or incorrect
lubricant.
2. Loose clutch housing-to-engine, or
transmission-to-clutch, housing
bolts.
3. Misaligned clutch housing bore to
crankshaft pilot.
4. Worn or damaged control assembly,
transmission gears, or bearing
components.
l. Worn offset lever plastic insert or
loose lever.
2. Worn or damaged control assembly,
shift forks, selector plates, interlock
plate, selector arm, shift rail, springs
or shift cover.
3. Worn or tapered gear teeth, worn or
damaged synchronizer assemblies,
excessive end play caused by worn
thrust washers or output shaft gears.
1. Worn, damaged, or incorrectly
assembled control assembly, selector
plates, interlock plate, or selector
arm.
2. Damaged or worn synchronizer
sleeves or hubs.
CORRECTION
I. Turn ignition switch to "RUN"
position and check for voltage
(12 volts) at the reverse lockout.
2. Remove and check function of
reverse lockout assembly. Replace
worn or damaged parts as necessary.
3. Remove, disassemble, and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
1. Refer to SECTION 7C.
2. Drain and refill manual transmis-
sion assembly. If lubricant level
was low, check for leaks and repair
as necessary.
3. Remove, disassemble and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
I. Drain and refill manual transmis-
sion assembly. If lubricant level
was low, check for leaks and repair
as necessary.
2. Check for correct bolt torque and
torque as necessary.
3. Check alignment.
4. Remove, disassemble and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
l. Remove control assembly and
check for loose offset lever or worn
insert. Replace worn or damaged
components as necessary.
2. Remove, disassemble, and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
3. Remove, disassemble and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
1. Remove, disassemble, and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
2. Remove, disassemble, and inspect
manual transmission assembly.
Replace worn or damaged compo-
nents as necessary.
78-4 MANUAL TRANSMISSION ON-VEHICLE SERVICE

CONDITION POSSIBLE CAUSE CORRECTION

Locked In One Gear, Cannot
Be Shifted Out
1. Worn or broken shift rail(s). Bent or
damaged shift fork.
2. Worn control assembly. Incorrectly
assembled or broken shift mecha-
nism. Worn or damaged gear train
components.
I. Remove, disassemble, and inspect
manual transmission assembly.
2. Remove, disassemble, and inspect
manual transmission assembly.
Replace worn or damaged parts or
assemble correctly.

ON-VEHICLE SERVICE blies is the shape. The removal and installation procedure
for the two different mount assemblies will be the same.
CHECKING MANUAL TRANSMISSION
ASSEMBLY FLUID LEVEL !+,.I Remove or Disconnect
CAUTION: Refer to "Caution" under
Figure 1 "Disconnecting the Battery Negative
l+,.I Remove or Disconnect
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
1. Raise and suitably support vehicle. Refer to SEC- 2. Raise and suitably support vehicle. Refer to SEC-
TION OA. TION OA.

1.,1 Clean
• All dirt and oil from around fill plug (10 or 11 ).
- Fill plug (11) is located on right side of
5-speed manual transmission assembly.
- Fill plug (10) is located on left side of
6-speed manual transmission assembly.
2. Fill plug (10 or 11 ).
3. Fluid level should be even with bottom of fill plug
hole.
3. Support manual transmission assembly (1 or 2) with
transmission stand.
4. Transmission mount nut ( 16) and washer ( 17) from
transmission mount assembly (13).
5. Transmission support bolts/screws (15) from rail
assembly.
6. Transmission support (14).
7. Transmission mount bolts/screws (18) from manual
transmission assembly ( 1 or 2). ·
8. Transmission mount assembly (13).

l++I Install or Connect l++I Install or Connect

NOTICE: No lubricant other than DEXRON®-II NOTICE: See "Notice" on page 78-1 of this
GM P/N 1051855, should be used in this manual section.
transmission assembly. Other lubricants or additives
1. Transmission mount assembly (13) to manual
may damage the blocker ring friction material or its
transmission assembly (1 or 2).
adhesive.
2. Transmission mount bolts/screws (18).
NOTICE: See "Notice" on page 7B-1 of this
section.
1. Lubricant, if required.
l~I Tighten

2. Fill plug (10 or 11 ). • Transmission mount bolts/screws (18) to 54

N•m (40 lb. ft.).
l~I Tighten
3. Transmission support (14) to rail assemblies.
4. Transmission support bolts/screws ( 15).
• Fill plug (11) on 5-speed manual transmission
assembly to 27 N•m (20 lb. ft.).
• Fill plug (10) on 6-speed manual transmission
l~I Tighten
assembly to 30 N•m (22 lb. ft.). • Transmission suppo11 bolts/screws ( 15) to
3. Lower vehicle. 58 N•m (43 lb. ft.).
5. Transmission mount washer (17) and nut (16).
TRANSMISSION SUPPORT AND
TRANSMISSION MOUNT ASSEMBLY l~I Tighten
• Transmission mount nut (16) to 47 N•m
Figure 2
(35 lb. ft.).
The transmission mount assembly for the 5-speed
6. Remove transmission stand supporting manual
manual transmission assembly is similar to the transmis-
sion mount assembly for the 6-speed manual transmission transmission assembly ( 1 or 2).
assembly. The difference between the two mount assem- 7. Lower vehicle.
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78·5

5 12

7 8

10 55
A B 6

A 6-SPEED MANUAL TRANSMISSION COMPONENT

LOCATIONS
B 5-SPEED MANUAL TRANSMISSION COMPONENT
LOCATIONS
1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL
3 SWITCH ASSEMBLY, BACKUP LAMP (6-SPEED)
4 SWITCH ASSEMBLY, BACKUP LAMP (5-SPEED)
5 PLUG, TRANSMISSION OIL DRAIN (6-SPEED)
6 PLUG, TRANSMISSION OIL DRAIN (5-SPEED)
7 SOLENOID, REVERSE LOCKOUT (6-SPEED)
8 LOCKOUT ASSEMBLY, REVERSE (6-SPEED)
9 SENSOR, ELECTRONIC SPEED (6-SPEED)
10 PLUG, TRANSMISSION OIL FILL (6-SPEED)
11 PLUG, TRANSMISSION OIL FILL (5-SPEED)
12 SENSOR ASSEMBLY, SPEED (5-SPEED)
55 SOLENOID, SKIP SHIFT (6-SPEED)

RC0001-7B-F-RP

Figure 1 - Manual Transmission Assembly Component Locations

78-6 MANUAL TRANSMISSION ON-VEHICLE SERVICE

13

17--?
14

16 ~---15
1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL
13 MOUNT ASSEMBLY, TRANSMISSION
14 SUPPORT, TRANSMISSION
15 BOLT/SCREW, TRANSMISSION SUPPORT, 58 N•m
(43 LB. FT.)
16 NUT, TRANSMISSION MOUNT, 47 N•m (35 LB. FT.)
17 WASHER, TRANSMISSION MOUNT
18 BOLT/SCREW, TRANSMISSION MOUNT, 54 N•m
(40 LB. FT.)
PC0002-7B-F-RP

Figure 2 - Transmission Support and Transmission Mount Assembly (Typical)

8. Battery negative cable assembly.

!++I Install or Connect

MANUAL TRANSMISSION CONTROL LEVER NOTICE: See "Notice" on page 7B-1 of this
section.
BOOT ASSEMBLY
1. Boot assembly (24 or 25) to front compa11ment floor
pan assembly (44 or 51).
Figures 3 and 4 2. Boot bolts/screws (22 or 23).
l++I Remove or Disconnect
!~I Tighten
I. Front floor console trim plate assembly. Refer to • Boot bolts/screws (22 or 23) to 1.7 N•m
SECTION 8C. (15 lb. in.).
2. Handle bolts/screws (27), for 6-speed manual 3. Handle assembly (26) to control assembly (20).
transmission assembly.
4. Handle bolts/screws (27).
3. Handle assembly (26), for 6-speed manual trans-
mission assembly. l~I Tighten
4. Boot bolts/screws (22 or 23). • Handle bolts/screws (27) to 25 N•m (18 lb. ft.).
5. Boot assembly (24 or 25) from front compartment 5. Front floor console trim plate assembly. Refer to
floor pan assembly (44 or 51 ). SECTION 8C.
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78·7

24

19

\ 21

2
!VtEWA!

2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL

19 BOLT/SCREW, TRANSMISSION CONTROL, 17 N•m
(13 LB. FT.)
21 CONTROL ASSEMBLY, MANUAL TRANSMISSION
23 BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER BOOT, 1.7 N•m (15 LB. IN.)
24 BOOT ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
51 PAN ASSEMBLY, FRONT COMPARTMENT FLOOR
PC0003-7B-F-RP

Figure 3 - Manual Transmission Control Lever Boot Assembly (5-Speed)

MANUAL TRANSMISSION CONTROL

ASSEMBLY (5-SPEED) I-++! Install or Connect
NOTICE: See "Notice" on page 7B-1 of this
Figure 3 section.

!+-+I Remove or Disconnect !~! Clean

I. Front floor console trim plate assembly. Refer to
SECTION 8C.
2. Boot bolts/screws (23).
3. Boot assembly (24).
4. Transmission control bolts/screws (19).
5. Control assembly (21 ).
NOTICE: The upper and lower transmission control
levers are bonded together. Separation of the levers
will cause damage, requiring replacement of the
transmission control assembly.
• Sealant from manual transmission extension
housing.
• Sealant from control assembly (21), if rein-
stalling.
1. Apply a continuous 3 mm (1/8-inch) bead of RTV
Sealant GM P/N 12345739, or equivalent to manual
transmission extension housing-to-control assembly
sealing surface.
2. Control assembly (21 ).
3. Transmission control bolts/screws (19).
78·8 MANUAL TRANSMISSION ON-VEHICLE SERVICE

1©..I Tighten
• Transmission control bolts/screws ( 19) to
17 N•m (13 lb. ft.).
4. Boot assembly (24).
5. Boot bolts/screws (23).

l©..I Tighten
• Boot bolts/screws (23) to 1.7 N•m (15 lb. in.).
6. Front floor console trim plate assembly. Refer to
SECTION 8C.

MANUAL TRANSMISSION CONTROL LEVER

HANDLE ASSEMBLY (6-SPEED)

Figure 4

!+-+I Remove or Disconnect

1. Front floor console trim plate assembly. Refer to
SECTION 8C.
2. Control lever handle bolts/screws (27).
3. Control lever handle assembly (26).
!++I Install or Connect
NOTICE: See "Notice" on page 7B-l of this
section.
1. Control lever handle assembly (26).
2. Control lever handle bolts/screws (27).
l©..I Tighten
• Control lever handle bolts/screws (27) to
25 N•m (18 lb. ft.).
A REMOVAL OF 6-SPEED MANUAL TRANSMISSION
CONtROL LEVER BOOT ASSEMBLY
B REMOVAL OF 6-SPEED MANUAL TRANSMISSION
CONTROL LEVER HANDLE ASSEMBLY
20 CONTROL ASSEMBLY, MANUAL TRANSMISSION
(6-SPEED)
22 BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER BOOT, 1.7 N•m (15 LB. IN.)
25 BOOT ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
26 HANDLE ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
27 BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER HANDLE, 25 N•m (18 LB. FT.)
44 PAN ASSEMBLY, FRONT COMPARTMENT FLOOR
52 BOLT/SCREW, TRANSMISSION CONTROL,
18 N•m (13 LB. FT.)
PC0004-7B-F-RP

3. Front floor console trim plate assembly. Refer to Figure 4 - Manual Transmission Control, Handle, and Boot
Assemblies (6-Speed)
SECTION 8C.

MANUAL TRANSMISSION CONTROL

ASSEMBLY (6-SPEED) !W:.W!Clean
Figure 4 • Sealant from manual transmission extension
housing.
!++I Remove or Disconnect • Sealant from control assembly (20), if rein-
stalling.
1. Front floor console trim plate assembly. Refer to
SECTION 8C. 1. Apply a continuous 3 mm (1/8-inch) bead of RTV
Sealant GM PIN 12345739, or equivalent to manual
2. Handle.bolts/screws (27). transmission extension housing-to-control assembly
3. Handle assembly (26). sealing surface.
4. Boot bolts/screws (22). 2. Control assembly (20).
5. Boot assembly (25). 3. Transmission control bolts/screws (52).
6. Transmission control bolts/screws (52).
7. Control assembly (20).
l~I Tighten
• Transmission control bolts/screws (52) to
!++I Install or Connect 18 N•m (13 lb. ft.).
NOTICE: See "Notice" on page 7B-1 of this 4. Boot assembly (25).
section. 5. Boot bolts/screws (22).
 MANUAL TRANSMISSION ON-VEHICLE SERVICE ,79.9

OUTPUT SHAFT SEAL

I~! Tighten The output shaft seal for the 5-speed manual trans-
mission assembly is similar to the output shaft seal for the
• Boot bolts/screws (22) to 1.7 N•m (15 lb. in.).
6-speed manual transmission assembly. While there are
6. Handle assembly (26) to control assembly (20). differences in the design, the removal and installation
7. Handle bolts/screws (27). procedures for the two different output shaft seals is
essentially the same. The only difference is the installa-
l~I Tighten tion tool used to install the different seals.
Figures 5 and 6
• Handle bolts/screws (27) to 25 N•m (18 lb. ft.)
8. Front floor console trim plate assembly. Refer to Tools Required:
SECTION 8C. J 23907 Slide Hammer
J 26941 Extension Housing Seal Remover
J 21426 Extension Housing Seal Installer,
5-Speed Manual Transmission Assembly

J 39440

!VIEW Al
B
A
A REMOVAL OF OUTPUT SHAFT SEAL
B INSTALLATION OF OUTPUT SHAFT SEAL
28 C RUBBER MALLET
1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
28 SEAL, OUTPUT SHAFT
PCOOOS-78-F-RP

Figure 5 - Manual Transmission OLJtput Shaft Seal (6-Speed)

!VIEWA I
A
A REMOVAL OF OUTPUT.SHAFT SEAL
B INSTALLATION OF OUTPUT SHAFT SEAL
29 C RUBBER MALLET
2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL
29 SEAL, OUTPUT SHAFT PC0006-7B-F-RP

Figure 6 - Manual Transmission Output Shaft Seal (5-Speed)

78~10 MANUAL TRANSMISSION ON-VEHICLE SERVICE

J 39440 Extension Housing Seal Installer, 6-speed manual transmission assembly is located on the
6-Speed Manual Transmission Assembly right-hand side.

!+--+I Remove or Disconnect Figures 7 and 8

1. Propeller shaft assembly. Refer to SECTION 4A.
2. Output shaft seal (28 or 29) using J 26941 with
J 23907.
!-++-I Install or Connect
NOTICE: See "Notice" on page 7B- l of this
section.
1. Output shaft seal (28 or 29), using J 21426 for
5-speed manual transmission assembly, or J 39440
for 6-speed manual transmission assembly.
2. Lubricate inside diameter of output shaft seal (28 or
29) with transmission fluid.
3. Propeller shaft assembly. Refer to SECTION 4A.
!+--+I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Electrical connector from backup lamp switch
assembly (3 or 4).
4. Backup lamp switch assembly (3 or 4) from manual
transmission assembly (1 or 2).

!L"i'I Inspect l++I Install or Connect

• Manual transmission assembly fluid level. Refer to
"Checking Manual Transmission Assembly Fluid
Level" in this section.
BACKUP LAMP SWITCH ASSEMBLY
The backup lamp switch assembly is located on the
left-hand side of the 5-speed manual transmission assem-
bly, while the backup lamp switch assembly on the
NOTICE: See "Notice" on page 7B-1 of this
section.
1. Apply thin coating of teflon sealant, GM PIN
1052080 or equivalent to threads of backup lamp
switch assembly (3 or 4).
2. Backup lamp switch assembly (3 or 4) to manual
transmission assembly (1 or 2).

2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL

4 SWITCH ASSEMBLY, BACKUP LAMP
12 SENSOR ASSEMBLY, SPEED
30 BOLT/SCREW, SPEED SENSOR RETAINING, 10 N•m
(89 LB. IN.)
31 DRIVEN GEAR, SPEEDOMETER PC0007·7B-F-RP

Figure 7 - Manual Transmission Backup Lamp Switch and Speed Sensor Assemblies (5-Speed)

I~! Tighten
• Backup lamp switch assembly (4) 38 N•m
(28 lb. ft.) for 5-speed manual transmission
assembly.
• Backup lamp switch assembly (3) to 20 N•m
( 15 lb. ft.) for 6-speed manual transmission
assembly.
3. Electrical connector to backup lamp switch assem-
bly (3 or 4).
4. Lower vehicle.
5. Battery negative cable assembly.
SPEED SENSOR ASSEMBLY (5-SPEED)
Figure 7
!++I Install or Connect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA. .
3. Electrical connector from speed sensor assembly
(12).
4. Speed sensor retaining bolt/screw (30) from 5-speed
manual transmission assembly (2).
5. Speed sensor assembly ( 12) and speedometer driven
gear (31) from 5-speed manual transmission assem-
bly (2).
!++! Install or Connect
NOTICE: See "Notice" on page 7B-l of this
section.
1. Speedometer driven gear (31) and speed sensor
assembly (12) to 5-speed manual transmission
assembly (2).
2. Speed sensor retaining bolt/screw (30) to 5-speed
manual transmission assembly (2).
l~I Tighten
• Speed sensor retammg bolt/screw (30) to
10 N•m (89 lb. in.).
3. Electrical connector to speed sensor assembly (12).
4. Lower vehicle.
5. Battery negative cable assembly.
ELECTRONIC SPEED SENSOR (6-SPEED)
Figure 8
!++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
MANUAL TRANSMISSION ON-VEHICLE SERVICE 78~11
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Electrical connector from electronic speed sensor
(9).
4. Electronic speed sensor retaining bolt/screw (32)
from 6-speed manuartransmission assembly (1 ).
5. Electronic speed sensor (9) from 6-speed manual
transmission assembly (1 ).
!++I Install or Connect
NOTICE: See "Notice" on page 7B-l of this
section.
1. Electronic speed sensor (9) to 6-speed manual
transmission assembly (1).
2. Electronic speed sensor retaining bolt/screw (32) to
6-speed manual transmission assembly ( 1).
!~I Tighten
• Electronic speed sensor retaining bolt/screw
(32) to 10 N•m (89 lb. in.).
3. Electrical connector to electronic speed sensor (9).
4. Lower vehicle.
5. Battery negative cable assembly.
REVERSE LOCKOUT SOLENOID (6-SPEED)
Figures 8 and 9
!++I Remove or Disconnect
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Raise and suitably support vehicle. Refer to SEC-
TION OA.
3. Electrical connector from reverse lockout solenoid
(7).
4. Reverse lockout bolt/screw (40).
5. Reverse lockout assembly (8).
6. Reverse lockout solenoid (7) from reverse lockout
assembly (8).
!++I Install or Conn,ect
NOTICE: See "Notice" on page 7B-1 of this
section.
1. Reverse lockout solenoid (7) to reverse lockout
assembly (8).
l~I Tighten
• Reverse lockout solenoid (7) to 41 N•m
(30 lb. ft.).
2. Reverse lockout assembly (8) to 6-speed manual
transmission assembly ( 1).
3. Reverse lockout bolt/screw ( 40).
78-12 MANUAL TRANSMISSION ON-VEHICLE SERVICE

39

A LEFT-HAND SIDE
B RIGHT-HAND SIDE
1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
3 SWITCH ASSEMBLY, BACKUP LAMP
7 SOLENOID, REVERSE LOCKOUT
8 LOCKOUT ASSEMBLY, REVERSE
9 SENSOR, ELECTRONIC SPEED
32 BOLT/SCREW, ELECTRONIC SPEED SENSOR
RETAINING, 10 N•m (89 LB. IN.)
33 RING, REVERSE LOCKOUT SNAP
34 PLUNGER, REVERSE LOCKOUT
35 SPRING, REVERSE LOCKOUT OUTER
36 SEAT,REVERSELOCKOUT
37 RETAINING RING, REVERSE LOCKOUT
38 SPRING, REVERSE LOCKOUT INNER
39 BODY,REVERSELOCKOUT
40 BOLT/SCREW, REVERSE LOCKOUT, 18 N•m (13 LB. FT.)
PCOOOll-78-F-RP

Figure 8 - Manual Transmi.ssion Backup Lamp Switch, Electronic Speed Sensor, Reverse Lockout Solenoid, and Reverse
Lockout Assembly (6-Speed)
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78-13

I Apply 12 volts to reverse lockout solenoid. I

I
Remove reverse lockout
solenoid assembly
Solenoid plunger extended. ~ Check reverse lockout assembly.
Refer to SECTION 78-1 OB
(Extension Housing).

I Solenoid plunger retracted

I

I Replace reverse lockout solenoid. I

Reverse lockout plunger can Reverse lockout plunger

be depressed easily with thumb. cannot be depressed easily
with thumb.

Reverse lockout solenoid

and reverse lockout Remove reverse lockout
assembly ok solenoid from reverse lockout
assembly.

Check reverse lockout

solenoid circuit. Refer to
SECTION SA I Reverse lockout plunger can
be depressed easily with thumb.
I Reverse lockout plunger cannot
be depressed easily with thumb.

I Replace reverse lockout solenoid. I Check reverse lockout assembly.

Refer to SECTION 78-108.
(Extension Housing)

PC0009-7B·f-RP

Figure 9 - Reverse Lockout Assembly Bench Check

78-14 MANUAL TRANSMISSION ON-VEHICLE SERVICE

2. Raise and suitably support vehicle. Refer to SEC-

I~! Tighten TION OA.
3. Electrical connector from skip shift solenoid (55).
• Reverse lockout bolt/screw ( 40) to 18 N •m
(13 lb. ft.). 4. Skip shift solenoid (55) from transmission assembly
(1 ).
4. Electrical connector to reverse lockout solenoid (7).
5. Lower vehicle.
6. Battery negative cable assembly.
!•+I Install or Connect
1. Skip shift solenoid (55) to transmission assembly
(l).
REVERSE LOCKOUT ASSEMBLY (6-SPEED)
Figures 8 and 9 !~I Tighten
• Skip shift solenoid (55) to 40 N•m (30 lb. ft.).
!+-+! Remove or Disconnect 2. Electrical connector to skip shift solenoid (55).
CAUTION: Refer to "Caution" under 3. Lower vehicle.
"Disconnecting the Battery Negative 4. Battery negative cable assembly.
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly. 5-SPEED MANUAL TRANSMISSION
2. Raise and suitably support vehicle. Refer to SEC- ASSEMBLY (RPO M49)
TION OA. Figures 1,2,3 and 11
3. Electrical connector from reverse lockout solenoid Tools Required:
(7).
J 36842 Transmission Holding Fixture
4. Reverse lockout bolt/screw (40) from 6-speed
J 3289-20 Bench Mount Holding Fixture Base
manual transmission assembly (1 ).
5. Reverse lockout assembly (8) from 6-speed manual
transmission assembly (1 ).
l+-+I Remove or Disconnect
CAUTION: Refer to "Caution" under
IL'&'! Inspect "Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
• Reverse lockout assembly. Refer to SECTION 1. Battery negative cable assembly.
7B-1 OB for inspection and disassembly pro-
cedures. 2. Front floor console trim plate assembly. Refer to
SECTION 8C.
!-++! Install or Connect 3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
NOTICE: See "Notice" on page 7B-1 of this
section.
1. Reverse lockout assembly (8) to 6-speed manual
transmission assembly (1).
2. Reverse lockout bolt/screw ( 40) to 6-speed manual
transmission assembly ( 1).

I~! Tighten
• Reverse lockout bolt/screw (40) to 18 N •m
(13 lb. ft.).
3. Electrical connector to reverse lockout solenoid (7).
4. Lower vehicle.
5. Battery negative cable assembly.

SKIP SHIFT SOLENOID (6-SPEED)

Figure 10
1 TRANSMISSION ASSEMBLY
!+-+I Remove or Disconnect 55 SOLENOID, SKIP SHIFT

CAUTION: Refer to "Caution" under

"Disconnecting the Battery Negative RC0002·7B-F-RP
Cable Assembly" in SECTION OA. Figure 1O- Skip Shift Solenoid (6-Speed)
I. Battery negative cable assembly.
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78-15

4. Drain fluid from 5-speed manual transmission

assembly (2).
5. Propeller shaft assembly. Refer to SECTION 4A.
l~! Tighten
• Transmission bolts/screws (41) to 75 N•m
6. Support rear axle assembly with jack stand. (55 lb. ft.).
7. Rear axle torque arm assembly. Refer to SECTION 5. Apply a continuous 3 mm (1/8-inch) bead of RTV
3D. Sealant GM P/N 12345739, or equivalent to manual
8. Catalytic converter hanger assembly. Refer to SEC- transmission extension housing-to-control assembly
TION 6F. sealing surface.
9. Wiring harness connector from backup lamp switch 6. Raise 5-speed manual transmission assembly (2) up
assembly (4). engaging manual transmission control assembly
(21 ).
10. Wiring harness connector from speed sensor
7. Transmission control bolts/screws (19).
assembly (12).
11. Support engine assembly with a jack stand.
12. Support 5-speed manual transmission assembly (2)
l~! Tighten
with jack stand. • Transmission control bolts/screws (19) to 17
N•m (13 lb. ft.).
13. Transmission support and transmission mount
8. Raise 5-speed manual transmission assembly (2) to
assembly. Refer to "Transmission Support and
installed position.
Transmission Mount Assembly" in this section.
14. Lower 5-speed manual transmission assembly (2),
enough to reach transmission control bolts/screws 45
(19), with aid of helper.
15. Transmission control bolts/screws (19).
NOTICE: Manual transmission control assembly
must be held when lowering manual transmission
assembly, as control assembly is not retained in
vehicle. If control assembly is not held it could drop
causing damage to the component.
16. Lower 5-speed manual transmission assembly (2).
17. Manual transmission control assembly (21 ).
18. Transmission bolts/screws (41 ).
19. 5-speed manual transmission assembly (2) to fly-
wheel housing assembly (45) with aid of helper.
20. Place 5-speed manual transmission assembly (2) in
J 36842.

!++! Install or Connect

NOTICE: See "Notice" on page 7B-l of this
section.

IS,! Clean
• Sealant from manual transmission extension
housing.
• Sealant from control assembly (21 ), if rein-
stalling.
1. Control assembly (21) to installed position on
vehicle.
2. 5-speed manual transmission assembly (2) to fly- 2 TRANSMISSION ASSEMBLY, 5-SPEED MANUAL
41 BOLT/SCREW, TRANSMISSION, 75 N•m (55 LB. FT.)
wheel housing assembly ( 45), with aid of helper.
45 HOUSING ASSEMBLY, FLYWHEEL
• Pilot splined input shaft assembly (53) into 53 SHAFT ASSEMBLY, INPUT
clutch disc hub assembly and pilot bearing.
PC0010-7B-F-RP
3. Support 5-speed manual transmission assembly (2)
with jack stand. Figure 11 - Manual Transmission Assembly to Engine
Assembly (5-Speed)
4. Transmission bolts/screws (41 ).
78·16 MANUAL TRANSMISSION ON-VEHICLE SERVICE

9. Transmission support and transmission mount NOTICE: Disconnect the clutch master cylinder
assembly. Refer to "Transmission Support and pushrod before removing the actuator cylinder
Transmission Mount Assembly" in this section. assembly. If not disconnected, permanent damage to
l 0. Remove jack stands from transmission and engine the actuator cylinder will occur if the clutch pedal is
assemblies. depressed while the actuator is disconnected.
11. Wiring harness connector to speed sensor assembly
(12).
[I] Important
12. Wiring harness connector to backup lamp switch • Do not let the actuator cylinder hang by
assembly (4). hydraulic line.
13. Catalytic converter hanger assembly. Refer to 15. C~utch actuator cylinder and retain with mechanic's
SECTION 6F. wire.
14. Rear axle torque arm assembly. Refer to SECTION 16. Actuator spacer ( 46).
30. 17. Pull clutch fork assembly (47) down to disengage
15. Remove support from rear axle assembly. from release bearing.
16. Propeller shaft assembly. Refer to SECTION 4A. 18. Wiring harness connector from electronic speed
sensor (9).
17. Check and fill manual transmission assembly with
fluid. Refer to "Checking Manual Transmission 19. Support engine assembly with jack stand.
Assembly Fluid Level" in this section. 20. Support 6-speed manual transmission assembly (1)
18. Lower vehicle. with jack stand.
21. Transmission support and transmission mount
19. Front floor console trim plate assembly. Refer to
assembly. Refer to "Transmission Support and
SECTION 8C.
Transmission Mount Assembly" in this section.
6-SPEED MANUAL TRANSMISSION NOTICE: The clutch fork assembly (47) must be
disengaged from the release bearing assembly to
ASSEMBLY (RPO MM6)
prevent damage to the clutch system.
Figures 1,2,4 and 12 22. Transmission bolts/screws (43).
Tool Required: 23. Six-speed manual transmission assembly (1) with
aid of helper.
J 39430 Transmission Holding Fixture
24. Place 6-speed manual transmission assembly (1) in
!+-+I Remove or Disconnect J 39430.
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
!-++I Install or Connect
Cable Assembly" in SECTION OA. NOTICE: See "Notice" on page 7B-1 of this
section.
1. Battery negative cable assembly.
1. Six-speed manual transmission assembly (1) with
2. Front floor console trim plate assembly. Refer to aid of helper.
SECTION 8C.
• Pilot transmission input shaft through the
3. Manual transmission control lever handle bolts/ release bearing, the clutch driven plate splines
screws (27). and into the clutch pilot bearing.
4. Handle assembly (26). 2. Support 6-speed manual transmission assembly (1)
5. Raise and suitably support vehicle. Refer to SEC- with jack stand.
TION OA. 3. Transmission bolts/screws (43).
6. Drain fluid from 6-speed manual transmission
assembly (1 ).
7. Support rear axle assembly with jack stand.
!~I Tighten
• Transmission bolts/screws (43) to 35 N•m
8. Propeller shaft assembly. Refer to SECTION 4A. (26 lb. ft.).
9. Rear axle torque arm. Refer to SECTION 30. 4. Transmission support and transmission mount
10. Catalytic converter hanger assembly. Refer to assembly. Refer to "Transmission Support and
SECTION 6F. Transmission Mount Assembly" in this section.
11. Wiring harness connector from reverse lockout 5. Remove jack stands from transmission and engine
solenoid (7). assemblies.
12. Wiring harness connector from skip shift solenoid 6. Push clutch fork assembly ( 47) up to engage release
(55). bearing.
13. Wiring harness connector from backup lamp switch 7. Actuator spacer (46).
assembly (3). 8. Actuator cylinder.
14. Actuator cylinder nuts (50). 9. Actuator cylinder nuts (50).
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78-17

A CYLINDER, CLUTCH ACTUATOR

1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
43 BOLT/SCREW, TRANSMISSION, 35 N•m (26 LB. FT.)
46 SPACER, CLUTCH ACTUATOR
47 FORK ASSEMBLY, CLUTCH
A
48 HOUSING ASSEMBLY, FLYWHEEL
49 ENGINE ASSEMBLY 43
50 NUT, CLUTCH ACTUATOR CYLINDER, 20 N•m
(15 LB. FT.)
54 SHAFT ASSEMBLY, INPUT PC0011-7B-F-RP

Figure 12 - Manual Transmission Assembly to Engine Assembly (6-Speed)

18. Fill transmission assembly with fluid. Refer to

l~I Tighten "Checking Manual Transmission Assembly Fluid
Level" in this section.
• Actuator cylinder nuts (50) to 20 N•m
19. Lower vehicle.
(15 lb. ft.).
20. Clutch master cylinder pushrod. Refer to SECTION
10. Wiring harness connector to electronic speed sensor 7C.
(9).
21. Manual transmission control lever handle assembly
11. Wiring harness connector to backup lamp switch (26).
assembly (3).
22. Manual transmission control lever handle bolts/
12. Wiring harness connector to skip shift solenoid (55). screws (27).
13. Wiring harness connector to reverse lockout sole-

14.
noid (7).
Catalytic converter hanger assembly. Refer to
!~I Tighten
• Manual transmission control lever handle
SECTION 6F. bolts/screws (27) to 25 N •m (18 lb. ft.).
I 5. Rear axle torque arm. Refer to SECTION 3D. 23. Front floor console trim plate assembly. Refer to
16. Propeller shaft assembly. Refer to SECTION 4A. SECTION 8C.
17. Remove support from rear axle assembly. 24. Battery negative cable assembly.
78-18 MANUAL TRANSMISSION ON-VEHICLE SERVICE

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Backup Lamp Switch Assembly (5-Speed) ............................... 38 N•m (28 lb. ft.)
Backup Lamp Switch Assembly (6-Speed) ............................... 20 N•m (15 lb. ft.)
Clutch Actuator Cylinder Nut .......................................... 20 N•m (15 lb. ft.)
Electronic Speed Sensor Retaining Bolt/Screw ............................ 10 N•m (89 lb. in.)
Manual Transmission Control Lever Boot Bolt/Screw (5-Speed) ............. 1.7 N•m (15 lb. in.)
Manual Transmission Control Lever Boot Bolt/Screw (6-Speed) ............. 1.7 N•m (15 lb. in.)
Manual Transmission Control Lever Handle Bolt/Screw ..................... 25 N•m (18 lb. ft.)
Reverse Lockout Bolt/Screw .......................................... 18 N•m (13 lb. ft.)
Reverse Lockout Solenoid ............................................ 41 N•m (30 lb. ft.)
Skip Shift Solenoid (6-Speed) ......................................... 40 N•m (30 lb. ft.)
Speed Sensor Retaining Bolt/Screw ..................................... 10 N•m (89 lb. in.)
Transmission Bolt/Screw (5-Speed) ..................................... 75 N•m (55 lb. ft.)
Transmission Bolt/Screw (6-Speed) ..................................... 35 N•m (26 lb. ft.)
Transmission Control Bolt/Screw (5-Speed) .............................. 17 N•m (13 lb. ft.)
Transmission Control Bolt/Screw (6-Speed) .............................. 18 N•m (13 lb. ft.)
Transmission Mount Bolt/Screw ........................................ 54 N•m (40 lb. ft.)
Transmission Mount Nut .............................................. 47 N•m (35 lb. ft.)
Transmission Oil Fill Plug (5-Speed) .................................... 27 N•m (20 lb. ft.)
Transmission Oil Fill Plug (6-Speed) .................................... 30 N•m (22 lb. ft.)
Transmission Support Bolt/Screw ...................................... 58 N•m (43 lb. ft.)

SPECIAL TOOLS

2.
4.

6-SPEED MANUAL TRANSMISSION ASSSEMBLY

1. BENCH MOUNT HOLDING FIXTURE BASE

2. TRANSMISSION HOLDING FIXTURE
3. SLIDE HAMMER
4. EXTENSION HOUSING SEAL INSTALLER
5. EXTENSION HOUSING SEAL REMOVER PC0012-7B·F-RP
 MANUAL TRANSMISSION ON-VEHICLE SERVICE 78·19

4.
J 21426

J 23907

E3 J 36842
unQuu,g,g
2.
,-- ·-}~
1=- ·-}

5-SPEED MANUAL TRANSMISSION ASSEMBLY

1. BENCH MOUNT HOLDING FIXTURE BASE

2. TRANSMISSION HOLDING FIXTURE
3. SLIDE HAMMER
4. EXTENSION HOUSING SEAL INSTALLER
5. EXTENSION HOUSING SEAL REMOVER
PC0013-7B-F-RP

SECTION 78-68
BORG-WARNER (T5) UNIT REPAIR
RPO M49
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correct torque value must
be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage
could result.
CONTENTS
Unit Disassembly ...................................... 7B-
Transmission Disassembly ......................... 7B-
Mainshaft Disassembly ............................. 7B-
Drive Gear Disassembly ........................... 7B-
Cleaning and Inspection ........................... 7B-
Transmission Case ................................ 7B-
Bearing Rollers and Spacers ................... 7B-
Gears .'............................................... 7B-
Front and Rear Bearings ........................ 7B-
Synchronizer Blocker Rings .................... 7B-
Third/Fourth Blocker Rings ..................... 7B-
First/Second Blocker Rings ........... :......... 7B-
UNIT DISASSEMBLY
TRANSMISSION DISASSEMBLY
Figures 1 through 18
~ Clean
• Exterior of the transmissio.n assembly thoroughly
with appropriate solvent.
I+++! Disassemble
Tools Required:
J 37359 Countershaft Bearing Remover
J 22912-01 Bearing and Gear Puller
• Remove drain bolt on transmission case and
drain lubricant.
NOTICE: Removal of offset lever in position
other than neutral (centered) may result in driving
the roll pin into the detent plate without releasing
lever, making further disassembly extremely
difficult.
• Position offset lever in neutral gate (centered).
1. Roll pin attaching offset lever to shift rail (Figure
3).
2. Extension housing-to-transmission case bolts.
BORG-WARNER (TS) UNIT REPAIR 78·68·1
1 Synchronizer Keys and Springs .................. 7B- 9
1 Extension Housing Oil Seal.. ..................... 7B-10
7 Extension Housing Bushing ....................... 7B-10
8 Drive Gear Bearing Retainer Oil
8 Seal ................................................. 78-10
8 Transmission Cover ................................. 7B-11
8 Front Countershaft Bearing ........................ 7B-12
8 Drive Gear Assembly .............................. 7B-12
8 Mainshaft Assembly ................................ 7B-13
9 Transmission Assembly ............................ 7B-14
9 Specifications ........................................... 7B-17
9 Special Tools ........................................... 7B-19
NOTICE: Do not attempt to remove the offset
lever while the extension housing is still bolted in
place. The lever has a positioning lug engaged in
the housing detent plate, which prevents moving
the lever far enough for removal.
3. Housing and offset lever as an assembly (Figure
4).
4. Detent ball and spring from offset lever (Figure
5).
5. Roll pin from extension housing or offset lever.
6. Oiling funnel from rear of countershaft (Figure
6),
7. Bolts attaching transmission cover and shift fork
assembly to case.
• Two of the transmission cover attaching
bolts are alignment-type dowel bolts. Note
the location of these bolts for assembly
reference.
8. Cover (Figure 7 ).
9. Reverse lever spring clip, pivot bolt and shift
lever (Figure 8).
10. Backup lamp switch.
11. Fifth gear synchronizer snap ring and retainer
from rear of countershaft (Figure 9 ).
12. Unhook reverse lock spring from front of
transmission case (Figure 10).
78-68-2 BORG.WARNER (T5) UNIT REPAIR

''- P0001-7B6B-F-RA

Figure 1 0 .isassembled V:;:ie;w;---------~ Pc

 BORG-WARNER (T5) UNIT REPAIR 78-68-3

1. COVER, TRANSMISSION 52. GEAR CLUSTER, COUNTERSHAFT

2. BOLT, ALIGNMENT DOWEL 53. RACE, REAR COUNTERSHAFT
3. BOLT 54. SHIM, COUNTERSHAFT BEARING ADJUSTMENT
4. SEAL, O·RING 55. RETAINER. COUNTERSHAFT
5. PLUG, SHIFT RAIL 56. BOLT, COUNTERSHAFT RETAINER
6. RAIL, SHIFT 57. GEAR. 5TH SPEED DRIVE
7. FORK, 3RD AND 4TH SHIFT 58. RING, BLOCKER - STH SYNCHRONIZER
8. ARM, SELECTOR 59. SPRING, 5TH SYNCHRONIZER
9. PLATE. GEAR SELECT INTERLOCK 60. HUB, 5TH SYNCHRONIZER
10. FORK, 1ST AND 2ND SHIFT 61. KEY, STH SYNCHRONIZER
11. INSERT, SHIFT FORK 62. SLEEVE, STH SYNCHRONIZER
12. PLATE, SHIFT FORK 63. RETAINER. STH SYNCHRONIZER
13. PIN, ROLL - SELECTOR ARM 64. RING, SNAP - STH ·
14. SHAFT, MAIN WITH 1ST AND 2ND SYNCHRONIZER RETAINER
SYNCHRONIZER HUB 65. FUNNEL, TRANSMISSION OILING
15. SPRING, SYNCHRONIZER 66. PLUG. FILL ANO DRAIN
16. GEAR. REVERSE SLIDING 67. CASE. TRANSMISSION
17. CONE, INNER - 1ST AND 2ND SYNCHRONIZER 68. SPRING, REVERSE LOCK
18. CONE, OUTER - 1ST AND 2ND SYNCHRONIZER 69. O·RING, REVERSE IDLER
19. RING, BLOCKER - 1ST AND 2ND SYNCHRONIZER 70. GEAR, REVERSE IDLER
20. SLEEVE, 1ST GEAR BEARING 71. PIN, ROLL - REVERSE IDLER
21. BEARING, 1ST GEAR 72. SHAFT. REVERSE IDLER
22. GEAR, 1ST SPEED 73. FORK, 5TH SHIFT
23. BEARING, MAINSHAFT REAR 74. PIN, ROLL - SHIFT FORK
24. RACE, MAINSHAFT REAR BEARING 75. RAIL, 5TH AND REVERSE SHIFT
25. GEAR, 5TH SPEED DRIVEN 76. CLIP, SPRING - STH AND REVERSE LEVER
26. RING, SNAP 77. LEVER. 5TH AND REVERSE SHIFT
27. GEAR, SPEEDOMETER DRIVE 78. BOLT, 5TH ANO REVERSE
28. CLIP, SPEEDOMETER DRIVE GEAR SHIFT LEVER PIVOT
29. BEARING. MAIN DRIVE·GEAR THRUST 79. SWITCH, REVERSE LAMP
30. RACE, MAIN DRIVE GEAR THRUST BEARING 80. CONTROL, TRANSMISSION SHIFT LEVER AND HOUSING
31. RING, BLOCKER - 3RD AND 4TH 81. SLEEVE, SHIFT LEVER DAMPER
SYNCHRONIZER 82. LEVER, OFFSET SHIFT
32. HUB, 3RD AND 4TH SYNCHRONIZER 83. r1N, ROLL - OFFSET LEVER
33. KEY, SYNCHRONIZER 84. SPRING, DETENT
34. SLEEVE. 3RD AND 4TH SYNCHRONIZER 85. BALL. DETENT
35. GEAR, 3RD SPEED 86. 0-RING, EXTENSION HOUSING VENT
36. BEARING, 3RD GEAR 87. VENT, EXTENSION HOUSING
37. SPACER, 3RD GEAR BEARING 88. SEAL, EXTENSION HOUSING REAR OIL
38. RING, SNAP 2ND GEAR THRUST WASHER 89. BUSHING, EXTENSION HOUSING
39. WASHER. THRUST - 2ND GEAR 90. HOUSING, EXTENSION
40. GEAR, 2ND SPEED 91. BOLT, EXTENSION HOUSING
41. BEARING, 2ND GEAR 92. BOLT, DRIVE GEAR BEARING RETAINER
42. SPACER. 2ND GEAR BEARING 93. RETAINER, DRIVE GEAR BEARING
43. RING, SPIRAL RETAINING - 2ND SYNCHRONIZER 94. SEAL, DRIVE GEAR BEARING RETAINER OIL
44. WASHER, THRUST - 2ND SYNCHRONIZER 95. SHIM, MAINSHAFT BEARING ADJUSTMENT
45.. KEY, 1ST-2ND SYNCHRONIZER 96. RACE, MAIN DRIVE GEAR FRONT BEARING
46. PIN, LOCATING - 1ST SPEED 97. GEAR, MAIN DRIVE
BEARING SLEEVE
98. BEARINGS, ROLLER - MAIN DRIVE GEAR PILOT
49. O·RING, BEARING RACE 99.SPACER
50. RACE, FRONT COUNTERSHAFT BEARING
51. BEARING, COUNTERSHAFT

MC0002-7B-F-RP

Figure 2 Disassembled View - Legend

78-68-4 BORG-WARNER (T5) UNIT REPAIR

13. Fifth gear, synchronizer, shift fork and shift rail

as an assembly. If necessary, rotate rail to
disengage from reverse lever assembly (Figure
11).
14. Circlip, speedometer gear and retaining clip.
15. Snap ring from fifth speed driven gear (Figure
12).
16. Front bearing retainer bolts.
17. Front bearing retainer.
18. Front bearing race and end play shims from front
bearing retainer (Figure 13).
19. Rotate drive gear until flat surface faces
countershaft and remove drive gear from the
transmission case.
• Be careful not to drop the 15 roller bearings,
thrust bearing, or race from the rear of drive
gear (Figure 14).
KC0002-7B-F-RP
20. Fourth gear blocker ring from third/fourth Figure 4 Extension Housing to Transmission Case
synchronizer.
21. Mainshaft rear bearing race.
• If the race sticks, it is probably misaligned
in the case bore. To free the race, work the
shaft back and fourth in the case.
• Tilt mainshaft upward and remove assembly
from transmission case (Figure 15).
22. Reverse fork assembly from transmission case.
23. Countershaft retainer and shims (Figure 16).
24. Roll pin from forward end of reverse idler shaft.
25. Remove reverse idler shaft, rubber 0-ring and
gear from the transmission case (Figure 17).
26. Rear countershaft bearing race.
27. Countershaft bearing using appropriate pullers
(Figure 18).
• Move countershaft assembly rearward, tilt
85. DETENT
countershaft upward and remove from case. BALL
28. Rear countershaft bearing from shaft using J KC0014-7B'F·RP
37359 with J 22912-01. Figure 5 Detent and Offset Lever

82. OFFSET
LEVER
83. ROLL PIN
KC0013-7B-F-RP KC0015-7B-F-RP

Figure 3 Offset Lever Figure 6 Oiling Funnel

 BORG-WARNER (T5) UNIT REPAIR 78-68·5

------ ---
.........

63. RETAINER
64. SNAP RING

KC0018-7B-F-RP
Figure 9 Fifth Gear Synchronizer Retainer

KC0016-7B-F-RP
Figure 7 Transmission Cover

68. SPRING
75. FIFTH/REVERSE
SHIFT RAIL
77. REVERSE LEVER
KC0019-7B-F-RP
76, SPRING CLIP Figure 10 Reverse Lock Spring
KC0017-7B-F-RP
Figure 8 Reverse Lever Spring Clip
78-68-6 BORG-WARNER (T5) UNIT REPAIR

KC0020-7B-F-RP
Figure 11 Fifth Gear Synchronizer

KC0005-7B-F-RP
Figure 14 Drive Gear

';(
P0002-7B6B-F-RA

Figure 12 Fifth Gear Snap Ring

Figure 15 Mainshaft

93. DRIVE GEAR

54. SHIM
BEARING RETAINER
55. COUNTERSHAFT
95. SHIM RETAINER
96. FRONT BEARING
RACE
KC0021-7B-F-RP KC0022-7B-F-RP
Figure 13 Bearing Retainer and Shims Figure 16 Countershaft Retainer
 BORG-WARNER (TS) UNIT REPAIR 78-68-7

9. First/second synchronizer spring and keys from

first-reverse sliding gear.
10. Sleeve from mainshaft hub.
NOTICE: Do not attempt to remove the first-
second-reverse hub from mainshaft. The hub and
shaft are permanently assembled and machined as
a matched set.
11. Fifth gear, using J 22912-01 and press.
12. Mainshaft rear bearing assembly.
13. First gear.
14. Needle bearing and sleeve.
15. Locating pin.
16. Three-piece first gear blocker ring assembly.
71. ROLL PIN
KC0023-7B·F·RP
Figure 17 Removing Reverse Idler Shaft Roll Pin

J 22912-01

KC0024-7B-F-RP
Figure 18 Removing Countershaft Bearing

MAINSHAFT DISASSEMBLY
Figures 19 through 21

l+t+I Disassemble Figure 19 Removing Third-Fourth Synchronizer

Tool Required:
J 22912-01 Bearing and Gear Puller
1. Thrust bearing and race from front end of
mainshaft.
• Scribe reference mark on third-fourth
synchronizer hub and sleeve for reassembly.
2. Third-fourth synchronizer, third blocker ring,
sleeve, hub and third gear as an assembly from
mainshaft, using J 22912-01 and press.
3. Needle bearing assembly and spacer.
4. Second gear snap ring and thrust washer.
5. Second gear, spacer and needle bearing.
6. Spiral snap ring. 14. MAINSHAFT
7. Thrust washer. 36. NEEDLE BEARING
8. Three-piece second gear blocker ring assembly. 37. SPACER
KC0026-7B-F-RP
• Scribe reference mark on first-second
Figure 20 Needle Bearing and Spacer
synchronizer hub and sleeve for reassembly.
78-68·8 BORG-WARNER (TS) UNIT REPAIR

17. INNER CONE

18. OUTER CONE
19. BLOCKER RING KC0027-7B-F-RP
KC0029-7B·F-RP

Figure 21 Three-Piece Blocker Ring Figure 23 Removing Drive Gear Bearing

CLEANING AND INSPECTION

DRIVE GEAR DISASSEMBLY
Transmission Case
Figures 22 and 23
l+!+I Disassemble
!~I Clean
1. Transmission case thoroughly inside and outside
Tool Required: with appropriate solvent.
J 22912-01 Bearing and Gear Puller 2. Magnetic disk at the bottom of the transmission
case.
1. Bearing race.
2. Thrust bearing. !L•l 1nspect
3. Roller bearings from cavity of drive gear. 1. Case for cracks.
4. Remove bearing from drive gear using J 22912-01 2. Front and rear faces of the transmission case for
and a press. burrs, and if present, dress them off with a fine
mill file.
1,:.1 Clean Bearing Rollers and Spacers
• Parts in appropriate solvent.
!L•l 1nspect
IL•l 1nspect • Drive gear bearing rollers.
• Gear teeth and shaft pilot for wear. • Reverse idler shaft.
• Spacers.

29. THRUST BEARING Gears

30. THRUST RACE
98. ROLLER BEARINGS
!L•l 1nspect
• Drive gear bearing rollers for chips, cracks, or
excessive wear and replace if necessary.
• Clutch sleeves to insure that they slide freely on
their hubs.

Front and Rear Bearings

~Clean
• Front and rear bearings thoroughly with
appropriate solvent.
NOTICE: Do not allow the bearings to spin.
Turn them slowly by hand. Spinning bearings may
KC002B-7B-F-RP
damage the race and rollers.
Figure 22 Drive Gear Bearings • Blow out bearings with compressed air.
• Lubricate bearings with transmission lubricant.
 BORG-WARNER (T5} UNIT .REPAIR 78-68-9

IL•! inspect
• Bearings for roughness by slowly turning race by
hand.
A. BLOCKER TEETH
Synchronizer Blocker Rings B. FEELER GAGE
Figure 24 C. CLUTCH TEETH
First/second synchronizer outer cone and third/
fourth blocker ring are lined with friction material and
cannot be checked visually for wear. Replacement is
necessary when gap between blocker teeth and adjacent
clutch teeth is significantly less than specified. Fifth
gear blocker ring is brass and can be checked visually KC0030-7B-F-RP
for wear and damage.
Figure 24 Measuring Blocker Ring Wear
NOTICE: Make certain the blocker rings are
correctly identified before assembly. First/second
synchronizer blocker ring does not have friction SYNCHRONIZER KEYS AND SPRINGS
material. The third/fourth synchronizer blocker
ring has friction material. Assembling one in place Figures 25 through 27
of the other will result in serious damage to the NOTICE: The synchronizer hubs and sliding
transmission. sleeves are a selected assembly and should be kept
IL•! inspect together as originally assembled, but the keys and
springs may be replaced if worn or broken.
• Fifth gear blocker ring for wear and damage.
!++! Remove or Disconnect
Third/Fourth Blocker Rings • Keys and springs.
Figure 24 • If relation of hub and sleeve are not already
marked, mark for assembly purposes.
!+;+j Assemble • Push the sliding sleeve from the hub. The
1. Third gear blocker ring to third gear with keys will fall free and the springs may be
twisting motion to fully seat. easily removed.
2. Fourth gear blocker ring to main drive gear with
twisting motion to fully seat.
!++! Install or Connect
!@! Measure • Keys and springs.
• Place a blocker ring on side of the hub and
• Gap between vertical faces of blocker teeth and sleeve and install keys and retain with a
clutch teeth. Nominal gap is 0.88-1.50 mm (0. spring.
035-0.059 inch) for new blocker rings (Figure 28). • Place a blocker ring on opposite side of the
hub and sleeve and install remaining spring.
First/Second Blocker Rings
Figure 24

!+!+! Assemble
1. Three-piece first gear blocker ring assembly,
using a twisting motion to fully seat.
2. Three-piece first gear blocker ring assembly, with
needle bearing and bearing sleeve, to first gear.
3. Three-piece second gear blocker ring assembly,
using a twisting motion to fully seat.
4. Three-piece second gear blocker ring assembly,
with thrust washer, to second gear.
!@! Measure
• Gap between vertical faces of blocker teeth and 15. SPRING 32. HUB 34. SLEEVE
clutch teeth. Nominal gap is 0.81-1.40 mm (0. 31. BLOCKER RING 33. KEYS
032-0.055 inch) for new blocker ring assemblies KC0031-7B-F-RP

(Figure 28). Figure 25 Third-Fourth Synchronizer Assembly

78-68-10 BORG-WARNER (T5) UNIT REPAIR

~ MAINSHAFT WITH HUB

B SPRING

~ REVERSE SLIDING GEAR

~ INNERCONE

~ OUTERCONE

~ BLOCKER RING

~ KEYS
MC0003-7B-F-RP
Figure 26 First-Second Synchronizer Assembly

-EXTENSION HOUSING BUSHING

Figure28
I++! Remove or Disconnect
Tools Required:
J 8092 Universal Driver Handle
J 23062-14 Extension Housing Bushing
Remover and Installer
1. Oil seal out of extension housing, using a
screwdriver or small chisel.
2. Bushing out of housing, using J 8092 with J
23062-14.
58. BLOCKER 62. SLEEVE
RING
59. SPRING
60. HUB
61. KEYS 63. RETAINER !++! Install or Connect
KC0033-7B-F-RP Tools Required:
Figure 27 Fifth Gear Synchronizer Assembly
J 8092 Universal Driver Handle
J 23062-14 Extension Housing Bushing
Remover and Installer
EXTENSION HOUSING OIL SEAL
J 21426 Extension Housing Seal Installer
I++! Remove or Disconnect 1. Bushing in housing, using J 8092 with J 23062-14.
2. New oil seal into extension housing using J 21426.
• Oil seal out of extension housing, using a
screwdriver or small chisel. • Lubricate inside diameter of seal with
transmission lubricant.
I++! Install or Connect
Tool Required: DRIVE GEAR BEARING RETAINER Oil SEAL
J 21426 Extension Housing Seal Installer
Figure 29
• New oil seal into extension housing using J 21426.
• Lubricate inside diameter of seal with
transmission lubricant.
!++! Remove or Disconnect
• Oil seal, using a screwdriver or small chiseL
 BORG-WARNER (T5) UNIT REPAIR 78-68-11

1. Selector arm roll pin usmg a pm punch and

!++! Install or Connect hammer (Figure 31).
Tool Required: 2. Shift rail, shift forks, shift fork plates, selector
arm, interlock plate and roll pin.
J 37375 Drive Gear Bearing Retainer Seal 3. Transmission cover to extension housing 0-ring
Installer seal using a screwdriver.
• New seal into retainer using J 37375 until it 4. Nylon inserts and shift fork plates from shift
bottoms in bore. forks.
• Lubricate inside diameter of seal with • Note position of inserts and plates for
transmission lubricant. assembly reference.

!+!+! Assemble
1. Nylon inserts and shift fork plates in shift forks.
• If removed, coat edges of shift rail plug with
sealer GM p/n 1052624, or equivalent, before
installing. ·
J 23062-14
• Coat shift rail and rail bores with transmission
lubricant.
2. Shift rail in cover until flush with inside edge of
cover.
3. Place first-second shift fork in cover with fork
offset facing rear of cover and push shift rail
through fork.
• The first-second shift fork is the larger of
the two forks.
KC0034-7B-F-RP 4. Selector arm and C-shaped interlock plate in
Figure 28 Installing Extension Housing Bushing cover and insert shift rail through arm.
• Widest part of interlock plate must face
away from cover, and selector arm roll pin
hole must face downward and toward rear
of cover.
5. Third-fourth shift fork in cover with fork offset
facing rear of cover.
• Third-fourth shift fork plate must be under
first-second shift fork plate.
6. Shift rail through third-fourth shift fork and into
front bore in cover.
• Rotate shift rail until shift fork plate at forward
end of rail faces away from, but is parallel to
cover.
• Align roll pin holes in selector arm and shift rail
and install roll pin.
• Roll pin must be flush with surface of
KC0054-7B-F·RP selector arm to prevent pin from contacting
Figure 29 Installing Bearing Retainer Oil Seal shift fork plates during shifts.
7. New transmission cover to extension housing 0-
TRANSMISSION COVER ring seal.
Figures 30 and 31 • Coat 0-ring seal with transmission lubricant.

!+!+! Disassemble
• Place selector arm plates and shift rail in neutral
position (centered).
• Rotate shift rail until selector arm disengages
from selector arm plates and roll pin is accessible.
78-68-12 BORG-WARNER (TS) UNIT REPAIR

FRONT COUNTERSHAFT BEARING

Figures 32 through 35
l++I Remove or Disconnect
Tools Required:
J 37358-1, -2 Bearing Race Receiver and
Case Support
J 22912-01 Bearing and Gear Puller
J 37359 Countershaft Bearing Remover
J 8092 Universal Driver Handle

NOTICE: Failure to support the case properly

will result in permanent distortion of the case
during bearing race removal.
1. Countershaft front bearing race and 0-ring from
the transmission case, using J 37358-1 with J
37358-2 and a press.
• Remove the front countershaft bearing race
1. TRANSMISSION COVER 8. SELECTOR ARM only if it is worn or damaged.
2. ALIGNMENT BOLT 9. INTERLOCK PLATE 2. Countershaft front bearing from the
3. BOLT 10. 1ST/2ND SHIFT FORK countershaft, using J 22912-01 with J 37359, J
4. 0-RING SEAL 11. INSERT. 8092 and a press.
5. SHIFT RAIL PLUG 12. SHIFT FORK PLATE
6. SHIFT RAIL
7. 3R0/4TH SHIFT FORK
13. ROLL PIN I++! Install or Connect
NC1002-7B-F-RP Tools Required:
Figure 30 Transmission Cover J 37357 Countershaft Bearing and Race
Remover and Installer
J 22912-01 Bearing and Gear Puller
J 8092 Universal Driver Handle
13, ROLL PIN
1. Countershaft front bearing onto the countershaft,
using J 37357 with J 22912-01, J 8092 and a press.
2. New 0-ring onto the countershaft front bearing
race.
• Lubricate the 0-ring.
3. Countershaft front bearing race into the
transmission case, using J 37357 with J 8092 and a
press.
• Lightly tap the race into its bore until the 0-
ring is compressed.
• Use a press to install the race until its
shoulder rests on the inside of the case.
DRIVE GEAR ASSEMBLY
)+!+! Assemble
KC0036-7B-F-RP Tools Required:
Figure 31 Removing Selector Arm Roll Pin J 22912-01 Bearing and Gear Puller
J 6133-01 Installer
1. Bearing onto the drive gear, using J 22912-01
with J 6133-01 and a press.
• Coat roller bearings and drive gear bearing
bore with lightweight grease.
2. Roller bearings into the bore of the drive gear.
3. Thrust bearing and race into the drive gear.
 BORG-WARNER (T5) UNIT REPAIR 78-~B-13

J 37357

J 37358-2

KC0037-7B-F-RP KC0039-7B-F-RP
Figure 32 Removing Bearing Race from Case Figure 35 Installing Bearing Race to Case

MAIN SHAFT ASSEMBLY

Figures 19, 20, 21 and 36

!-+!+-! Assemble
Tools Required:
· J 25234 Front and Rear Bearing Installer
J 37360 Spiral Snap Ring Installer
J 37372 Synchronizer and Gear Installer
J 37359
NOTICE: If replacing first/second or third/fourth
synchronizer blocker rings, soak new blocker ring
LCOOOl-78-F-RP assemblies for 10 minutes in Dexron®-IIE or
Figure 33 Removing Bearing from Countershaft equivalent before assembly on mainshaft.

• Coat mainshaft and gear bores with transmission

lubricant.
1. First-second synchronizer sleeve on mainshaft
hub aligning marks made at disassembly.
NOTICE: Use care in synchronizer spring
placement. If synchronizer is assembled with
improper spring replacement, hard shifting will
result.
2. First-second synchronizer keys and springs.
• Engage tang end of each spring in same
synchronizer key, but position open end of
springs opposite of each other.
3. Three-piece first gear blocker ring assembly.
4. Locating pin into mainshaft.
67. TRANSMISSION
5. Sleeve and needle bearing onto mainshaft,
49. 0-RING
CASE aligning notch in sleeve with locating pin.
50. BEARING
RACE 6. First gear, aligning slots in first gear with .tabs on
KC0038-7B-F-RP blocker ring assembly.
Figure 34 Front Countershaft Bearing Assembly 7. Rear mainshaft bearing with taper facing rear of
shaft.
• Lubricate fifth gear splines with petroleum jelly.
78-68-14 BORG-WARNER (T5) UNIT REPAIR

NOTICE: Carefully align the mainshaft and gear TRANSMISSION ASSEMBLY

splines. If splines are improperly aligned, damage
could occur when the gear is pressed onto the
mainshaft.
8. Fifth gear onto mainshaft, using J 25234 and a
press.
9. Fifth gear snap ring.
10. Three-piece second gear blocker ring assembly
and thrust washer.
11. Spiral snap ring, using J 37360.
12. Second gear spacer, needle bearing and gear,
aligning slots in second gear with tabs on blocker
ring assembly.
13. Second gear thrust washer and snap ring.
14. Third gear spacer and needle bearing assembly.
• Make sure the bearing spacer is not trapped
between the gear face and snap ring. The
spacer runs inside the gear bore.
15. Third-fourth synchronizer, third blocker ring,
sleeve, hub and third gear as an assembly, using
J 37372 and a press.
16. Thrust bearing and race to front end of
mainshaft.
[I] Important
• Before pressing components together, make sure
the synchronizer hub faces the short end of the
mainshaft. Hold third gear against the
synchronizer to maintain blocker ring alignment
with keys.
Figures 1 through 18 and 37 through 39
!+!+-! Assemble
Tools Required:
J 37357 Countershaft Bearing and Race
Remover and Installer
J 8092 Universal Driver Handle
J 37372 Synchronizer and Gear Installer
J 8001 Dial Indicator
1. Front countershaft bearing onto countershaft
using J 37357 with J 8092 and a press.
2. Countershaft in case.
3. Rear countershaft bearing to countershaft using
J 37372 and a press (Figure 37).
NOTICE: Failure to properly support the
countershaft may result in permanent distortion of
the case during installation.
• Support the countershaft with J 37357.
51. REAR COUNTERSHAFT
BEARING
J 37372

Figure 37 Installing Rear Countershaft Bearing

4. Rear countershaft bearing race.

5. Rubl;,er 0-ring and reverse idler gear in case with
shift lever groove facing rear of case.
15. SPRING 6. Reverse idler shaft from rear of case.
33. KEY KC0040-7B-F-RP 7. Roll pin in idler shaft.
Figure 36 Synchronizer Springs
 BORG-WARNER (T5) UNIT REPAIR 78-68·15

8. Countershaft retainer (without shims) to 15. Blocker ring and fifth gear synchronizer in fifth
transmission housing. gear shift fork.

!~! Tighten • Slide fork rail assembly and synchronizer into

position.
• Countershaft retainer bolts to 20 N · m (15 16. Fifth gear synchronizer retainer and snap ring
lb. ft.). (Figure 9).
17. Oiling funnel into rear of countershaft (Figure
!@! Measure 18.
6 ).
Fifth/reverse shift lever in case.
• Countershaft end play using dial indicator
19. Lever return spring to front of case.
J 8001.
• Make sure reverse shift fork pin and fifth
gear shift rail pin are engaged with shift
lever.
20. Fifth gear/reverse lever pivot bolts and retaining
clip.
• Coat pivot bolt threads with pipe thread
sealant GM p/n 1052080.
!~! Tighten
• Pivot bolt to 27 N · m (20 lb. ft.).
J 8001 21. Backup lamp switch.
• Coat threads with pipe thread sealant
GM p/n 1052080.
KC0042-7B-F-RP
22. Speedometer gear and retaining clip.
Figure 38 Measuring Countershaft End Play
23. Circlip.
• Apply 3 mm (1/8-inch) bead of RTV Sealant
• Remove retainer and install shim(s) as GM p/n 12345739 to transmission cover assembly.
necessary to provide proper end play. Zero • Make sure all synchronizers are in the neutral
end play with no preload is ideal, but up to position and that the shift forks in the cover are
0.10 mm (0.004 inch) end play is allowable. in the neutral (center) position.
Do not preload bearing with shim(s) larger • Lower cover onto case while aligning shift forks
than original end play measurement. Refer and synchronizer sleeves.
II II
to Specifications in this section.
24. Cover and install two dowel bolts.
• Reinstall retainer and bolts. 25. Remaining cover bolts.
!~! Tighten !~! Tighten
• Bolts to 20 N ·m (15 lb. ft.). • Cover bolts to 13 N·m (115 lb. in.).
• Bend tabs over the four attaching bolts. • Apply 3 mm (1/8-inch) bead of RTV Sealant
9. Reverse shift fork in case. GM p/n 12345739 to extension housing mating
10. Assembled mainshaft in transmission case. surface.
11. Rear mainshaft bearing race in case. • Coat detent spring with petroleum jelly and insert
in offset lever.
12. Drive gear in case (make sure rollers, thrust
bearing and washer are in place), and engage in • Lubricate detent plate and install detent ball in
third-fourth synchronizer sleeve and blocker neutral position on plate.
ring. • Position offset lever in extension housing with
13. Front bearing race in front bearing retainer. spring over detent ball. Slide lever and extension
into position as an assembly.
• Do not install shims in front bearing
retainer at this time. 26. Extension housing vent.
• Press downward on offset lever to compress
• Temporarily install front bearing retainer. detent spring and push lever and housing into
14. Fifth gear on countershaft. position.
• Slide shift rail/fifth gear shift fork assembly 27. Extension housing bolts.
into case. As shift rail enters case, align • Apply pipe thread sealant GM p/n 1052080
reverse shift fork and slide rail through fork. to threads of bolts.
Position lever return spring in case with
long end of spring to rear, and slide rail
through spring (Figure 10).
!~! Tighten
• Extension housing bolts to 30 N ·m (22 lb. ft.).
78-68-16 BORG-WARNER (T5) UNIT REPAIR

28. Roll pin in offset lever and shift rail. • Apply pipe thread sealant GM p/n 1052080 to
29. Damper sleeve in offset lever. the threads of the drain and fill plugs.
• Turn transmission case on end, and mount a dial 32. Drain plug.
indicator on extension housing with indicator on
the end of mainshaft (Figure 39). I~! Tighten
l@I Measure •
• Drain plug to 27 N · m (20 lb. ft.).
Fill the transmission to its proper level· with
• Mainshaft end play. Dexron®-IIE.
- Rotate mainshaft and zero dial
indicator. Pull upward on mainshaft 33. Fill plug.
until end play is removed and record
reading.
- Ideal mainshaft end play is zero with
!~! Tighten
plus or minus 0.02 mm (0.001 inch) • Fill plug to 27 N ·m (20 lb. ft.).
allowable.
- To set preload, select a shim pack
equal to the dial indicator reading J 8001
recorded.
• Remove front bearing retainer and front bearing
race.
• Install necessary shims and reinstall bearing race.
Refer to "Specifications" in this section.
• Apply a 3 mm diameter (1/8-inch) bead of
RTV Sealant GM p/n 12345739 on case mating
surface of front bearing retainer.
30. Bearing retainer.
• Apply pipe thread sealant GM p/n 1052080 to
the threads of the retainer bolts.
31. Retainer bolts.

l~I Tighten Figure 39

KC0043-7B·F·RP
Measuring Mainshaft End Play
• Retainer bolts to 20 N · m ( 15 lb. ft.).
 BORG-WARNER (TS) UNIT REPAIR 78-68-17

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Catalytic Converter-to-Transmission Nut ....................................................... 52 N·m (38 lb. ft.)
Transmission-to-Flywheel Housing Bolt ........................................................ 75 N ·m (55 lb. ft.)
Extension Housing Bolt .................................................................................. 30 N · m (22 lb. ft.)
Transmission .Cover-to-Case Bolt .................................................................. 13 N ·m (115 lb. in.)
Front Bearing Retainer Bolt .......................................................................... 20 N·m (15 lb. ft.)
Countershaft Retainer Bolt ............................................................................ 20 N·m (15 lb. ft.)
Reverse Pivot Bolt .......................................................................................... 27 N ·m (20 lb. ft.)
Fill Plug .......................................................................................................... 27 N · m (20 lb. ft.)
Drain Plug ...................................................................................................... 27 N · m (20 lb, ft.)
Support-to-Rail Bolt ........................................................................................ 54 N·m (40 lb. ft.)
Transmission Mount-to-Transmission Bolt .................................................... 54 N · m (40 lb. ft.)
Transmission Mount-to-Support Nut.. ............................................................ 47 N·m (35 lb. ft.)
Transmission Mount-to-Support Bolt ............................................................ 54 N ·m (40 lb. ft.)
Speed Sensor Retainer Bolt ......... .............. ....... ........ ... ................. .... ... ....... .. .. 10 N · m (89 lb. in)
Shift Control Assembly Boot Screw ................................................................ 6 N · m (53 lb. in)
Shift Control Assembly Bolt .......................................................................... 17 N · m ( 13 lb. ft.)
Vehicle Speed Sensor Retainer Bolt.. .............................................................. 10 N ·m (89 lb. in.)
Torque Arm Outer Bracket Nut ...................................................................... 41 N·m (30 lb. ft.)
Torque Arm-to-Rear Axle Differential Nut .................................................... .133 N·m (98 lb. ft.)

LUBRICANT SPECIFICATIONS

Lubricant Capacity (approximate) ............................................................ 2.8 Liters (2.96 quarts)

Lubricant Recommended ........................................................................ Dexron®-IIE

SPEEDOMETER GEAR CHART

SPEEDOMETER GEAR CHART

TIRE SIZE AXLE RATIO TRANSMISSION DRIVE GEAR DRIVEN GEAR

COLOR TEETH COLOR TEETH
P215/65R15
P235/55R16 3.08 M39 RED 9 GREY 22
P245/50ZR16
P215/65R15 MB1
3.42 PURPLE 7 WHITE 19
P245/50ZR16 MK6

MC0004-7B-F-RP
78-68-18 BORG-WARNER (TS) UNIT REPAIR

SHIM SPECIFICATIONS

lnput/Mainshaft Countershaft

Thickness Thickness
(inches) GM PIN (Inches) GM P/N

0.012 14050783 0.1005 10117781

0.014 14050780 0.102 10117782
0.016 14050781 0.1035 10117783
0.018 14050782 0.105 10117784
0.020 14050784 0.1065 10117785
0.022 14050786 0.108 10117786
0.023 14050787 0.1095 10117787
0.024 14069868 0.111 10117788
0.025 14069869 0.1125 10117789
0.026 14069870 0.114 10117790
0.027 14069871 0.1155 10117791
0.028 14069872 0.117 10117792
0.029 14069873 0.1185 10117793
0.030 14069874 0.120 10117794
0.031 14069875 0.1215 10117795
0.032 14069876 0.123 10117796
0.033 14069877 0.1245 10117797
0.034 14069878 0.126 10117798
0.035 14069879 0.1275 10117799
0.036 14050785 0.129 10117800
0.037 14069880 0.1305 10117801
0.038 14069881 0.132 10117802
0.039 14069882 0.1335 10117803
0.040 14069883 0.135 10117804
0.041 14069884 0.1365 10117805
0.042 14069885 0.138 10117806
0.043 14069886 0.1395 10117807
0.044 14069887 0.141 10117808
0.1425 10117809
0.144 10117810
0.1455 10117811
0.147 10117812
0.1485 10117813
0.150 10117814
0.1515 10117815
0.1530 10117816

LC0002-7B-F-RP
 BORG-WARNER (T5) UNIT REPAIR 78-68-19

SPECIAL TOOLS

GJ
~q J 8001 0 ~ J 6133-01

~
0 J 8092

0 J 37357

c®
J 21426

~ ~ J 37358-1

J 37358-2

J22912-01

J 23062-14
~
© J 37359

~ c D J 37360

J 25234
J 37372

J 37375
J34162-A
0

[2] DIAL INDICATOR

0 COUNTERSHAFT BEARING AND RACE

0 UNIVERSAL DRIVER HANDLE

REMOVER AND INSTALLER

0 EXTENSION HOUSING SEAL INSTALLER EJ BEARING RACE RECEIVER AND CASE SUPPORT

0 BEARING AND GEAR PULLER B COUNTERSHAFT BEARING REMOVER

0 EXTENSION HOUSING BUSHING REMOVER ~ SPIRAL SNAP RING INSTALLER

AND INST ALLER [!] SYNCHRONIZER AND GEAR INSTALLER

0 FRONT AND REAR BEARING INSTALLER

B DRIVE GEAR BEARING RETAINER
0 HOLDING FIXTURE
SEAL INSTALLER

0 INSTALLER ~ HEAVY DUTY PULLEY PULLER

NC1001 78 F RP

SECTION 78-108
BORG-WARNER (T56) UNIT REPAIR
RPO MM6
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correct torque value must
be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage
could result.
CONTENTS
General Description ............................. 7B-10B- 1
Unit Disassembly ................................ 7B-10B- 1
Shifter ........................................... 7B-10B- 1
Transmission Disassembled View .......... 7B-1 OB- 2
Extension Housing ..................... , ...... 7B-10B- 4
Speedometer Gear ............................ 7B-1 OB- 5
Reverse Speed Gear .......................... 7B-10B- 5
Reverse Shift Fork ............................ 7B-10B- 6
5th/6th Driven Gear .......................... 7B-10B- 6
Countershaft Extension Assembly ......... 7B-10B- 7
Transmission Case ............................ 7B-10B- 7
Guide Plate ..................................... 7B-10B- 8
Shift Rail Assemblies and Gear
Clusters ....................................... 7B-1 OB- 9
Unit Subassembly Repair and Inspection ... 7B-10B- 9
Input Shaft ..................................... 7B-10B- 9
Mainshaft ....................................... 7B-1OB-10
Countershaft .................................... 7B-1 OB-13
Countershaft Extension Assembly ......... 7B-10B-13
Synchronizers ......................... ; ........ 7B-10B-16
Shift Rail and Fork Assemblies ............ 7B-10B-19
Transmission Adapter Plate ................. 7B-10B-21
Transmission Case ............................ 7B-1 OB-21
Extension Housing ............................ 7B-10B-23
GENERAL DESCRIPTION
To ensure good fuel economy and compliance
with federal fuel economy standards, 2nd and 3rd
gears are inhibited when shifting out of 1st gear under
the following conditions:
• Coolant temperature is above 77°C
(161 °F).
• Throttle is opened 35% or less.
• Vehicle speed is between 24 and 34 kmh
(15 and 21 mph).
• Reset at less than 2 kmh (1 mph).
UNIT DISASSEMBLY
A complete disassembled view is shown on
page 2.
BORG·WARNER (T56) UNIT REPAIR 78·108·1
Unit Assembly ................................... 7B-10B-26
Shift Rail Assemblies and Gear
Clusters ....................................... 7B-10B-26
Guide Plate ..................................... 7B-10B-27
Transmission Case ............................ 7B-10B-27
Countershaft Extension Assembly ......... 7B-10B-28
5th/6th Driven Gear .......................... 7B-10B-29
Reverse Shift Fork ............................ 7B-10B-29
Reverse Speed Gear .......................... 7B-10B-29
Speedometer Gear ............................ 7B-10B-30
Extension Housing ............................ 7B-10B-30
Shifter ........................................... 7B-10B-31
Shimming Procedures ........................... 7B-10B-32
Input Shaft/Mainshaft and Countershaft .. 7B-1 OB-32
Countershaft Extension ....................... 7B-1 OB-32
Specifications ..................................... 7B-1 OB-35
Fastener Tightening Specifications ......... 7B-1 OB-35
Shimming Specifications ..................... 7B-1 OB-35
Lubricant Specifications ..................... 7B-10B-35
Special Tools ..................................... 7B-10B-36
SHIFTER
Figures 3 and 4
Tools Required:
J 3289-20 Holding Fixture Bench Mount
J 39430 Transmission Support Fixture
!+ •! Remove or Disconnect
1. Vent tube (161).
2. Clutch housing bolts (163).
3. Clutch housing (162).
4. Clutch fork bolt (166).
5. Clutch fork (164) and T-handle (165).
6. Install transmission to J 39430 and J 3289-20.
• Use bolts (163) to secure transmission to
J 39430.
78-108-2 BORG-WARNER (T56) UNIT REPAIR

175

74 73

71

30

168

R0001-7B10B-RA

Figure 1 Disassembled View

 BORG-WARNER (T56) UNIT REPAIR 78-108·3

1 PLATE, TRANSMISSION ADAPTER 67 RETAINER.REVERSE 129 BEARING, COUNTERSHAFT

2 PLUG SYNCHRONIZER KEY EXTENSION TAPERED
3 PIN, DOWEL 68 WASHER, THRUST 130 RACE, COUNTERSHAFT
4 PIN.DOWEL 69 RING, SNAP EXTENSION BEARING
5 BUSHING, SHIFT RAIL 70 RING, REVERSE GEAR BLOCKER 131 SHIM, COUNTERSHAFT EXTENSION
6 SEAL, INPUT SHAFT 71 WASHER, WAVE 132 FUNNEL, OIL
7 SHIM, INPUT SHAFT 72 BEARING, REVERSE GEAR 133 BOLT, REVERSE IDLER SHAFT
8 RACE, INPUT SHAFT BEARING NEEDLE BRACKET
9 BEARING, INPUT SHAFT TAPERED 73 GEAR.REVERSE 134 BRACKET, REVERSE IDLER SHAFT
10 SHAFT, INPL)T 74 WASHER, THRUST 135 WASHER, REVERSE IDLER GEAR
11 RACE, INPUT SHAFT BEARING 75 RING, SNAP THRUST
12 RING, 4TH GEAR BLOCKER 76 SPACER 136 GEAR,REVERSEIDLER
13 RING, SNAP 77 BEARING, REAR MAINSHAFT 137 BEARING, REVERSE IDLER GEAR
14 SYNCHRONIZER ASSEMBLY, 78 SPACER ROLLER
3RD/4TH 79 RING, SNAP 138 SHAFT, REVERSE IDLER GEAR
15 SPRING, 3RD/4TH SYNCHRONIZER 80 RING, SNAP 139 WASHER, REVERSE IDLER GEAR
16 KEY. 3RD/4TH SYNCRONIZER 81 GEAR, SPEEDOMETER THRUST
17 HUB, 3RD/4TH SYNCHRONIZER (ELECTRONIC) 140 RAIL ASSEMBLY, 5TH/6TH SHIFT
18 SLEEVE, 3RD/4TH SYNCHRONIZER 82 RING, SNAP 141 PIN, ROLL
19 RING, 3RD GEAR BLOCKER 84 RING, SNAP 142 COLLAR
20 GEAR, 3RD SPEED 85 RACE, MAINSHAFT BEARING 143 RAIL, SHIFT
21 BEARING, 3RD GEAR NEEDLE 86 HOUSING, TRANSMISSION 144 LEVER, 5TH/6TH SHIFT RAIL
22 BEARING, MAINSHAFT SMALL EXTENSION 145 PAD, 5TH/6TH SHIFT RAIL LEVER
TAPERED · 87 SENSOR, ELECTRONIC SPEED 146 BUSHING, 5TH/6TH SHIFT RAIL
23 MAIN SHAFT 88 BOLT, SPEED SENSOR LEVER
24 BEARING, 2ND GEAR NEEDLE 89 SOLENOID,. REVERSE LOCKOUT 147 PIN, ROLL
25 GEAR, 2ND SPEED 90 BOLT, REVERSE LOCKOUT 148 LEVER, REVERSE SHIFT RAIL
26 WASHER, THRUST ASSEMBLY .. 149 RAIL ASSEMBLY, 1ST/2ND 3RD/4TH
27 CONE, INNER 91 BODY ASSEMBLY, REVERSE SHIFT
28 CONE, FRICTION LOCKOUT 150 FORK, 1ST/2ND SHIFT
29 RING, 2ND GEAR BLOCKER 92 BUSHING, SHIFT RAIL 151 PAD, 1ST/2ND SHIFT FORK
30 SYNCHRONIZER ASSEMBLY, 93 LEVER, REAR OFFSET SHIFT 152 LINK, SHIFT
1ST/2ND 94 PIN, REAR OFFSET SHIFT LEVER 153 RAIL ASSEMBLY, 1ST/2ND 3RD/4TH
31 SPRING, 1ST/2ND SYNCHRONIZER ROLL SHIFT
32 KEY, 1ST/2ND SYNCHRONIZER 95 CUP, ISOLATOR 154 PIN, ROLL
33 HUB, 1ST/2ND SYNCHRONIZER 96 SHIFTER ASSEMBLY 155 PIN, SELECTOR
34 SLEEVE, 1ST/2ND SYNCHRONIZER 97 BOLT, SHIFTER ASSEMBLY 156 PLATE,.INTERLOCK
35 RING, 1ST GEAR BLOCKER 98 BOOT, SHIFTER 157 LINK, SHIFT
36 CONE, FRICTION 99 SEAL AND BOOT, REAR OUTPUT 158 FORK, 3RD/4TH SHIFT
37 CONE, INNER 100 BOLT, TRANSMISSION 159 PAD, 3RD/4TH SHIFT FORK
38 WASHER, THRUST EXTENSION HOUSING 160 0-RING, REVERSE LOCKOUT
39 RING, SNAP 101 PLUG, DRAIN ASSEMBLY
40 BEARING, 1ST GEAR NEEDLE 102 SHIM, COUNTERSHAFT 161 TUBE, VENT
41 GEAR, 1ST SPEED 103 RACE, COUNTERSHAFT BEARING 162 HOUSING, CLUTCH ADAPTER
42 BEARING, MAINSHAFT LARGE 104 BEARING, COUNTERSHAFT 163 BOLT, CLUTCH ADAPTER HOUSING
TAPERED TAPERED 164 FORK, CLUTCH
43 RACE, MAINSHAFT BEARING 105 COUNTERS HAFT 165 T-HANDLE, CLUTCH FORK PIVOT
44 CASE, TRANSMISSION 106 BEARING, COUNTERSHAFT 166 BOLT, CLUTCH FORK PIVOT
45 BOLT, SHIFT LEVER GUIDE TAPERED 167 HOUSING, CLUTCH ACTUATOR
46 BOLT, SHIFT LEVER GUIDE 107 RACE, COUNTERSHAFT BEARING ADAPTER
47 BOLT, SHIFT DETENT COVER 108 WASHER, THRUST 168 BOLT, CLUTCH ACTUATOR
48 COVER, SHIFT DETENT 109 GEAR, 6TH DRIVE ADAPTER HOUSING
49 BUSHING, SHIFT RAIL 110 BEARING, 6TH GEAR NEEDLE 169 RING, SNAP
50 PIN, FRONT OFFSET LEVER ROLL 111 FORK, REVERSE SHIFT 170 PLUNGER, REVERSE LOCKOUT
51 LEVER, FRONT OFFSET 112 PAD, REVERSE SHIFT FORK 171 SPRING, REVERSE LOCKOUT
52 SPRING, SHIFT DETENT 113 RING, SNAP OUTER
53 BALL, SHIFT DETENT 114 RING, 6TH GEAR BLOCKER 172 COLLAR,REVERSELOCKOUT
54 BOLT, SHIFT GUIDEPLATE 115 SPACER 173 RING, SNAP
55 PLATE, SHIFT GUIDE 116 RING, SNAP 174 SPRING, REVERSE LOCKOUT INNER
56 DETENT ASSEMBLY, SHIFT 117 SYNCHRONIZER ASSEMBLY, 5TH/ 175 BODY, REVERSE LOCKOUT
57 MAGNET 6TH 176 BODY, REVERSE LOCKOUT
58 PIN,DOWEL 118 SPRING, 5TH/6TH SYNCHRONIZER 177 BUMPER, TRANSMISSION
59 SWITCH, BACK-UP LAMP 119 KEY, 5TH/6TH SYNCHRONIZER 178 BOLT; TRANSMISSION ADAPTER
60 PLUG, FILL 120 HUB, 5TH/6TH SYNCHRONIZER PLATE
61 GEAR, 5TH/6TH DRIVEN 121 SLEEVE, 5TH/6TH SYNCHRONIZER 179 SPACER
62 SYNCHRONIZER ASSEMBLY, 122 FORK, 5TH/6TH SHIFT 180 FITTING, VENT TUBE
REVERSE 123 PAD, 5TH/6TH SHIFT FORK 181 SOLENOID, COMPUTER AIDED
63 SPRING, REVERSE 124 RING, SNAP GEAR SELECT
SYNCHRONIZER 125 RING, 5TH GEAR BLOCKER 182 PIN, ROLL
64 KEY, REVERSE SYNCHRONIZER 126 GEAR, 5TH DRIVE 183 LEVER, COMPUTER AIDED GEAR
65 HUB, REVERSE SYNCHRONIZER 127 BEARING, 5TH GEAR NEEDLE SELECT SOLENOID
66 SLEEVE.REVERSE 128 EXTENSION, COUNTERSHAFT
SYNCHRONIZER R0002-7B10B-RA

Figure 2 Disassembled View - Legend

78-108·4 BORG-WARNER (T56) UNIT REPAIR

7. Rotate transmission in horizontal position,

shifter up.
8. Plug (101) and drain transmission fluid.
9. Put transmission in 3rd/4th neutral position.
10. Shifter bolts (97).
11. Shifter (96).

!L•I Inspect
95

• Isolator cup (95) for wear. Replace rear

offset shift lever (93) if wear is excessive
or isolator cup (95) is loose.
86 HOUSING,
TRANSMISSION
EXTENSION
95 CUP, ISOLATOR
96 SHIFTER ASSEMBLY 1-
97 BOLT, SHIFTER ASSEMBLY
\~-"'I
P0004-7B10B-RA
......._
Figure 4 Shifter

EXTENSION HOUSING
Figure 5

E3 Remove or Disconnect
1. Rear offset shift lever roll pin (94).

[I] Important
• If isolator cup (95) is not fully retained in rear
offset lever with adhesive, replace rear offset
lever assembly (93).
2. Rear offset shift lever (93) and isolator cup (95)
assembly.
3. Extension housing bolts ( 100).
4. Extension housing (86).
• With transmission in horizontal position,
slide extension housing (86) off shift rails
(140 and 149).

163 BOLT, CLUTCH HOUSING

P0003-7B10B-RA

Figure 3 Transmission Support Fixture

 BORG-WARNER (T56) UNIT REPAIR 78·108·5

J 39431-1
23

149

44 CASE. TRANSMISSION 23 MAINSHAFT

86 HOUSING, TRANSMISSr<5N EXTENSION 73 GEAR.REVERSE
140 RAIL ASSEMBLY, 5TH/6TH SHIFT 81 GEAR, SPEEDOMETER (ELECTRONIC)
149 RAIL ASSEMBLY, 1ST/2ND 3RD/4TH SHIFT
POOOS-78108-RA
P0006-7B10B·RA
Figure 5 Extension Housing
Figure 6 Speedometer Gear
SPEEDOMETER GEAR
REVERSE SPEED GEAR
Figure 6
Tools Required: Figure 7
J 8433 Universal Bridge Puller
J 39431 Gear Remover E3 Remove or Disconnect
J 39431-1 Gear Remover Bolts 1. Roller bearing snap ring (79).
2. Spacer (78).
E31. Remove or Disconnect
Rotate transmission in vertical position.
3. Roller bearing (77).
4. Spacer (76).
2. Sealing ring.
3. Speedometer gear snap ring (82). 5. Snap ring (75).
4. Speedometer gear (81) using J 8433, J 39431 6. Thrust washer (74).
and J 39431-1. 7. Reverse speed gear (73).
A. Set J 8433 onto nose of main shaft (23). 8. Caged needle bearing (72).
B. Slide J 39431 under speedometer gear. 9. Wave washer (71).
C. Install bolts J 39431-1 to J 39431. 10. Blocker ring (70).
D. Speedometer gear (81) using J 8433,
J 39431 and J 39431-1.
5. Speedometer gear snap ring (80).
78-108-6 BORG-WARNER (T56) UNIT REPAIR

111

~'c~
II"" / 1 1

62 SYNCHRONIZER ASSEMBLY, REVERSE

69 RING, SNAP
111 FORK, REVERSE SHIFT
113 RING.SNAP POOOB-78108-RA

70 RING, REVERSE GEAR BLOCKER

71 WASHER, WAVE Figure 8 Reverse Shift Fork
72 BEARING, REVERSE GEAR NEEDLE
73 GEAR.REVERSE 5th/6th DRIVEN GEAR
74 WASHER, THRUST
75 RING, SNAP Figure 9
76 SPACER Tools Required:
77 BEARING, ROLLER
78 SPACER J 8433 Universal Bridge Puller
79 RING, SNAP P0007-7B10B-RA
J 39431 Gear Remover
Figure 7 Reverse Speed Gear J 39431-2 Gear Remover Bolts

REVERSE SHIFT FORK !+ +! Remove or Disconnect

Figure 8 1. 5th/6th driven gear (61) using J 8433, J 39431

and J 39431-2.
E3 Remove or Disconnect A. Set J 8433 onto nose of main shaft (23).
1. Reverse synchronizer snap ring (69). B. Slide J 39431 under 5th/6th driven gear.
2. Reverse shift fork snap ring (113) and discard. C. Install bolts J 39431-2 to J 39431.
3. Reverse shift fork (111), synchronizer (62) and D. 5th/6th driven gear (61) using J 8433,
thrust washer (68) at the same time. J 39431 and J 39431-2.
 BORG-WARNER (T56) UNIT REPAIR 78-108-7

J 8433

J 39431-2

108 WASHER, THRUST

109 GEAR, 6TH DRIVE
110 BEARING, 6TH GEAR NEEDLE
114 RING, 6TH GEAR BLOCKER
115 SPACER
116 RING, SNAP
117 SYNCHRONIZER
ASSEMBLY, 5TH/6TH
122 FORK, 5TH/6TH SHIFT
124 RING, SNAP
126 GEAR, 5TH DRIVE
128 EXTENSION, COUNTERSHAFT
129 BEARING, COUNTERSHAFT
EXTENSION TAPERED P0010·7B10B-RA

Figure 10 Countershaft Extension Assembly

TRANSMISSION CASE
Figures 11 and 12

61 GEAR, 5th/6th DRIVEN

E3 Remove or Disconnect

P0009-7810B-RA
1. Computer aided gear select solenoid (181).
2. Cover plate bolts (47).
Figure 9 5th/6th Driven Gear 3. Cover plate (48).
COUNTERSHAFT EXTENSION ASSEMBLY 4. Shift detent assembly (56).
5. Roll pin (182).
Figure 10 6. Front offset lever rollpin (50).
E3 Remove or Disconnect
7. 8 of the 10 adapter plate to transmission case
bolts (178) .
1. 5th/6th shift fork snap ring (124 ). 8. Rotate transmission into vertical position.
2. Rotate transmission in horizontal position, 9. Last 2 adapter plate to transmission case bolts
guide plate up. (178).
3. Countershaft extension assembly with 5th/6th 10. Shift lever guide bolts (45 and 46).
shift fork (122). 11. Magnets (57).
78-108-8 BORG-WARNER (T56) UNIT REPAIR

12. Transmission case (44) and front offset lever

(51).
• Slide transmission case (44) up off of gear
clusters and shift rail components.
• Hold offset lever (51) against guideplate
(55) to prevent release of detent ball (53)
and spnng (52).
• Note that the loose detent ball (53) and
spring (52) will come out.
• Remove solenoid lever (183). 0

~ Clean
• Shift lever guide bolt threads (45 and 46).
• Case (44) and magnets (57) with solvent and dry
with compressed air.
GUIDE PLATE
Figure 11

E3 Remove or Disconnect
1. Shift guide plate bolts (54).
2. Guide plate (55).

55

56

50 PIN, FRONT OFFSET LEVER ROLL

51 LEVER, FRONT OFFSET
54 BOLT, SHIFT GUIDE PLATE
55 PLATE, SHIFT GUIDE
56 ENHANCER, SHIFT

P0011-7B10B-RA
1 PLATE, TRANSMISSION ADAPTER
Figure 11 Shift Detent Assembly 44 CASE, TRANSMISSION
45 BOLT, SHIFT LEVER GUIDE
46 BOLT, SHIFT LEVER GUIDE

P0012·7B10B·RA

Figure 12 Transmission Case

 BORG-WARNER. (T56) UNIT REPAIR 78-108-9

SHIFT RAIL ASSEMBLIES AND GEAR

CLUSTERS
Figure 13

E3 Remove or Disconnect
1. Rotate 5th/6th and reverse shift rail levers (140)
off shift interlock plate (156).
2. 5th/6th and reverse shift rail assembly (140).
3. Countershaft (105).
• Lift up mainshaft (23) enough to remove
countershaft (105).
4. Mainshaft (23) and shift rail assembly (149).
• Remove components as an assembly.
5. Shift rail assembly (149) from mainshaft (23).
6. 4th gear blocker ring {12).
7. Input shaft (10).
UNIT SUBASSEMBLY REPAIR AND
INSPECTION
INPUT SHAFT
Figure 14
Tools Required:
J 5590 Press Tube
J 22912-01 Split Plate
J 23907 Slide Hammer
J 28537-17 Race Installer
J 39594 Race Remover
Hydraulic Press 1 PLATE, TRANSMISSION ADAPTER
10 SHAFT, INPUT
f:3 Disassemble 23
105
MAINS HAFT
COUNTERSHAFT
LI] Important 140 RAIL ASSEMBLY, 5TH/6TH
AND REVERSE SHIFT
• Do not replace tapered bearing (9) or race
153 RAIL ASSEMBLY,
(11) unless inspection shows bearing or 1ST/2ND 3RD/4TH SHIFT
race damage.
156 PLATE, INTERLOCK
1. Input shaft tapered bearing (9) from input shaft 183 LEVER, COMPUTER AIDED
(10) using J 22912-01 and hydraulic press. GEAR SELECT SOLENOID
2. Input shaft bearing race ( 11) using J 23907 and
J 39594.

~ Clean
• Input shaft components wit.h solvent and dry
with compressed air.

IL•I Inspect
• Input shaft components.
Shaft (10) and spline for excessive wear or
cracks. Replace if these conditions exist.
Gear teeth for excessive wear, pitting,
scoring, spalling or fractures.
Bearing (9) for roughness of rotation, R0003-7B10B-RA
burred or pitted conditions. Replace if
these conditions exist. Figure 13 Shift Rail Assemblies and Gear Clusters
78-108-10 BORG-WARNER (T56) UNIT REPAIR

• If scuffed, nicked, burred or scoring conditions 7. 2nd speed gear caged needle bearing (24).
cannot be reconditioned by hand with a soft 8. 3rd/4th synchronizer snap ring (13).
stone or crocus cloth, replace the component.
9. 3rd speed gear (20) using J 39473, V-blocks
• When replacing bearing (9) also replace bearing and hydraulic press.
race (8). • 3rd/4th synchronizer assembly (14) and
• When re.12lacing bearing race (11) also replace 3rd speed gear blocker ring (19) will press
bearing (22). off with 3rd speed gear (20).
10. Spacer (179).
!+i+! Assemble
11. 3rd speed gear caged needle bearing (21).
1. New bearing race (11) to input shaft (10) using
J 28537-17 hydraulic press. II] Important
2. New input shaft tapered bearing (9) to input • Do not replace tapered bearing (22) unless
shaft (10) using J 5590 and hydraulic press. inspection shows bearing damage.
12. Mainshaft small tapered bearing (22) using
J 39442, J 39443 and hydraulic press.
MAIN SHAFT
• Discard small tapered bearing (22).
Figure 15
Tools Required: ~ Clean
J 36183 Press Tube • Mainshaft components with solvent and dry with
compressed air.
J 36184 Press Tube Adapter
J 36513 Split Plate !L•! Inspect
J 39371 1st/2nd Synchronizer Installer • Mainshaft components.
J 39428 Split Plate Shaft (23) and spline for excessive wear or
J 39442 Press Adapter cracks. Replace if these conditions exist.
J 39443 Split plate Gear teeth (20, 25 and 41) for excessive
J 39473 Bearing Installer/Press Adapter wear, pittrng, scoring, spalling or
Hydraulic Press fractures.
V-Blocks Bearings (22 and 42) for roughness of
rotation, burred or pitted conditions.
F:•! Disassemble
Replace if these conditions exist.
- Synchronizers (14 and 30). Refer to
II] Important "Synchronizers" in this section.
• Identify and mark blocker rings. DO NOT • When replacing bearings (22 or 42) also replace
MIX. bearing races. (11 or 43).
• If scuffed, nicked, burred or scoring conditions
1. Mainshaft large tapered bearing ( 42) and cannot be reconditioned by hand with a soft
0-ring. stone or crocus cloth, replace the component.
2. 1st speed gear (41).
3. 1st speed gear caged needle bearing (40). !•t+! . Assemble
4. Snap ring (39). 1. New mainshaft small tapered bearing (22) using
5. 1st speed gear blocker ring assembly. J 39473, V-blocks and hydraulic press.
A. Thrust washer (38). 2. 3rd speed gear caged needle bearing (21).
B. Inner cone (37). 3. Spacer (179).
C. Friction' cone (36). 4. 3rd speed gear (20).
5. 3rd speed gear blocker ring (19).
D. Blocker ring (35).
6. 2nd speed gear (25) using J 36513 and [I] Important
hydraulic press. • When pressing the 3rd/4th synchronizer
• 1st/2nd synchronizer assembly (30), 2nd assembly (14):
speed gear blocker ring (29), friction cone A. Start press operation. STOP before
(28), 2nd speed gear inner cone (27), and keys engage blocker ring slots.
thrust washer (26), will press off with 2nd B. Lift and rotate 3rd speed gear (20) to
speed gear (25). engage keys with blocker ring.
C. Continue to press until seated.
 BORG-WARNER (T56) UNIT REPAIR 78-108·11

J 23907

J 39594

11

PRESS
10

10

B
D
PRESS

J 5590

PRESS BED

A BEARING REMOVAL
B BEARING INSTALLATION
C RACE REMOVAL
D RACE INSTALLATION
9 BEARING, INPUT SHAFT TAPERED.
10 SHAFT, INPUT
11 RACE, INPUT SHAFT BEARING
P0014-7810B-RA

Figure 14 Input Shaft

78-108-12 BORG-WARNER (T56) UNIT REPAIR

A B

42

41

40 14

20

PREss---·
BED

23
29 c

28
J39442
27 21
22 J39443
26
~179
IQ) I
25 20

24---

D E

PRESS~

J39473
22 J36183

14
PRESS BED

I
A 2ND GEAR REMOVAL 22 BEARING, MAINSHAFT SMALL TAPER 37 CONE, INNER
B 3RD GEAR REMOVAL 23 MAIN SHAFT 38 WASHER, THRUST
c BEARING REMOVAL 24 BEARING, 2ND GEAR NEEDLE 39 RING, SNAP
D BEARING INSTALLATION 25 GEAR, 2ND SPEED 40 BEARING, 1ST GEAR NEEDLE
E 3RD/4TH SYNCHRONIZER INSTALLATION 26 WASHER, THRUST 41 GEAR, 1ST SPEED
F 1ST/2ND SYNCHRONIZER INSTALLATION 27 CONE INNER 42 BEARING, MAINSHAFT LARGE
13 RING, SNAP 28 CONE, FRICTION TAPERED
14 SYNCHRONIZER ASSEMBLY, 3RD/4TH 29 RING, 2ND GEAR BLOCKER 179 SPACER
19 RING, 3RD GEAR B,LOCKER 30 SYNCHRONIZER ASSEMBLY, 1ST/2ND
20 GEAR, 3RD SPEED 35 RING, 1ST GEAR BLOCKER
21 BEARING, 3RD GEAR NEEDLE 36 CONE, FRICTION P0015-7B10B·RA

Figure 15 Mainshaft
 BORG-WARNER (T56) UNIT REPAIR 78·108-13

6. 3rd/4th synchronizer assembly (14) using 1. Small tapered bearing (104) using J 22912-01,
J 36183, J 36184 and hydraulic press. J 39473 and hydraulic press.
• Install 3rd/4th synchronizer so ID groove • Discard tapered bearing (104).
on sleeve faces 3rd gear.
7. 3rd/4th synchronizer snap ring (13). 2. Large tapered bearing (106) using J 39511,
J 39547 and hydraulic press.
8. 2nd speed gear caged needle bearing (24).
9. 2nd speed gear (25). • Discard tapered bearing (106).
10. Thrust washer (26).
11. 2nd speed gear inner cone (27).
~ Clean
12. Friction cone (28). • Countershaft with solvent and c;lry with
13. 2nd speed gear blocker ring (29). compressed air.

(I] Important IL•! Inspect

• When pressing the 1st/2nd synchronizer • Countershaft components.
assembly (30):
Shaft (105) for excessive wear or cracks.
A. Start press operation. STOP before Replace if these conditions exist.
keys engage blocker ring slots.
Gear teeth for excessive wear, pitting,
B. Lift and rotate 2nd speed gear (25) to scoring, spalling or fractures.
engage keys with blocker ring.
Bearings (104 and 106) for roughness of
C. Continue to press until seated. rotation, burred or pitted conditions.
14. 1st/2nd synchronizer assembly (30) using Replace if these conditions exist.
J 39371, J 39428 and hydraulic press.
• When replacing bearings (104 or 106) also
• Install 1st/2nd synchronizer so ID groove replace bearing races (103 or 107).
on sleeve faces 1st gear.
• If scuffed, nicked, burred or scoring conditions
15. 1st speed gear blocker ring assembly. cannot be reconditioned by hand with a soft
A. Blocker ring (35). stone or crocus cloth, replace the component.
B. Friction cone (36).
C. Inner cone (37). !•!+! Assemble
D. Thrust washer (38). 1. New large tapered bearing (106) using J 39438
16. Snap ring (39). and hydraulic press.
17. 1st speed gear caged needle bearing (40). 2. New small tapered bearing (104) using J 5590
18. 1st speed gear (41). and hydraulic press.
19. Mainshaft large tapered bearing (42) and
0-ring.
COUNTERSHAFT EXTENSION ASSEMBLY
COUNTERSHAFT Figure 17
Figure 16 Tools Required:
Tools Required: J 5590 Press Tube
J 5590 Press Tube J 36513 Split Plate
J 22912-01 Split Plate J 39442 Press Adapter
J 39438 Large Countershaft Bearing J 39443 Split Plate
Installer
J 39473 Bearing Installer
J 39473 Press Adapter
Hydraulic Press
J 39511 Split Plate
V-Blocks
J 39547 Press Adapter
Hydraulic Press
V-Blocks
!•t•! Disassemble
1. 5th/6th shift fork (122).
1±) Disassemble 2. Thrust washer (108).
3. 6th drive gear (109).
(I] Important 4. Caged needle bearing (110).
• Do not replace tapered bearings (104 and 5. Spacer (115).
106) unless inspection shows bearing
damage. 6. 6th drive gear blocker ring (114).
78-108;,14 BORG-WARNER (T56) UNIT REPAIR
7. 5th/6th synchronizer snap ring (l 16) and
discard.
IL•I
8. 5th drive gear (126) using J 36513 and
hydraulic press.
• 5th/6th synchronizer assembly (117) and
5th drive gear blocker ring (125) will
press off with 5th drive gear (126).
9. 5th drive gear caged needle bearing (127).
[I) Important
• Do not replace small tapered bearing
(129) unless inspection shows bearing
damage.
10. Small tapered bearing (129) using J 39442,
J 39443 and hydraulic press.
~ Clean
• Countershaft extension components with solvent
and dry with compressed air.
PRESS
B J.
PREss/i
A SMALL TAPERED BEARING REMOVAL
B SMALL TAPERED BEARING INSTALLATION
C LARGE TAPERED BEARING REMOVAL
D LARGE TAPERED BEARING INSTALLATION
104 BEARING, COUNTERSHAFT TAPERED
105 COUNTERSHAFT
106 BEARING, COUNTERSHAFT TAPERED
Figure 16 Countershaft
Inspect
• Countershaft extension components.
Shaft (128) and spline for excessive wear
or cracks. Replace if these conditions
exist.
Gear teeth (109 and 126) for excessive
wear, pitting, scoring, spalling or
fractures.
Bearing (129) for roughness of rotation,
burred or pitted conditions. Replace if
these conditions exist.
- Synchronizer (117). Refer to
"Synchronizers" in this section.
• When replacing bearing (129) also replace
bearing race (130).
• If scuffed, nicked, burred or scoring conditions
cannot be reconditioned by hand with a soft
stone or crocus cloth, replace the component.
J 39511
D 1•1
J 5590 PRESS~
106
P0016-7B10B·RA
PRESS BED
 BORG-WARNER (T56) UNIT REPAIR 78-108-15

PRESS BED

PRESS
J 39442
B

PRESS BED

A 5th GEAR REMOVAL PRESS BED

B TAPERED BEARING
REMOVAL
c TAPERED BEARING
INSTALLATION
D 5th/6th SYNCHRONIZER
INSTALLATION
114
108 WASHER, THRUST

~
D
109 GEAR, 6th DRIVE
110 BEARING, 6th GEAR
NEEDLE
114 RING, 6th GEAR
BLOCKER 109
117
115 SPACER
116 RING, SNAP
117 SYNCHRONIZER
ASSEMBLY, 5th/6th
125 RING, 5th GEAR
BLOCKER
126 GEAR, 5th DRIVE
127 BEARING, 5th PRESS BED
GEAR NEEDLE ~108
128 EXTENSION,
COUNTERS HAFT
I
129 BEARING, COUNTERSHAFT
EXTENSION TAPERED P0017-7B10B·RA

Figure 17 Countershaft Extension

78-108-16 BORG-WARNER (T56) UNIT REPAIR

!+:+! Assemble ~ Clean

1. New small tapered· bearing (129) using • Synchronizer components with solvent and dry
J 39473, V-blocks and hydraulic press. with compressed air.
2. 5th drive gear caged needle bearing (127).
3. 5th drive gear (126). !L•! Inspect
4. 5th drive gear blocker ring (125). • Synchronizer components.
Teeth for wear, nicked, burred or broken
[TI Important teeth. Replace hub and sleeve if excessive
• When pressing the 5th/6th synchronizer wear exists.
assembly (117): Keys for wear or distortion. Replace if
A. Start press operation. STOP before these conditions exist.
keys engage blocker ring slots. Springs for distortion, cracks or wear.
B. Lift and rotate 5th drive gear (126) to Replace if these conditions exist.
engage keys with blocker ring. • If scuffed, nicked or burred conditions cannot be
C. Continue to press until seated. corrected by hand with a soft stone or crocus
cloth, replace the component.
5. 5th/6th synchronizer assembly (117) using
J 5590 and hydraulic press.
• Install 5th/6th synchronizer so ID groove
on sleeve faces 5th gear.
6. New 5th/6th synchronizer snap ring (116).
7. 6th drive gear blocker ring (114).
8. 6th drive gear spacer (115).
9. 6th drive gear caged needle bearing (110).
10. 6th drive gear (109).
11. 6th drive gear thrust washer (108).
12. 5th/6th shift fork (122).

SYNCHRONIZERS
1st/2nd, 3rd/4th, 5th/6th Synchronizers
Figures 18, 19, 20 and 22

[]] Important
• Synchronizer components are not
interchangeable. Keep synchronizer components
separate.
• Synchronizer hubs and sleeves are a selected
assembly and should be kept together as
originally assembled.

F:3 Disassemble
1. Synchronizer spring (15), (31), (118) using a
small-bladed screwdriver.
2. Turn synchronizer assembly (14), (30), (117)
over.
31 SPRING, 1st/2nd SYNCHRONIZER
3. Synchronizer spring (15), (31), (118) using a 32 KEY, 1st/2nd SYNCHRONIZER
small-bladed screwdriver. 33 HUB, 1st/2nd SYNCHRONIZER
4. Keys (16), (32), (119). 34 SLEEVE, 1st/2nd SYNCHRONIZER P0018-7B10B-RA

5. Synchronizer sleeve (18), (34), (121) from hub

Figure 18 1st/2nd Synchronizer
(17), (33), (120).
 BORG-WARNER (T56) UNIT REPAIR 78-108-17

l+:·I Assemble
1. Synchronizer sleeve (18), (34), (121) to hub
(17), (33), (120). 118

•Alifln key openings in hub (17), (33),

~12 ) with cuts in synchronizer sleeve
18), (34), (121).
2. Keys (16), (32), (119) with slots facing hub
(17), (33), (120).
3. Synchronizer spring (15), (31), (118) using a 121
small-bladed screwdriver.
•Locate spring tang to one of the key slots .
4. Turn synchronizer assembly (14), (30), (117)
over.
5. Synchronizer spring (15), (31), (118) using a
small-bladed screwariver.
• ~ocate SI?rin8:" tang on same key but wind
m opposite trectton. 120

~
15

118 SPRiNG, 5th/6th SYNCHRONIZER

119 KEY, 5th/6th SYNCHRONIZER
120 HUB, 5th/6th SYNCHRONIZER
121 SLEEVE, 5th/6th SYNCHRONIZER
P0020-7B10B-RA

Figure 20 5th/6th Synchronizer

Reverse Synchronizer
Figure 21

Ft+! Disassemble

15
1. Synchronizer spring (63) using a small-bladed
screwdriver.
2. Synchronizer sleeve (66) from hub (65) by
pressing against inner hub (65).
3. Turn hub (65) over.
• Keys (64) will slide out from hub (65).
15 SPRING, 3rd/4th SYNCHRONIZER 4. Synchronizer key retainer (67) using a
16 KEY, 3rd/4th SYNCHRONIZER small-bladed screwdriver through key slots of
17 HUB, 3rd/4th SYNCHRONIZER
hub (65) and discard retainer (67). ·
18 SLEEVE, 3rd/4th SYNCHRONIZER 5. Synchronizer spring (63) using a small-bladed
screwdriver.
P0019-7B10B-RA

Figure 19 3rd/4th Synchronizer

78-108-18 80RG-WA.RNER (T56) UNIT REPAIR
~ Clean
• Synchronizer components with solvent and dry
with compressed air.
IL•I Inspect
• Synchronizer components.
Teeth for wear, nicked, burred or broken
teeth. Replace hub and sleeve if excessive
wear exists.
Keys for wear or distortion. Replace if
these conditions exist.
Springs for distortion, cracks or wear.
Replace if these conditions exist.
Retainer for distortion. Replace if this
condition exists.
• If scuffed, nicked or burred conditions cannot be
corrected by hand with a soft stone or crocus
cloth, replace the component.
63 SPRING, REVERSE SYNCHRONIZER
64 KEY, REVERSE SYNCHRONIZER
65 HUB, REVERSE SYNCHRONIZER
66 SLEEVE, REVERSE SYNCHRONIZER
67 RETAINER, REVERSE SYNCHRONIZER KEY
P0021-7B10B-RA
Figure 21 Reverse Synchronizer
l•!•I Assemble
1. Synchronizer sleeve (66) to hub (65).
• Align key openings in hub (65) with cuts
2.
in synchromzer sleeve (66).
Keys (64) with slots facing hub (65).
3. Synchronizer spring (63) using a small-bladed
screwdriver.
• Locate spring tang to one of the key slots.
4. Turn synchronizer assembly (62) over.
5. Synchronizer spring (63) using a small-bladed
screwdriver.
• ~ocate SI?ring_ tang on same key but wind
m opposite duection.
6. New synchronizer key retainer (67).
• Locate key retainer tangs over
synchronizer keys (64 ).
Synchronizer Blocker Ring Inspection
Figure 22
• Inspect the gear cones, clutch teeth and blocker
rings for excessive wear.
• Inspect the synchronizer sleeve and gear clutch
teeth for evidence of gear clash or cause of
hop-out.
• Measure the gap between the blocker ring and
the speed gear. Make sure the correct blocker
ring is measured with the correct gear and the
blocker ring is fully seated on the gear.
• Replace blocker rings for 1st, 2nd, 3rd, 4th, 5th
and 6th gears if the wear gap is less than 0.38
mm (0.015 in.).
• Replace the reverse blocker ring if the wear gap
is less than 0.75 mm (0.030 in.), when measureo
without the wave washer (71) in between the
blocker ring and reverse gear.
A BLOCKER TEETH
B FEELER GAGE
C CLUTCH TEETH
c P0033-7B10B-RA
Figure 22 Measuring Blocker Ring Wear
 BORG-WARNER (T56) UNIT REPAIR 78-108-19

SHIFT RAIL AND FORK ASSEMBLIES 5th/6th, Reverse Shift Rail Assembly
1st/2nd, 3rd/4th Shift Rail Assembly Figure 23
Figure 23 Tool Required:
J 23907 Slide Hammer
1±) Disassemble J 36800 Bushing Remover
1. Rotate selector pin (155) until opposite shift J 39437 Bushing Installer
links (152 and 157).
2. 3rd/4th shift fork (158) with shift link (157)
from rail (153).
l•:3 Disassemble
1. Collar roll pin (141).
3. 1st/2nd shift fork (150) with shift link (152) 2. Collar (142).
from rail (153).
3. 5th/6th shift rail lever (144) from rail (143).
4. Roll pin (182) and computer aided gear select
solenoid lever (183) from rail (153).
5. Interlock plate (156) from rail (153).
rn Important

6. Selector pin roll pin (154).
7. Selector pin (155).
~ Clean
• Shift rail and fork assembly components with
solvent and dry with compressed air.
• Do not replace bushings (146) unless
inspection shows bushing damage.
4. 5th/6th shift rail lever bushings (146) using
J 23907 and J 36800.
5. Reverse shift rail lever roll pin (147).
6. Reverse shift rail lever (148) from rail (143).

IL•! Inspect &!I Clean

• Shift rail and fork assembly components. • Shift rail assembly components with solvent and
dry with compressed au.
Rail (153) for excessive wear or burrs.
Replace if these conditions exist.
- Shift forks (150 and 158) for excessive
IL•! Inspect
• Shift rail assembly components.
wear, fracture or distortion. Replace if
these conditions exist. Rail (143) for excessive wear or burrs.
Shift links (152 and 157) for excessive Replace if these conditions exist.
wear, fracture or distortion. Replace if Shift rail levers (144 and 148) for
these conditions exist. excessive wear, fracture or distortion.
Shift fork nylon inserts (151 and 159) for Replace if these conditions exist.
excessive wear. Replace if this condition Shift rail lever nylon insert for excessive
exists. wear. Replace if this condition exists.
Shift rail lever bushings (146) for
l•t•! Assemble excessive wear. Replace if this condition
exists.
1. Selector pin (155).
2. Selector pin roll pin (154).
3. Interlock plate (156) to rail (153).
4. 1st/2nd shift fork (150) with shift link (152) to
rail (153).
5. Comr.uter aided gear select solenoid lever (183)
to rail (153).
6. Roll pin (182) to lever (183).
7. 3rd/4th shift fork (158) with shift link (157) to
rail (153).
8. Align selector pin (155) with slots in shift links
(152 and 157).
78-108-20 BORG-WARNER (T56) UNIT REPAIR

141---~

142

150

143

153

147~

183

144

148

1 PLATE, TRANSMISSION ADAPTER 151 PAD, 1ST/2ND SHIFT FORK

23 MAINS HAFT 152 LINK, SHIFT
105 COUNTERSHAFT 153 RAIL ASSEMBLY, 1ST/2ND 3RD/4TH SHIFT
140 RAIL ASSEMBLY, 5TH/6TH AND REVERSE SHIFT 154 PIN, ROLL
141 PIN, ROLL 155 PIN, SELECTOR
142 COLLAR 156 PLATE, INTERLOCK
143 RAIL, SHIFT 157 LINK, SHIFT
144 LEVER, 5TH/6TH SHIFT RAIL 158 FORK, 3RD/4TH SHIFT
147 PIN, ROLL 159 PAD, 3RD/4TH SHIFT FORK
148 LEVER, REVERSE SHIFT RAIL 182 PIN, ROLL
150 FORK, 1ST/2ND SHIFT 183 LEVER, COMPUTER AIDED GEAR SELECT SOLENOID
R0004-7B10B-RA

Figure 23 Shift Rail and Fork Assemblies

 BORG-WARNER (T56) UNIT REPAIR 78-108-21

l+i+I Assemble H•I Assemble

1. Reverse shift rail lever (148) to rail (143). 1. Dowel pins (3 and 4).
• Locate reverse shift rail lever (148) to roll 2. 1st/2nd, 3rd/4th shift rail bushing (5) using
pin ho!e at opposite end of rail (143) from J 39437.
snap rmg groove. 3. Input shaft seal (6) using J 39433.
- Notched edge of reverse shift rail
lever should face towards other roll [I] Important
pin hole.
• Do not install shims (102 and 7) until after
2. Reverse shift rail lever roll pin (147). performing "Shimming Procedures" later
3. 5th/6th shift rail lever bushings (146) using m this section.
J 39437. 4. Countershaft bearing race (103).
4. 5th/6th shift rail lever (144) to rail (143). 5. Input shaft bearing race (8).
5. Collar (142).
6. Collar roll pin (141).
TRANSMISSION CASE
TRANSMISSION ADAPTER PLATE Figure 25
Figure 24 Tools Required
Tools Required: J 8092 Drive Handle
J 23907 Slide Hammer J 36190 Drive Handle
J 36800 Bushing Remover J 39435 Mainshaft Bearing Race Installer
J 39433 Input Shaft Seal Installer J 39436 Countershaft Bearing Race
J 39437 Bushing Installer Installer
J 39437 Bushing Installer
F:3 Disassemble J 39439 Bushing Remover
1. Input shaft bearing race (8) and shim (7). J 39790 Mainshaft Bearing Race Remover
2. Countershaft bearing race (103) and shim (102). J 39791 Countershaft Bearing Race
Remover
3. Adapter plate plug (2).
4. Input shaft seal (6). !+:+! Disassemble
rn•
Important
Do not replace bushing (5). unless
1. Guide plate bolts (54) and guide plate (55).
2. Fill plug (60).
inspection shows bushing damage. 3. Backup lamp switch (59).
5. 1st/2nd, 3rd/4th shift rail bushing (5) using 4. Computer aided gear select solenoid (185).
J 23907 and J 36800. 5. Dowel pins (58).
6. Dowel pins (3 and 4).
[I] Important
~ Clean • Do not replace bearing races (107 and 43)
• Adapter plate components with solvent and dry unless inspection shows bearing race
with compressed air. damage.
6. Countershaft bearing race (107) using J 8092
!L•I Inspect and J 39791.
• Adapter plate components. 7. Mains haft bearing race (43) using J 8092 and
Bearing races (8 and 103) and bores for
J 39790.
wear, scratches or grooves. 8. 1st/2nd, 3rd/4th shift rail bushing (49) using
Bushing (5) for excessive wear or burrs.
J 36190 and J 39439.
Replace if this condition exists.
Case for cracks, sealing surfaces for nicks,
~ Clean
burrs or scratches. If case is cracked, it • Transmission case components with solvent and
must be replaced. dry with compressed au.
• If scratches, grooves or nicks cannot be removed
by hand with a soft stone or crocus cloth, replace
the components.
78-108-22 BORG-WARNER (T56) UNIT REPAIR

REMOVE

J 23907

INSTALL

tJ
J 39433
39437

J ~ 36800

L_
5

103

102
7

1 PLATE, TRANSMISSION ADAPTER

2 PLUG
4 PIN, DOWEL
5 BUSHING, SHIFT RAIL
4 6 SEAL, INPUT SHAFT
7 SHIM, INPUT SHAFT
8 RACE, INPUT SHAFT BEARING
102 SHIM, COUNTERSHAFT
103 RACE, COUNTERSHAFT BEARING
P0023-7B10B-RA

Figure 24 Transmission Adapter Plate

 BORG-WARNER (T56) UNIT REPAIR 78-108-23

IL•! Inspect 6. Thrust washer (139).

• Transmission case components.
Bearing races (43 and 107) and bores for
wear, scratches or grooves.
Bushing (49) for excessive wear. Replace
if this condition exists.
Case (44) for cracks, threaded openings for
damaged threads, sealing surfaces for
nicks, burrs or scratches. If case is
cracked, it must be replaced.
• If scratches, grooves or scoring cannot be
removed by hand with a soft stone or crocus
cloth, replace the component.
!+:+! Assemble
1. 1st/2nd, 3rd/4th shift rail bushing (49) using
J 39437.
2. Mainshaft bearing race (43) using J 8092 and
J 39435.
3. Countershaft bearing race (107) using J 8092
and J 39436.
4. Dowel pins (58).
5. Computer aided gear select solenoid (185).
6. Backup lamp switch (59).
7. Reverse idler shaft (138).
8. Countershaft extension bearing race (130).
9. Shim (131).
10. Funnel (132).
11. Plug (101).
12. Reverse lockout assembly bolt (90).
CAUTION: The reverse lockout as-
sembly is under spring pressure. Exer-
cise caution when removing snap ring
(173), as bodily injury may result.
13. Reverse lockout assembly (91).
A. Reverse lockout solenoid (89) from reverse
lockout body (175).
B. 0-ring (160) from body (175).
C. Snap ring (169) from body (175).
D. Reverse lockout inner spring (174).
E. Compress reverse lockout /lunger (170)
and collar (172) in vise an remove snap
ring (173).
F. Reverse lockout plunger (170).
G. Reverse lockout outer spring ( 171).
H. Reverse lockout collar (172).

!~! Tighten
14. Vehicle speed sensor bolt (88).
15. Vehicle speed sensor (87) and clamp.
• Switch (59) to 27 N·m (20 lb. ft.)
• 0-ring seal from vehicle speed sensor
7. Fill plug (60) with sealant GM p/n 1052080. (87).
!~! Tighten 16. Rear seal and boot (99).
• Fill plug (60) to 18 N·m (13 lb. ft.). • Pry out seal and boot (99) with suitable
tool.
8. Guide plate (55) and guide plate bolts (54). 17. Mainshaft bearing race snap ring (84).

!~! Tighten [I) Important

• Bolts (54) to 22 N·m (16 lb. ft.). • Do not replace bearing race (85) unless
inspection shows bearing race damage.
EXTENSION HOUSING
18. Mainshaft bearing race (85) using J 8092 and
Figure 26 J 39789.
Tools Required:
J 8092 Drive Handle
rn
•
Important
Do not replace bushing (92) unless inspection
· J 39439 Bushing Remover/Installer shows bushing damage.
J 39440 Rear Boot and Seal Installer
19. Shift rail bushing (92) using J 36190 and
J 39546 Bearing Race Installer J 39439.
J 39789 Bearing Race Remover
~ Clean
1±) Disassemble
• Extension housing components with solvent and
1. Reverse idler shaft bracket bolts (133). dry with compressed air.
2. Reverse idler shaft bracket (134)~
3. Reverse idler gear thrust washer (135).
4. Reverse idler gear (136).
5. Roller bearing (137).
78-108-24 BORG-WARNER (T56) UNIT REPAIR

INSTALL REMOVE
J 39437 J 39439-1 J 36190

~----w--~.,...,...
REMOVE

(_«_«_a......-__~ - ~J-3-94-:-r-5--INu..f
....
i=»L.J)
, \ ~ ~
J 8092 J 39790 ,- J 8092
INSTALL

\
J 8092 J 39791 44
1t \
107 J 39436 J 8092
Ell J

REMOVE

43 RACE, MAINSHAFT BEARING

44 CASE, TRANSMISSION
49 BUSHING, SHIFT RAIL
107 RACE, COUNTERSHAFT BEARING

P0024-7B10B-RA

Figure 25 Transmission Case

IL•I Inspect 6. Vehicle speed sensor (87) and clamp.

• Extension housing components.
Bearing races (85 and 130) and bores for
wear, scratches or grooves.
Bushing (92) for excessive wear or burrs.
Replace if this condition exists.
Case (86) for cracks, sealing surfaces for
nicks, burrs or scratches. If case is
cracked, it must be replaced.
7. Vehicle speed sensor bolt (88).
!~I Tighten
• Bolt (88) to 10 N·m (84 lb. in.)
CAUTION: The reverse lockout as-
sembly is under spring pressure. Exer-
cise caution when installing snap ring
(173), as bodily injury may result.

• If scratches, grooves or nicks cannot be removed 8. Assemble reverse lockout body assembly.
by hand with a soft stone or crocus cloth, replace A. Reverse lockout plunger (170).
the component. B. Reverse lockout outer spring (171 ).
l+i+I Assemble
C.
D.
Reverse lockout collar (172).
Compress reverse lockout plunger (170),
1. Shift rail bushing (92) using J 36190 and collar (172) and outer spring (171) in vise
J 39439. and install snap ring (173).
2. Mainshaft bearing race (85) using J 8092 and E. Reverse lockout inner spring (174).
1 39546.
F. Install reverse lockout com onents in
3. Mainshaft bearing race snap ring (84). 1
lockout body (175) and instal snap ring
4. Rear seal and boot (99) using J 39440. (169).
• Locate drain hole in rear seal and boot G. Reverse lockout solenoid (89) to reverse
(99) down. lockout body assembly (91).
5. 0-ring seal to vehicle speed sensor (87). l~I Tighten
• Solenoid (89) to 40 N·m (30 lb. ft.).
H. 0-ring (160) to body assembly (91).
 BORG-WARNER (T56) UNIT REPAIR 78-108-25

160 91
89

J 39440

REMOVE/INSTALL
J 39439

85

'

~ ~84

_, LY!___~ .
J 8092
REMOVE~'J
(1}..._JI INSTALL
J 39546
J 39789 • , J 8092
84 RING, SNAP ~
101 139
85 RACE, MAINSHAFT BEARING
86 HOUSING, TRANSMISSION -
-~
d 138
137 136
EXTENSION

ffir£
88 BOLT, SPEED SENSOR

~·~
89 SOLENOID, REVERSE LOCKOUT ~~·~134
90 BOLT, REVERSE LOCKOUT ASSEMBLY
132
91 BODY ASSEMBLY, REVERSE 131
LOCKOUT O
92 BUSHING, SHIFT RAIL .
99 SEAL AND BOOT, REAR OUTPUT
101 PLUG, DRAIN
130 RACE, COUNTERSHAFT EXTEN-
SION BEARING
131 SHIM, COUNTERSHAFT
EXTENSION
132 FUNNEL, OIL
160 0-RING, REVERSE LOCKOUT
ASSEMBLY P0025-7B10B-RA

Figure 26. Transmission Extension Housing

10. Reverse lockout assembly. 13. Countershaft extension bearing race (130).
11. Reverse lockout assembly bolt (90).

l~I Tighten
rn Important
• Do not install shim ( 131) until after
• Bolt (90) to 18 N·m (13 lb. ft.). performing "Shimming Procedures" later
m this section.
12. Plug (101) with sealant GM p/n 1052080.

l~I Tighten
• Plug (101) to 18 N·m (13 lb. ft.).
78-108-26 BORG-WARNER (T56) UNIT REPAIR

UNIT ASSEMBL V
SHIFT RAIL ASSEMBLIES AND GEAR
CLUSTERS
Figure 27
Tool Required:
J 36850 Transmission Assembly Lube

!++! Install or Connect

• Lubricate all components as assembly
progresses. Use J 36850 Transmission
Assembly Lube or equivalent.
1. Selective shims (7 and 102). Refer to "Input
Shaft/Mainshaft and Countershaft" under
"Shimming Procedures" in this section.
2. Input shaft bearing race (8).
3. Countershaft bearing race (103).
4. Input shaft (10) and 4th gear blocker ring (12).
5. Shift rail assembly (149) to mainshaft assembly.
6. Mainshaft assembly with shift rail assembly
(149).
7. Countershaft assembly.
A. Lift up mainshaft assembly enough to
install countershaft assembly.
B. Countershaft assembly.
C. Lift mainshaft assembly enough to rotate
input shaft (10) to engage synchronizer
keys (16) with 4th gear blocker ring (12).
1 PLATE, TRANSMISSION ADAPTER
8. 5th/6th and reverse shift rail (140). 10 SHAFT, INPUT
• Align slots of shift rail levers with 23 MAINS HAFT
interlock plate (156). 105 COUNTERSHAFT
140 RAIL ASSEMBLY, 5TH/6TH
AND REVERSE SHIFT
153 RAIL ASSEMBLY,
1ST/2ND 3RD/4TH SHIFT
156 PLATE, INTERLOCK
183 LEVER, COMPUTER AIDED
GEAR SELECT SOLENOID

R0003-7B10B·RA

Figure 27 Shift Rail Assemblies and Gear Clusters

 BORG-WARNER (T56) UNIT REPAIR 78-108-27

GUIDE PLATE 1. Sealant GM p/n 12345739 at transmission case

to adapter plate mating surface.
Figure 28
• Assemble ball detent in offset lever.
Tool Required:
2. Transmission case (44) and front offset lever
J 36850 Transmission Assembly Lube (51).

E3 Install or Connect [I] Important

1. Guide plate (55). • Make sure transmission is in NEUTRAL
2. Shift .guide plate bolts (54). to keep 3rd/4th shift rail from engaging.
• Install solenoid lever (183).
l~I Tighten • Compress front offset lever (51) together
• Bolts (54) to 22 N·m (16 lb. ft.). while sliding onto shift rail (149) to
prevent spring release of inner
components.
• Slide transmission case (44) onto gear
clusters and shift rail components.
3. Shift lever guide bolts (45 and 46).
• Apply anaerobic threadlocker GM l?ln
12345382 to threads of shift lever gmde
bolts (45 and 46).
• Pull up on 5th/6th and reverse shift rail
assembly (140) enough to align the slot of
the shift interlock plate (156) with guide
55
bolt hole.
l~I Tighten
• Bolts (45 and 46) to 27 N·m (20 lb. ft.).
4. Adapter plate to transmission case bolts (178).
56
l~I Tighten
• Bolts (178) to 35 N·m (26 lb. ft.).
5. Front offset lever roll pin (50).
50 PIN, FRONT OFFSET LEVER ROLL 6. Roll pin (182).
51 LEVER, FRONT OFFSET
54 BOLT, SHIFT GUIDE PLATE
7. Shift detent assembly (56).
55
56
PLATE, SHIFT GUIDE
ENHANCER, SHIFT l~I Tighten
• Apply anaerobic threadlocker GM p/n
P0011-7B10B-RA
12345382 to threads of shift detent
Figure 28 Shift Detent Assembly assembly (56).
• Shift detent assembly (56) to 40 N·m
TRANSMISSION CASE (30 lb. ft.).
Figures 28 and 29 8. Cover plate (48).
Tool Required: • Apply sealant GM p/n 12345739 to
mating surface of cover plate (48).
J 36850 Transmission Assembly Lube
9. Cover plate bolts (47).
l••I Install or Connect l~I Tighten
• Lubricate all components as assembly • Bolts (47) to 20 N·m (15 lb. ft.).
progresses. Use J 36850 Transmission
Assembly Lube. 10. Computer aided gear select so~enoid (181).
78-108·28 BORG-WARNER (T56) UNIT REPAIR

COUNTERSHAFT EXTENSION ASSEMBLY

Figure 30

l••I Install or Connect

1. Countershaft extension assembly and 5th/6th
shift fork (122) with transmission in horizontal
position.
• Ensure splines of countershaft extension
0
(128) engage splines of countershaft
(105).
2. 5th/6th shift fork snap ring (124).

129

124

122

128

116

108 WASHER, THRUST

109 GEAR, 6TH DRIVE
110 BEARING, 6TH GEAR NEEDLE
114 RING, 6TH GEAR BLOCKER
115 SPACER
116 RING, SNAP
117 SYNCHRONIZER
ASSEMBLY, STH/6TH
122 FORK, 5TH/6TH SHIFT
124 RING, SNAP
126 GEAR, STH DRIVE
128 EXTENSION, COUNTERSHAFT
129 BEARING, COUNTERSHAFT
EXTENSION TAPERED P0010-7B10B·RA

Figure 30 Countershaft Extension Assembly

1 PLATE, TRANSMISSION ADAPTER

44 CASE, TRANSMISSION
45 BOLT, SHIFT LEVER GUIDE
46 BOLT, SHIFT LEVER GUIDE

P0012·7B10B-RA

Figure 29 Transmission Case

 BORG-WARNER (T56) UNIT REPAIR 78-108-29

5th/6th DRIVEN GEAR REVERSE SHIFT FORK

Figure 31 Figure 32
Tool Required:
J 39441 Gear Installer
E1 Install or Connect
1. Reverse shift fork (111), synchronizer (62) and
J 39441-1 Gear Installer Bolts thrust washer (68) at the same time.
!•+! Install or Connect
2.
3.
New reverse shift fork snap ring (113).
Reverse synchronizer snap ring (69).
• 5th/6th driven gear (61) usmg J 39441 and
J 39441-1.
Smaller OD gear down.
Engage splines of 5th/6th driven gear (61)
to shaft splines (23) before pressing gear
onto shaft.

J 39441-1

113
J 39441
111

62 SYNCHRONIZER ASSEMBLY, REVERSE

69 RING, SNAP
111 FORK, REVERSE SHIFT
113 RING, SNAP
P0008-7B10B-RA

Figure 32 Reverse Shift Fork

61 REVERSE SPEED GEAR

Figure 33

!•+! Install or Connect

1. Blocker ring (70).
2. Wave washer (71).
• Install wave washer (71) so concave side
faces blocker ring (70).
61 GEAR, 5th/6th DRIVEN 3. Needle bearing (72).
P0026-7B10B-RA
4. Reverse speed gear (73).
5. Thrust washer (74).
Figure 31 5th/6th Driven Gear
78-108-30 BORG-WARNER (T56) UNIT REPAIR

6. Snap ring (75). 3. Speedometer gear snap ring (82):

7. Spacer (76). 4. Sealing ring.
8. Roller bearing (77).
9. Spacer (78).
10. Roller bearing sn~p ring (79).

J 39441 '

81 GEAR, SPEEDOMETER (ELECTRONIC)

P0032-7B10B-RA

Figure 34 Speedometer Gear

EXTENSION HOUSING
70 RING, REVERSE GEAR BLOCKER
71 WASHER, WAVE Figure 35
72 BEARING, REVERSE GEAR NEEDLE
73
74
GEAR,REVERSE
WASHER, THRUST
E3 Install or Connect
1. Funnel (132).
75 RING, SNAP
76 SPACER 2. Selective shim (131 ). Refer to "Countershaft
~70 Extension" under "Shimming Procedures" in
77 BEARING, ROLLER
78 SPACER this section.
79 RING, SNAP
P0007-7B10B·RA
3. Countershaft extension bearing race ( 130).
Figure 33 Reverse Speed Gear 4. Reverse idler shaft (138).
5. Thrust washer (139).
SPEEDOMETER GEAR 6. Roller bearing (137).
Figure 34 7. Reverse idler gear (136).
8. Reverse idler gear thrust washer ( 135).
Tool Required:
9. Reverse idler shaft bracket (134).
J 39441 Gear Installer 10. Reverse idler shaft bracket bolts ( 133).
J 39441-2 Gear Installer Bolts
• Apply sealant GM p/n 12345382 to
l++I Install or Connect
threads of bolts ( 133).

1. Speedometer gear snap ring (80). l~I Tighten

2. Speedometer gear (81) using J 39441 and • Bolts (133) to 25 N·m (18 lb. ft.).
J 39441-2.
 BORG-WARNER (T56) UNIT REPAIR 78-108-31

11. Extension housing (86). SHIFTER

• Apply sealant GM p/n 12345739 at Figure 36
extension housing to transmission case
mating surface.
• Align 5th/6th and reverse shift rail (140)
l••I Install or Connect
with extension housing bore. 1. Shifter (96).
12. Extension housing bolts (100) and transmission • Apply sealant GM p/n 12345739 at
bumper (177). extension housing to shifter mating
surface.
l~I Tighten 2. Bolts (97).
•Apply sealant GM p/n 1052080 to threads
of bolts retaining transmission bumper. l~I Tighten
• Bolts (100) to 35 N·m (26 lb. ft.). • Bolts (97) to 20 N·m (15 lb. ft.).
13. Rear offset shift lever (93) and isolator cup (95). 3. Remove transmission from J 39430 and
14. Rear offset shift lever roll pin (94). J 3289-20.
4. Clutch fork (164) and T-handle (165).
5. Clutch fork bolt (166).
l~I Tighten
• Apply sealant GM p/n 12345382 to
threads of clutch fork bolt (166).
• Bolt (166) to 25 N·m (18 lb. ft.).
6. Clutch housing (162).
7. Clutch housing bolts (163).
l~I Tighten
• Bolts (163) to 35 N·m (26 lb. ft.).
8. Vent tube (161).

86
95

86 HOUSING, TRANSMISSION EXTENSION

130 RACE, COUNTERSHAFT EXTENSION BEARING 86 HOUSING,
131 SHIM, COUNTERSHAFT EXTENSION TRANSMISSION
132 FUNNEL, OIL EXTENSION
133 BOLT, REVERSE IDLER SHAFT BRACKET 95 CUP, ISOLATOR
134 BRACKET, REVERSE IDLER SHAFT 96 SHIFTER ASSEMBLY
135 WASHER, REVERSE IDLER GEAR THRUST 97 BOLT, SHIFTER ASSEMBLY P0004-78108-RA ·1
........... \_~
136 GEAR,REVERSEIDLER
137 BEARING, REVERSE IDLER GEAR ROLLER Figure 36 Shifter
138 SHAFT, REVERSE IDLER GEAR
139 WASHER, REVERSE IDLER GEAR THRUST
P0027·7B1DB·RA

Figure 35 Extension Housing

78-108:32 BORG-WARNER (T56) UNIT REPAIR

SHIMMING PROCEDURES 6. Input shaft bearing race (8).

7. Countershaft bearing race (103).
INPUT SHAFT/MAINSHAFT AND
COUNTERSHAFT COUNTERSHAFT EXTENSION
Figure 37 Figure 38
Tools Required: Tools Required:
J 8001 Dial Indicator Set J 8001 Dial Indicator Set
J 39444-1 Countershaft End Play J 39444-2 Countershaft Extension End
Measuring Tool Play Measuring Rod
l••I Install or Connect l••I Install or Connect
1. Position transmission in vertical position.
2. Input shaft (10) to adapter plate (1 ).
[I) Important

3. Mainshaft (23) to input shaft (10). •This procedure cannot be performed

accurately until the "Countershaft
4. Countershaft (105). Shimming Procedure" has. been
A. Lift up mainshaft (23) enough to install completed and the transmission has been
countershaft (105). assembled to the point of installing the
B. Countershaft (105). countershaft extension.
5. Transmission case (44). 1. Position transmission in horizontal position.
6. Adapter plate to transmission case bolts (178). 2. Countershaft extension (128) to countershaft
(105) making sure splines fully engage.
l~I Tighten 3. Extension housing (86).
4. Extension housing bolts (100).
• Bolts (178) to 35 N·m (26 lb. ft.).
7. Place tip of J 8001 on end of mainshaft (23). l~I Tighten

~ Measure • Bolts (100) to 35 N·m (26 lb. ft.).

A. Input shaft/mainshaft end play by moving
input shaft (10) up and down.
B. Select shim (6) to achieve 0.000 to
0.002 inch· (0.00 to 0.05 mm) preload ..
8. Remove J 8001.
5. J 39444-2 through adapter plate plug hole and
screw J 39444-2 into countershaft extension.
7. J 8001 so tip is on end of J 39444-2.
l@I Measure

9. Place tip of J 8001 on end of countershaft A. Position transmission in vertical position.

(105).
10. J 39444-1 through adapter plate plug hole.
~ Measure
A. Countershaft end play using J 39444-1 to
move countershaft (105) up and down.
B. Select shim (102) to achieve 0.000 to
0.002 inch (0.00 to 0.05 mm) preload.
11. Remove J 39444-1 and J 8001.
B. Countershaft extension end play using
J 39444-2 to move countershaft extension
(128) up and down.
C. Select shim (131) to achieve 0.002 to
0.005 inch (0.05 to 0.13 mm) axial play.
8. Remove J 8001 and J 39444-2.
9. Install adapter plate plug (2).
• Apply sealant GM p/n 1052080 to plug
threads (2).

E3 Remove or Disconnect l~I Tighten

1. Adapter plate to transmission case bolts (167). • Plug (2) to 27 N·m (20 lb. ft.).
2.
3.
Transmission case (44).
Countershaft (105).
E3 Remove or Disconnect

A. Lift up mainshaft (23) enough to remove 1. Extension housing bolts (100).

countershaft (105). 2. Extension housing (86).
B. Countershaft (105). 3. Countershaft extension (128).
4. Mainshaft (23). 4. Countershaft extension bearing race (130).
5. Input shaft (10) from adapter plate (1).
 BORG-WARNER (T56) UNIT REPAIR 78-108-33

J 39444-1

J 39444-1 44

44

A COUNTERSHAFT SHIMMING PROCEDURE

B INPUT SHAFT/MAINSHAFT SHIMMING PROCEDURE 23
10 SHAFT, INPUT
23 MAIN SHAFT
44 CASE, TRANSMISSION
105 COUNTERSHAFT

P0028-7B10B-RA

Figure 37 Input Shaft/Mainshaft and Countershaft

78-108-34 BORG-WARNER (T56) UNIT REPAIR

J 8001

NOTE: COUNTERSHAFT SHIMMING

PROCEDURE MUST BE
PERFORMED FIRST. COUNTERSHAFT
AND CORRECT SHIM MUST BE IN-
STALLED DURING THIS PROCEDURE

P0029-7B10B-RA

Figure 38 Countershaft Extension

 BORG-WARNER (T56) UNIT REPAIR 78-108-35

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS

NO.* DESCRIPTION TORQUE

2 Adapter Plate Plug 27 N•m (20 lb. ft.)
178 Adapter Plate to Transmission Case Bolts 35 N•m (26 lb. ft.)
59 Backup Lamp Switch 27 N•m (20 lb. ft.)
166 Clutch Fork Bolt 25 N•m (18 lb. ft.)
163 Clutch Housing to Adapter Plate Bolt 35 N•m (26 lb. ft.)
48 Cover Plate Bolts 20 N•m (15 lb. ft.)
101 Extension Housing Plug 27 N•m (20 lb. ft.)
100 Extension Housing to Transmission Case Bolts 35 N•m (26 lb. ft.)
133 Reverse Idler Shaft Bracket Bolts 25 N•m (18 lb. ft.)
90 Reverse Lockout Assembly Bolt 18 N•m (13 lb. ft.)
89 Reverse Lockout Solenoid 40 N•m (30 lb. ft.)
97 Shifter Bolts 20 N•m (15 lb. ft.)
56 Shift Detent Assembly 40 N•m (30 lb. ft.)
45,46 Shift Lever Guide Bolts 27 N•m (20 lb. ft.)
54 Shift Guide Plate Bolts 22 N•m (16 lb. ft.)
60 Transmission Case Fill Plug 27 N•m (20 lb. ft.)
88 Vehicle Speed Sensor Bolt 10 N•m (89 lb. in.)
*Disassembled Parts Illustration, Figure 1 RCPC1-7B1-T56

SHIMMING SPECIFICATIONS
SHIM NO.* DESCRIPTION SHIM TO ATTAIN
7 Input Shaft/Mainshaft Shim Preload of 0.0-0.002 inch
(O.O to 0.05 mm)
102 Countershaft Shim Preload of 0.0-0.002 inch
(0.0 to 0.05 mm)
131 Countershaft Extension Shim Axial Play of 0.002-0.005 inch
(0.05 to 0.13 mm)
*Disassembled Parts Illustration, Figure 1 RCPC2-7B1-T56

LUBRICANT SPECIFICATIONS
Lube Capacity (Approximate) ......................... ; .................................................. 3.9 Liters (4.1 Quarts)
After refill, fluid level must be checked as outlined under On-Vehicle Service in Section 7B.
Recommended Lube ......................................................................................... Dexron®-III, -IIE
78-108-36 BORG-WARNER (T56) UNIT REPAIR

SPECIAL TOOLS
HOLDING FIXTURE BEARING RACE INSTALLER TRANSMISSION HOLDING FIXTURE

PRESS TUBE PRESS TUBE GEAR REMOVER AND BOLTS

J5590 J36183 J39431,-1,-2

DIAL INDICATOR SET PRESS TUBE ADAPTER SPLIT PLATE

Q
J8001 J36184

UNIVERSAL DRIVE HANDLE DRIVE HANDLE SEAL INSTALLER

J8092 J36190 J39433

UNIVERSAL BRIDGE PULLER SPLIT PLATE BEARING RACE INSTALLER

SPLIT PLATE
J8433
tt
BUSHING REMOVER
J36513
~
BEARING RACE INSTALLER
J39435

~
J36800 J39436

SLIDE HAMMER 1ST/2ND SYNCHRONIZER INSTALLER BUSHING INSTALLER

Q J39437
J23907 J39371 P0030-7B10B-RA
 BORG-WARNER (156) UNIT REPAIR 78-108-37

SPECIAL TOOLS {CONT.)

BEARING INSTALLER COUNTERSHAFT END PLAY ROD PRESS ADAPTER

J39438 J39444-1 J39547

BUSHING REMOVER/INSTALLER COUNTERSHAFT EXTENSION END BEARING RACE REMOVER

PLAY ROD

J39439-1 J39594

REAR SEAL STORAGE CASE BEARING RACE REMOVER

AND BOOT INSTALLER

J39440 J39445 J39789

GEAR INSTALLER AND BOLTS BEARING INSTALLER/ADAPTER BEARING RACE REMOVER

J39441,-1,-2 J39473 J39790

PRESS ADAPTER SPLIT PLATE BEARING RACE REMOVER

J39442 J39511 J39791

SPLIT PLATE BEARING RACE INSTALLER

J39443 J39546

P0031-7B10B-RA
 CLUTCH 7C-1

SECTION 7C
CLUTCH
CAUTION: When servicin~ the clutch system, do not create dust by cleaning components
with compressed air. While not containing asbestos fibers, the clutch disc does contain
fiberglass fibers which could cause bodily harm if inhaled. Any residue should also be
washed from the skin as it could cause irritation.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 7C- l Clutch Pedal Position Switch Assembly
Principle Components . . . . . . . . . . . . . . . . . . . . 7C-1 (Clutch Start Switch Assembly) . . . . . . . . . . 7C-8
Driving Members . . . . . . . . . . . . . . . . . . . . . . 7C- l Clutch Driven Plate Assembly (5-Speed) . . . . . 7C-8
Driven Member ....................... 7C-l Clutch Driven Plate Assembly (6-Speed) ..... 7C-9
Hydraulic Clutch ..... , . . . . . . . . . . . . . . . . 7C-1 Clutch Fork Assembly and Clutch Release
Hydraulic Clutch Fluid . . . . . . . . . . . . . . . . . 7C-2 Bearing Assembly (5-Speed) ............ 7C-12
. Clu~ch Pilot Bearing . . . . . . . . . . . . . . . . . . . . 7C-2 Clutch Fork Assembly and Clutch Release
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-2 Bearing Assembly (6-Speed) ............ 7C-12
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . 7C-2 3.4L L32 Engine Flywheel
Clutch System Diagnosis . . . . . . . . . . . . . . . . . . 7C-2 Assembly .............. Refer to Section 6A2A
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 7C-4 5.7L LTl Engine Flywheel
Bleeding Hydraulic System . . . . . . . . . . . . . . . . 7C-4 Assembly .............. Refer to Section 6A3A
Clutch Master and Actuator Cylinder Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . 7C- l 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C- l 5
Clutch Pedal Assembly . . . . . . . . . . . . . . . . . . . 7C-7 Fastener Tightening Specifications . . . . . . . . . 7C-15
Clutch Anticipate Switch Assembly . . . . . . . . . 7C-7 Special Tools ............................ 7C-15

GENERAL DESCRIPTION
PRINCIPLE COMPONENTS
The principal components of the clutch system are
the driving members, attached to the engine assembly and
turning with the engine assembly; the driven member,
attached to the transmission assembly and turning with
the transmission assembly; and the operating members.
The operating members include the clutch master cylinder
and actuator assembly, the clutch release bearing assem-
bly, the clutch pedal assembly, and the clutch pilot
bearing.
Driving Members
The driving members. of the clutch consist of two
flat surfaced iron plates machined to a smooth finish. One
of these surfaces is the rear face of the engine flywheel
assembly and the other is the clutch pressure plate assem-
bly (with cover). The 3.4L L32 engine uses a push-type
clutch release system, while the 5.7L LTl engine utilizes a
pull-type clutch release system.
Driven Member
The driven member is the clutch driven plate assem-
bly. This clutch driven plate assembly has a splined hub
which meshes with the splines of the input shaft and
drives the input shaft.
The driving and driven members are held in contact
by spring pressure. This pressure is exerted by a dia-
phragm spring in the clutch pressure plate assembly (with
cover).
Hydraulic Clutch
A hydraulic clutch operating mechanism is used to
engage and disengage the clutch system. The mechanism
consists of a remote master cylinder reservoir, a clutch
master cylinder and a clutch actuator cylinder. The remote
master cylinder reservoir is mounted to the left-hand hood
strut bracket using a push-on retainer. The clutch master
cylinder is mounted on the front of dash with a U-bolt
fastener. The clutch actuator cylinder is mounted on the
flywheel housing assembly on the 3.4L L32 engine and to
the clutch actuator cylinder spacer on the flywheel hous-
ing assembly with the 5.7L LTl engine. The clutch master
cylinder is operated directly by the clutch pedal assembly.
When the clutch pedal assembly is pressed down,
hydraulic fluid under pressure from the clutch master
cylinder flows into the clutch actuator. On the 3.4L L32
engine the actuator piston engages the clutch fork
assembly, which moves the release bearing assembly,
pressing the diaphragm spring fingers to disengage the
clutch.
On the 5.7L LTl engine the actuator piston engages
the clutch fork assembly which moves the release bearing
7C-2 CLUTCH

assembly pulling the diaphragm spring fingers to disen-
gage the clutch.
The hydraulic clutch system sets the clutch pedal
height and provides automatic clutch adjustment. No
adjustment of clutch or clutch pedal assembly position is
required.
Hydraulic Clutch Fluid
When adding fluid to or refilling the system after
service operations use GM Delco-Supreme 11 ® brake
fluid or an equivalent fluid that meets DOT 3
specifications.
NOTICE: Do not use silicon, mineral or paraffin
based oil in the clutch hydraulic system. These
fluids will damage the rubber parts in the cylinders.
Clutch Pilot Bearing
The clutch pilot bearing is an oil-impregnated
bearing pressed into the crankshaft. This bearing requires
attention when the clutch is removed from the vehicle.
The clutch pilot bearing should be cleaned and inspected
for excessive wear or damage and replaced if necessary.
DIAGNOSIS
.Before removal of the clutch hydraulic system,
verify the malfunction by removing the flywheel housing
cover and measure the travel of the clutch actuator push-
rod. With the clutch pedal pushed fully to the floor, the
clutch actuator pushrod should extend a minimum of
11 mm (0.43 inch) against the clutch fork assembly. Do
not replace the hydraulic system if pushrod travel1exceeds
this distance. '
!
If the clutch actuator pushrod does not meet the
travel requirements, check the clutch master cylinder
reservoir fluid level.
• The clutch actuator cylinder must be in place
when checking the fluid level.
• The proper level is indicated by a step on the
clutch master cylinder reservoir. Fill to speci-
fied level with GM Delco-Supreme 11 ® brake
fluid or an equivalent fluid that meets DOT 3
specifications.
• Do not overfill. The upper portion of the clutch
master cylinder reservoir must accept fluid that
is displaced from the clutch actuator cylinder
as the clutch wears.

PRELIMINARY CHECKS
Before attempting to repair the clutch, manual trans-
mission assembly or related hydraulic components for any
reason other than an obvious failure, the problem and
probable cause should be identified. A large percentage of
clutch and manual transmission assembly problems show
up as shifting difficulties, such as high shift effort, gear
clash and grinding, or transmission assembly blackout.
When any of these conditions occur, a careful analysis of
these difficulties should be performed before removing
the clutch or manual transmission assembly for repairs.
Refer to "Clutch System Diagnosis" in this section for
conditions, causes and corrections.
NOTICE: Carefully clean the top and sides of the
clutch master cylinder reservoir before opening to
prevent contamination of the system with dirt, water
or other foreign material. Remove the clutch master
cylinder reservoir diaphragm before adding fluid.
Carefully replace the diaphragm, cover gasket and
cover after filling.
If the clutch master cylinder reservoir requires any
fluid, check the clutch hydraulic system components for
leakage. Remove rubber boots from the clutch master cyl-
inder and check for leakage past the pistons. A slight wet-
ting of the surfaces is acceptable. Replace the clutch
hydraulic system if excessive leakage is evident.

CLUTCH SYSTEM DIAGNOSIS

For diagnosis of either the 5-speed manual transmission clutch system or the 6-speed manual transmission clutch system
refer to the following chart:
CONDITION
Fails to Release (Pedal
assembly pressed to floor,
shift lever does not move
freely in and out of reverse
gear)
PROBABLE CAUSE
1. Faulty clutch pilot bearing.
2. Faulty driven plate assembly.
3. Fork assembly off of clutch fork ball
stud or ball stud loose on 5-speed
(called T-stud on 6-speed).
4. Driven plate assembly hub binding
on input shaft assembly splines.
5. Driven plate assembly warped or
bent.
6. Air in clutch hydraulic system.
7. Pedal assembly misaligned to the
cowl.
CORRECTION
1. Replace clutch pilot bearing.
2. Replace clutch driven plate
assembly.
3. Install properly and lightly lubricate
fingers at clutch release bearing and
clutch fork ball stud.
4. Repair or replace input shaft
assembly and/or driven plate
assembly.
5. Replace driven plate assembly.
Runout should not exceed 0.5 mm
(0.020 inch).
6. Bleed clutch hydraulic system.
7. Loosen pedal assembly mounting
bolts and realign pedal assembly.

CONDITION
Slipping
Grabbing (Chattering)
Release Bearing Assembly
Noise with Clutch Fully
Engaged
Noisy
Clutch Pedal Assembly Stays
on Floor when Disengaged
Excessive Pedal Pressure
Rapid Clutch Driven Plate
Assembly Wear
CLUTCH 7C·3
PROBABLE CAUSE CORRECTION
1. Oil-soaked driven plate assembly. 1. Install new clutch driven plate
assembly and correct leak at source.
2. Worn facing or facing torn from 2. Replace clutch driven plate
driven plate assembly. assembly.
3. Warped pressure plate assembly or 3. Replace pressure plate assembly or
flywheel assembly. flywheel assembly.
4. Weak diaphragm spring. 4. Replace. pressure plate assembly.
5. Clutch driven plate assembly not 5. Make 30 to 40 normal starts. Do not
seated in. overheat.
·6. Clutch driven plate assembly 6. Allow to cool.
overheated.
1. Oil on clutch pressure plate assembly 1. Install new clutch driven plate
facing or burned or glazed facing. assembly and correct leak at source.
2. Worn splines on input shaft 2. Replace input shaft assembly.
assembly.
3. Warped pressure plate assembly or 3. Replace pressure plate assembly or
flywheel assembly. flywheel assembly.
4. Burned or smeared resin on flywheel 4. Sand off if superficial. Replace
or pressure plate assemblies. burned or heat checked parts.
1. Release bearing binding on 1. Clean,.lubricate, check for burrs,
transmission bearing retainer. nicks, and other wear.
2. Fork assembly improperly installed. 2. Install properly.
1. Worn release bearing. 1. Replace bearing assembly.
2. Fork assembly off ball stud on 2. Install properly and lubricate fork
5-speed (called T-stud on 6-speed) assembly fingers and bearing
(heavy clicking). assembly.
3. Clutch pilot bearing loose in 3. Replace clutch pilot bearing.
crankshaft.
1. Bind in release bearing assembly. 1. Lubricate and free-up release
bearing assembly.
2. Master cylinder fell off pedal. 2. Install correctly.
1. Linkage needs lubrication. 1. Lubricate linkage.
2. Pressure plate assembly release 2. Free and lubricate.
fingers binding.
3. Linkage misaligned. 3. Align linkage.
4. Release bearing assembly sleeve 4. Free and lubricate.
binding on transmission bearing
retainer.
5. Sticking linkage, master cylinder or 5. Clean or replace as needed.
actuator cylinder.
1. Scored flywheel assembly or 1. Grind or replace.
pressure plate assembly.
2. Driver rides the clutch (rests left foot 2. Instruct driver.
on clutch while driving).
3. Driver races engine and slips clutch 3. Instruct driver.
excessively during starting.
4. Drjver holds vehicle on hill by 4 .. Instruct driver.
slipping clutch.
5. Weak pressure plate assembly 5. Rebuild or replace pressure plate
springs. assembly.
7C~4 CLUTCH
ON-VEHICLE SERVICE
BLEEDING HYDRAULIC SYSTEM
Figures 1, 2, and 3
Bleeding is necessary whenever the level of fluid in
the reservoir has been allowed to fall so low that air has
been drawn into the master cylinder.
NOTICE: Never, under any circumstances, use
fluid which has been bled from a system to fill the
clutch master cylinder reservoir as it may be aerated,
have too much moisture content and possibly be
contaminated.
NOTICE: See "Notice" on page 7C-1 of this sec-
tion.
1. Loosen clutch master cylinder nuts (23 and 24) to
end of threads on U-bolt (25).
2. Clean dirt and grease from the reservoir cap to
ensure no foreign substances will enter the system.
A RESERVOIR, CLUTCH MASTER CYLINDER
B MASTER CYLINDER, CLUTCH
C ACTUATOR CYLINDER, CLUTCH
1 CYLINDER ASSEMBLY, CLUTCH MASTER AND
ACTUATOR
2 BRACKET, HOOD STRUT LEFT-HAND
3 RETAINER, CLUTCH MASTER CYLINDER RESERVOIR
4 HOSE CLIP, CLUTCH MASTER CYLINDER AND
ACTUATOR
5 NUT, CLUTCH ACTUATOR CYLINDER, 20 N•m (15 LB. FT.)
Figure 1 - Clutch Hydraulic System (6-Speed)
3. Remove the reservoir cap and diaphragm.
4. Wrap a piece of mechanics wire around left-hand
hood strut bracket (2 or 8) making sure wire is acces-
sible from underside of vehicle.
5. Raise and suitably support vehicle. Refer to SEC-
TION OA.
6. Remove actuator cylinder nuts (5 or 10).
7. Remove actuator cylinder.
• Retain actuator cylinder in engine compart-
ment using mechanics wire previously
installed.
8. Lower vehicle.
9. Grasp actuator cylinder and depress hydraulic actua-
tor cylinder pushrod approximately 20.0 mm (0.787
inch) into actuator cylinder bore and hold.
10. Install diaphragm and reservoir cap while holding in
actuator cylinder pushrod.
c
lVIEWB I
PC0001 •7C-F-RP
 CLUTCH 7C·5

!VIEWB I !VIEWC!
9 HOSE CLIP, CLUTCH MASTER CYLINDER AND
A RESERVOIR, CLUTCH MASTER CYLINDER ACTUATOR
B MASTER CYLINDER, CLUTCH . 10 NUT, CLUTCH ACTUATOR CYLINDER, 20 N•m (15 LB. FT.)
C ACTUATOR CYLINDER, CLUTCH 11 NUT, TRANSMISSION BRACE, 50 N•m (37 LB. FT.)
6 CYLINDER ASSEMBLY, CLUTCH MASTER AND 12 COVER, FLYWHEEL HOUSING
ACTUATOR 13 BRACE, TRANSMISSION
7 RETAINER, CLUTCH MASTER CYLINDER RESERVOIR 14 BOLT/SCREW, TRANSMISSION BRACE,
8 BRACKET, HOOD STRUT LEFT-HAND 50 N•m (37 LB. FT.)
PC0002-7C-F-RP

Figure 2 - Clutch Hydraulic System (5-Speed)

11. Release actuator cylinder pushrod. 18. Install actuator cylinder nuts (5 or 10).
12. Hold actuator cylinder vertically with the pushrod
end facing down. 1~1 Tighten

rn Important
• Actuator cylinder should be lower than the
• Clutch actuator cylinder nuts (5 or 10) to 20
N•m (15 lb. ft.).
19. Lower vehicle.
master cylinder. 20. Remove mechanics wire from left-hand hood strut
13. Press pushrod into actuator cylinder bore with short bracket (2 or 8).
10.0 mm (0.390 inch) strokes. 21. Install clutch master cylinder nuts (23 and 24).

IL•l 1nspect l~I Tighten

• Master cylinder reservoir for air bubbles. • Clutch master cylinder nuts (23) to 27 N•m (20
14. Continue until air bubbles are no longer entering res- lb. ft.).

15.
ervoir.
Raise and suitably support vehicle. Refer to SEC-
ll•l 1nspect
TION OA. • Fluid level in clutch master cylinder reservoir.
Fill clutch master cylinder reservoir with
16. Remove actuator cylinder from mechanics wire. Delco-Supreme 11 ® fluid or equivalent DOT 3
17. Install actuator cylinder. fluid.
7C-6 CLUTCH

15~

<

16

24

A PUSHROD, CLUTCH MASTER CYLINDER 28

B MASTER CYLINDER, CLUTCH
C CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
!VIEWA I
27
ELECTRICAL
D CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
ELECTRICAL
E CONNECTOR, CLUTCH PEDAL POSITION SWITCH
HARNESS ELECTRICAL
15 NUT, BRAKE PEDAL, 25 N•m (18 LB. FT.)
16 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
17 NUT, BRAKE PEDAL PIVOT, 54 N•m (40 LB. FT.)
18 BUSHING, CLUTCH PEDAL PIVOT
19 PEDAL ASSEMBLY, CLUTCH
20 RETAINER, CLUTCH PEDAL LEVER PIN
21 BOLT/SCREW, BRAKE PEDAL PIVOT
22 BUMPER, CLUTCH PEDAL
23 NUT, CLUTCH MASTER CYLINDER, 27 N•m (20 LB. FT.)
24 NUT, CLUTCH MASTER CYLINDER (PUSH-ON)
25 U-BOLT, CLUTCH MASTER CYLINDER
26 SWITCH ASSEMBLY, CLUTCH ANTICIPATE (WITH 3.4L
L32 ENGINE)
27 SWITCH ASSEMBLY, CLUTCH ANTICIPATE (WITH 5.7L
LT1 ENGINE)
28 SWITCH ASSEMBLY, CLUTCH PEDAL POSITION (SWITCH
ASSEMBLY, CLUTCH START)

Figure 3 - Clutch Pedal Assembly and Switches

 CLUTCH 7C·7

CLUTCH MASTER AND ACTUATOR 10. Instrument panel driver knee bolster assembly.
CYLINDER ASSEMBLY Refer to SECTION 8C.
11. Battery negative cable assembly.
Figures 1, 2 and 3

l++I Remove or Disconnect CLUTCH PEDAL ASSEMBLY

CAUTION: Refer to "Caution" under Figure 3
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA. !++I Remove or Disconnect
1. Battery negative cable assembly. 1. Brake and accelerator and clutch pedal assembly
2. Instrument panel driver knee bolster assembly. (with bracket). Refer to SECTION 5.
Refer to SECTION 8C. 2. Brake pedal pivot nut (17) and bolt/screw (21 ).
3. Clutch master cylinder pushrod from clutch pedal 3. Clutch pedal assembly (19) with pivot bushings
assembly ( 19). (18).
4. Clutch master cylinder nuts (23 and 24) from dash
panel assembly. l++I Install or Connect
5. Clutch master cylinder U-bolt (25) from dash panel NOTICE: See "Notice" on page 7C-l of this sec-
assembly. tion.
6. Clutch master cylinder from dash panel assembly. 1. Clutch pedal assembly (19) with pivot bushings
7. Clutch master cylinder reservoir retainer (3 or 7). (18).
8. Clutch master cylinder reservoir from left-hand 2. Brake pedal pivot bolt/screw (21) and nut (17).
hood strut bracket (2 or 8).
9. Raise and suitably support vehicle. Refer to SEC-
l~I Tighten
TION OA. • Brake pedal pivot nut ( 17) to 54 N •m (40 lb.
ft.).
10. Clutch actuator cylinder nuts (5 or 10).
3. Brake and accelerator and clutch pedal assembly
11. Clutch actuator cylinder from clutch housing. (with bracket). Refer to SECTION 5.
12. Clutch master and actuator cylinder assembly (1 or
6) from vehicle.
CLUTCH ANTICIPATE SWITCH ASSEMBLY
l++I Install or Connect Figure3
NOTICE: See "Notice" on page 7B-l of this sec-
tion. !++I Remove or Disconnect
1. Clutch actuator cylinder. CAUTION: Refer to "Caution" under
2. Clutch actuator cylinder nuts (5 or 10). "Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
l~I Tighten 1. Battery negative cable assembly.
• Clutch actuator cylinder nuts (5 or 10) to 20 2. Instrument panel dr~ver knee bolster assembly.
N•m (15 lb. ft.). Refer to SECTION 8C.
3. Lower vehicle. 3. Clutch anticipate switch harness electrical connector
from clutch anticipate switch assembly (26 or 27).
4. Clutch master cylinder to dash panel assembly.
4. Clutch anticipate switch assembly (26 or 27) from
5. Clutch master cylinder U-bolt (25) to dash panel
brake and accelerator and clutch pedal assembly
assembly.
(with bracket) (16).
6. Clutch master cylinder nuts (23 and 24).

l~I Tighten l++I Install or Connect

• Clutch master cylinder nuts (23) to 27 N•m (20
lb. ft.).
7. Clutch master cylinder reservoir to left-hand hood
strut bracket (2 or 8).
8. Clutch master cylinder reservoir retainer (3 or 7).
9. Clutch master cylinder pushrod to clutch pedal
assembly (19).
1. Clutch anticipate switch assembly (26 or 27) to
brake and accelerator and clutch pedal assembly
(with bracket) (16).
2. Clutch anticipate switch harness electrical connector
to clutch anticipate switch assembly (26 or 27).
3. Instrument panel driver knee bolster assembly.
Refer to SECTION 8C.
4. Battery negative cable assembly.
7C-8 CLUTCH

CLUTCH PEDAL POSITION SWITCH 8. Transmission brace nut (11) and bolt/screw (14).
ASSEMBLY (CLUTCH START SWITCH 9. Transmission brace (13).
ASSEMBLY) 10. Flywheel housing cover bolts/screws (53).
Figure 3 11. Flywheel housing cover (12).
12. Flywheel housing bolts/screws (65).
l++I Remove or Disconnect 13. Flywheel housing assembly (34). ,
CAUTION: Refer to "Caution" under 14. Clutch pressure plate and cover bolts/screws (51).
"Disconnecting the Battery Negative 15. Clutch pressure plate assembly (with cover) (30)
Cable Assembly" in SECTION OA. and clutch driven plate assembly (37).
1. Battery negative cable assembly.
2. Instrument panel driver knee bolster assembly. IL•l 1nspect
Refer to SECTION 8C. • Clutch pressure plate assembly (with cover) (30) for
3. Clutch pedal position switch harness electrical con- wear or damage. Repair or replace as necessary.
nector from clutch pedal position switch assembly • Clutch driven plate assembly (37) for wear or dam-
(28). age. Replace as necessary.
4. Clutch pedal position switch assembly (28) ·from • Engine flywheel assembly. Refer to SECTION
brake and accelerator and clutch pedal assembly 6A2A.
(with bracket) (16).

l++I Install or Connect

!++I Install or Connect
NOTICE: See "Notice" on page 7C-l of this sec-
1. Clutch pedal position switch assembly (28) to brake tion.
and accelerator and clutch pedal assembly (with 1. Clutch driven plate assembly (37) to engine fly-
bracket) (16). wheel assembly (29).
2. Clutch pedal position switch harness electrical con- 2. Clutch pressure plate assembly (with cover) (30).
nector to clutch pedal position switch assembly (28).
3. Clutch pressure plate and cover bolts/screws (51).
3. Instrument panel driver knee bolster assembly.
Refer to SECTION 8C.
4. Battery negative cable assembly.
l~I Tighten
• Clutch pressure plate and cover bolts/screws
(51 ) finger tight.
CLUTCH DRIVEN PLATE ASSEMBLY
(5-SPEED) 4. Align clutch driven plate assembly (37) with pilot
bearing assembly (38) and clutch pressure plate
Figures 2, 3, 4 and 5 assembly (with cover) (30) using J 33169.
Tool Required:
J 33169 Clutch Alignment Arbor
l~I Tighten
• Clutch pressure plate and cover bolts/screws
l++I Remove or Disconnect
(51) to 20 N•m (15 lb. ft.) plus 30 degrees.
5. Flywheel housing assembly (34).
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative 6. Flywheel housing bolts/screws (65).

1.
Cable Assembly" in SECTION OA.
Battery negative cable assembly. l~I Tighten
2. Instrument panel driver knee bolster assembly. • Flywheel housing bolts/scr~ws (65) to 75 N•m
(55 lb. ft.).
3.

4.
Refer to SECTION 8C.
Clutch master cylinder pushrod from clutch pedal
assembly ( 19).
Raise and suitably support vehicle. Ref~r to SEC-
rn Important
• Check for proper clutch fork assembly (36) to
TION OA. clutch release bearing assembly (31) engage-
ment.
5. 5-Speed manual transmission assembly. Refer to
SECTION 7B. 7. Flywheel housing cover (12).
6. Clutch actuator cylinder nuts (10). 8. Flywheel housing cover bolts/screws (53).
NOTICE: Do not allow clutch actuator cylinder to
hang. by hydraulic lines as this could cause damage l~I Tighten
to clutch hydraulic lines. • Flywheel housing cover bolts/screws (53) to
7. Clutch actuator cylinder and retain with mechanics 8.5 N•m (75 lb. in.).
wire. 9. Transmission brace (13).
 CLUTCH 7C-9

33
34

38

A
A ACTUATOR CYLINDER, CLUTCH
29 FLYWHEEL ASSEMBLY, ENGINE
30 PLATE ASSEMBLY, CLUTCH PRESSURE (WITH COVER)
31 BEARING ASSEMBLY, CLUTCH RELEASE
32 STUD, CLUTCH FORK BALL
33 WASHER, CLUTCH FORK BALL STUD
34 HOUSING ASSEMBLY, FLYWHEEL
35 BOOT, CLUTCH FORK
36 FORK ASSEMBLY, CLUTCH
37 PLATE ASSEMBLY, CLUTCH DRIVl:N
38 BEARING, CLUTCH PILOT

PC0004-7C-F-RP

Figure 4 - Clutch System Cross Section (5-Speed)

10. Transmission brace nut (11) and bolt/screw (14). 16. Instrument panel driver knee bolster assembly.
Refer to SECTION 8C.
l~I Tighten 17. Battery negative cable assembly.
• Transmission brace nut ( 11) and bolt/screw
(14) to 50 N•m (37 lb. ft.). CLUTCH DRIVEN PLATE ASSEMBLY
(6-SPEED)
11. Clutch actuator cylinder.
12. Clutch actuator cylinder nuts (10). Figures 3, 6, and 7

l~I Tighten
l++I Remove or Disconnect
Tool Required:
• Clutch actuator cylinder nuts (10) to 20 N•m
(15 lb. ft.). J 38836 Clutch Alignment Arbor
13. 5-Speed manual transmission assembly. Refer to 1. Instrument panel driver knee bolster assembly.
Refer to SECTION 78C.
SECTION7B.
2. Clutch master cylinder pushrod from clutch pedal
14. Lower vehicle. assembly (19).
15. Clutch master cylinder pushrod to clutch pedal 3. Raise and suitably support vehicle. Refer to SEC-
assembly (19). TION OA.
7C-10 CLUTCH

12 COVER, FLYWHEEL HOUSING

29 FLYWHEEL ASSEMBLY, ENGINE
30 PLATE ASSEMBLY, CLUTCH PRESSURE (WITH COVER)
31 BEARING ASSEMBLY, CLUTCH RELEASE
32 STUD, CLUTCH FORK BALL
33 WASHER, CLUTCH FORK BALL STUD
34 HOUSING ASSEMBLY, FLYWHEEL
35 BOOT, CLUTCH FORK
36 FORK ASSEMBLY, CLUTCH
37 PLATE ASSEMBLY, CLUTCH DRIVEN
38 BEARING, CLUTCH PILOT
49 PIN, FLYWHEEL HOUSING LOCATOR
50 BOLT/SCREW, FLYWHEEL, 83 N•m (61 LB. FT.)
51 BOLT/SCREW, CLUTCH PRESSURE PLATE AND COVER,
20 N•m (15 LB. FT.) PLUS 30 DEGREES
52 PIN, FLYWHEEL GROOVE
53 BOLT/SCREW, FLYWHEEL HOUSING COVER, 8.5 N•m
(75 LB. IN.)
54 TRANSMISSION ASSEMBLY, MANUAL (5-SPEED)
65 BOLT/SCREW, FLYWHEEL HOUSING, 75 N•m
(55 LB. FT.)
PC0005-7C-F-RP

Figure 5 - Clutch System (5-Speed)

 CLUTCH 7C-H

42

41

43

44

A ACTUATOR CYLINDER, CLUTCH 46

39 PLATE ASSEMBLY, CLUTCH PRESSURE (WITH COVER)
40 BEARING ASSEMBLY, CLUTCH RELEASE
41 T-STUD, CLUTCH FORK
42 TRANSMISSION ASSEMBLY, MANUAL (6-SPEED)
43 SPACER, CLUTCH ACTUATOR CYLINDER
44 HOUSING ASSEMBLY, FLYWHEEL
45 FORK ASSEMBLY, CLUTCH
46 FLYWHEEL ASSEMBLY, ENGINE
47 PLATE ASSEMBLY, CLUTCH DRIVEN
48 BEARING, CLUTCH PILOT
PC0006-7C-F-RP

Figure 6 - Clutch System Cross Section (6-Speed)

4. 6-Speed manual transmission assembly. Refer to

SECTION 7B.
NOTICE: Do not allow clutch actuator cylinder to
hang by hydraulic lines as this could cause damage
to clutch hydraulic lines.
5. Flywheel housing cover bolts/screws (61).
6. Flywheel housing cover (56).
7. Flywheel housing bolts/screws (62).
8. Flywheel housing assembly (44). ·
9. Clutch pressure plate and cover bolts/screws (57).
10. Clutch pressure plate assembly (with cover) (39)
and clutch driven plate assembly (47).
ll•l1nspect
• Clutch pressure plate assembly (with cover) (39) for
wear or damage. Repair or replace as necessary.
• Clutch driven plate assembly (47) for wear or dam-
age. Replace as necessary.
• Engine flywheel assembly. Refer to SECTION
6A3A.
1++1 Install or Connect
NOTICE: See "Notice" on page 7C-1 of this sec-
tion.
1. Clutch driven plate assembly (47) to engine fly-
wheel assembly (46).
2. Clutch pressure plate assembly (with cover) (39).
3. Clutch pressure plate and cover bolts/screws (57).
l~I Tighten
• Clutch pressure plate and cover bolts/screws
(57) finger tight.
4. Align clutch driven plate assembly (47) with clutch
pilot bearing (48) and clutch pressure plate assembly
(with cover) (39) using J 38836.
l~I Tighten
• Clutch pressure plate and cover bolts/screws
(57) to 30 N•m (22 lb. ft.).
7C·12 CLUTCH

5. Flywheel housing assembly (44).

6. Flywheel housing bolts/screws (62). 1++1 Install or Connect

l~I Tighten
NOTICE: See "Notice" on page 7C-1 of this sec-
tion.
• Flywheel housing bolts/screws (62) to 47 N•m 1. Clutch fork ball stud (32) and washer (33).
(35 lb. ft.).
2. Lubricate clutch ball stud (32) using wheel bearing
7. Flywheel housing cover (56). lubricant GM PIN 1051344, or equivalent.
8. Flywheel housing cover bolts/screws (61). 3. Clutch fork assembly (36) onto clutch ball stud (32).

l~I Tighten
4. Lubricate recess on inside diameter of clutch release
bearing assembly (31) and the clutch fork groove
• Flywheel housing cover bolts/screws (61) to using wheel bearing lubricant GM PIN 1051344, or
8.5 N•m (75 lb. in.). equivalent.
9. 6-Speed manual transmission assembly. Refer to 5. Clutch release bearing assembly (31) to clutch fork
SECTION 7B. assembly ((36).
10. Lower vehicle. 6. Flywheel housing assembly (34).
11. Clutch master cylinder pushrod to clutch pedal 7. Flywheel housing bolts/screws (65).
assembly ( 19).
12. Instrument panel driver knee bolster assembly.
Refer to SECTION 8C.
l~ITighten
• Flywheel housing bolts/screws (65) to 75 N•m
(55 lb. ft.).
CLUTCH FORK ASSEMBLY AND CLUTCH
RELEASE BEARING ASSEMBLY (5-SPEED) 8. Flywheel housing cover (12).
9. Flywheel housing cover bolts/screws (53).
Figures 2, 4 and 5

l++I Remove or Disconnect

!~I Tighten
• Flywheel housing cover bolts/screws (53) to
1. Instrument panel driver knee bolster assembly. 8.5 N•m (75 lb. in.).
Refer to SECTION 8C.
10. Transmission brace (13).
2. Clutch master cylinder pushrod from clutch pedal
assembly (19). 11. Transmission brace nut (11) and bolt/screw ( 14).
3. Raise and suitably support vehicle. Refer to SEC-
TION OA. l~I Tighten
4. 5-Speed manual transmission assembly. Refer to • Transmission brace nut ( 11) and bolt/screw
SECTION 7B. (14) to 50 N•m (37 lb. ft.).
5. Clutch actuator cylinder nuts (10). 12. Clutch actuator cylinder.
NOTICE: Do not allow clutch actuator cylinder to 13. Clutch actuator cylinder nuts (10).
hang by hydraulic lines as this could cause damage
to clutch hydraulic lines. [~I Tighten
6. Clutch actuator cylinder and retain with mechanics • Clutch actuator cylinder nuts (10) to 20 N•m
wire. (15 lb. ft.).
7. Transmission brace nut ( 11) and bolt/screw ( 14). 14. 5-Speed manual transmission assembly. Refer to
8. Transmission brace ( 13). SECTION 7B.
9. Flywheel housing cover bolts/screws (53). 15. Lower vehicle.
10. Flywheel housing cover (12). 16. Clutch master cylinder pushrod to clutch pedal
11. Flywheel housing bolts/screws (65). assembly ( 19).
12. Flywheel housing assembly (34). 17. Instrument panel driver knee bolster assembly.
13. Clutch release bearing assembly (31). Refer to SECTION 8C.
14. Clutch fork assembly (36).
15. Clutch fork ball stud (32) and washer (33).
CLUTCH FORK ASSEMBLY AND CLUTCH
RELEASE BEARING ASSEMBLY (6-SPEED)
ll'l'I Inspect
Figures 3, 6, and 7
• Clutch release bearing assembly, clutch fork assem-
bly, and clutch fork ball stud for wear or damage. Tool Required:
Replace as necessary. J 33169 Clutch Alignment Arbor

l++I Remove or Disconnect
1. Instrument panel driver knee bolster assembly. Re-
fer to SECTION 8C.
2. Clutch master cylinder pushrod from clutch pedal
assembly (19).
3. Raise and suitably support vehicle. Refer to SEC-
TION OA.
4. 6-Speed manual transmission assembly. Refer to
SECTION 7B.
5. Flywheel housing cover bolts/screws (61).
6. Flywheel housing cover (56).
7. Flywheel housing bolts/screws (62).
8. Flywheel housing assembly (44).
9. Clutch pressure plate and cover bolts/screws (57).
10. Clutch pressure plate assembly (with cover) (39)
and clutch driven plate assembly (47).
11. Clutch release bearing retainer (58).
12. Clutch release bearing assembly (40).
13. Clutch fork assembly (45) from 6-speed manual
transmission assembly (42).
14. Bolt/screw (63) and clutch fork T-stud (41) from
6-speed manual transmission assembly (42).
IL•l 1nspect
• Clutch release bearing assembly (40), clutch fork
assembly (45), and clutch fork T-stud (41) for wear
or damage. Replace as necessary.
l++I Install or Connect
NOTICE: See "Notice" on page 7C-1 of this sec-
~~ .
1. Clutch fork T-stud (41) and bolt/screw (63).
l~I Tighten
• Clutch fork T-stud bolt/screw (63) to 24 N•m
(18 lb. ft.).
2. Lubricate clutch fork T-stud (41) using wheel bear-
ing lubricant GM PIN 1051344, or equivalent.
3. Clutch fork assembly (45) on clutch fork T-stud (41)
at first detent position.
• Do not fully seat clutch fork assembly (45) on
clutch fork T-stud (41) until after installation of
6-speed manual transmission assembly (42). It
will fully seat itself when transmission assem-
bly (42) is installed.
4. Clutch release bearing assembly (40) to clutch pres-
sure plate assembly (with cover) (39).
5. Clutch release bearing retainer (58).
6. Clutch driven plate assembly (47) to engine fly-
wheel assembly (46).
7. Clutch pressure plate assembly (with cover) (39).
8. Clutch pressure plate and cover bolts/screws (57).
CLUTCH 7C· 13
l~I Tighten
• Clutch pressure plate and cover bolts/screws
(57) finger tight.
9. Align clutch driven plate assembly (47) with clutch
pilot bearing (48) and clutch pressure plate assembly
(with cover) (39) using J 38836.
l~I Tighten
• Clutch pressure plate and cover bolts/screws
(57) to 30 N•m (22 lb. ft.).
10. Flywheel housing assembly (44).
11. Flywheel housing assembly bolts/screws (62).
l~I Tighten
. • Flywheel housing bolts/screws (62) to 47 N•m
(35 lb. ft.).
12. Flywheel housing cover (56).
13. Flywheel housing cover bolts/screws (61).
l~I Tighten
• Flywheel housing cover bolts/screws (61) to
8.5 N•m (75 lb. in.).
14. 6-Speed manual transmission assembly. Refer to
SECTION7B.
15. Lower vehicle.
16. Clutch master cylinder pushrod to clutch pedal
assembly (19).
17. Instrument panel driver knee bolster assembly.
Refer to SECTION 8C.
CLUTCH PILOT BEARING
Figures 5 through 7
Tool Required:
J 23907 Clutch Pilot Bearing Remover
l++I Remove or Disconnect
1. Clutch driven plate assembly. Refer to "Clutch
Driven Pla.te Assembly{5-Speed)" or "Clutch Driv-
en Plate Assembly (6-Speed)" in this section.
2. Engine flywheel assembly. Refer to SECTION
6A2A or 6A3A.
3. Clutch pilot bearing (38 or 48) using J 23907.
l++I Install or Connect
1. Clutch pilot bearing (38 or 48).
2. Engine flywheel assembly. Refer to SECTION
6A2A or 6A3A.
3. Clutch driven plate assembly. Refer to "Clutch
Driven Plate Assembly (5-Speed)" or "Clutch Driv-
en Plate Assembly (6-Speed)" in this section.
7C·14 CLUTCH

56 48

/
---- ---- 60

44
45
143
42

39 PLATE ASSEMBLY, CLUTCH PRESSURE (WITH COVER) 57 BOLT/SCREW, CLUTCH PRESSURE PLATE AND COVER
40 BEARING ASSEMBLY, CLUTCH RELEASE 30 N•m (22 LB. FT.)
41 T-STUD, CLUTCH FORK 58 RETAINER, CLUTCH RELEASE BEARING
42 TRANSMISSION ASSEMBLY, MANUAL (6-SPEED) 59 BOLT/SCREW, FLYWHEEL, 100 N•m (74 LB. FT.)
43 SPACER, CLUTCH ACTUATOR CYLINDER 60 PIN, FLYWHEEL GROOVE
44 HOUSING ASSEMBLY, FLYWHEEL 61 BOLT/SCREW, FLYWHEEL HOUSING COVER,
45 FORK ASSEMBLY, CLUTCH 8.5 N•m (75 LB. IN.)
46 FLYWHEEL ASSEMBLY, ENGINE 62 BOLT/SCREW, FLYWHEEL HOUSING, 47 N•m
47 PLATE ASSEMBLY, CLUTCH DRIVEN (35 LB. FT.)
48 BEARING, CLUTCH PILOT 63 BOLT/SCREW, CLUTCH FORK T-STUD, 24 N•m
55 PIN, FLYWHEEL HOUSING LOCATOR (18 LB. FT.)
56 COVER, FLYWHEEL HOUSING 64 BOLT/SCREW, TRANSMISSION, 35 N•m (26 LB. FT.)

PCG007-7C-f.RP

Figure 7 - Clutch System (6-Speed)

 CLUTCH 7C·15

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Brake Pedal Nut .................................................... 25 N•m (18 lb. ft.)
Brake Pedal Pivot Nut ................................................ 54 N•m (40 lb. ft.)
Clutch Actuator Cylinder Nut .......................................... 20 N•m (15 lb. ft.)
Clutch Fork T-Stud Bolt/Screw ......................................... 24 N•m (18 lb. ft.)
Clutch Master Cylinder Nut ........................................... 27 N•m (20 lb. ft.)
Clutch Pressure Plate and Cover Bolt/Screw (6-Speed) ...................... 30 N•m (22 lb. ft.)
Clutch Pressure Plate and Cover Bolt/Screw (5-Speed) . . . . . . . . 20 N•m (15 lb. ft.) Plus 45 Degrees
Flywheel Bolt/Screw (5-Speed) ........................................ 83 N•m (61 lb. ft.)
Flywheel Bolt/Screw (6-Speed) ....................................... 100 N•m (74 lb. ft.)
Flywheel Housing Cover Bolt/Screw ................................... 8.5 N•m (75 lb. in.)
Flywheel Housing Bolt/Screw (5-Speed) ................................. 75 N•m (55 lb. ft.)
Flywheel Housing Bolt/Screw (6-Speed) ................................. 47 N•m (35 lb. ft.)
Transmission Brace Bolt/Screw ........................................ 50 N•m (37 lb. ft.)
Transmission Brace Nut .............................................. 50 N•m (37 lb. ft.)
Transmission Bolt/Screw ............................................. 35 N•m (26 lb. ft.)

SPECIAL TOOLS

1 2.
· QJ_...,L}__ -=-=-=--------_-_:_:,;_,}
-11!))....= J 33169 ) ) J-6

3.

J 23907
1. CLUTCH ALIGNMENT ARBOR (3.4L L32 ENGINE)
2. CLUTCH ALIGNMENT ARBOR (5.7L LT1 ENGINE)
3. CLUTCH PILOT BEARING REMOVER
PC0008-7C-f.RP
 ELECTRICAL BODY AND CHASSIS 8·1

SECTION 8
ELECTRICAL
BODY AND CHASSIS
CONTENTS
Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... Section 8A
Lighting Systems and Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... Section 8B
Instrument Panel, Gages and Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... Section 8C
Windshield Wiper/Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... Section 8E
 LIGHTING SYSTEMS AND HORNS 88·1

SECTION 88

LIGHTING SYSTEMS AND HORNS

CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description ........................ 8B-2
Halogen Bulbs .......................... 8B-2
Exterior Lighting ........................ 8B-2
Backup Lamps ........................ 8B-2
Daytime Running Lamps
(Canadian Only) ..................... 8B-2
Front Fog Lamp Assemblies ............. 8B-2
Front Sidemarker Lamps . . . . . . . . . . . . . . . . 88-2
Hazard Lamp Flasher Assembly .......... 8B-2
Headlamp Capsule Assemblies and
Headlamp Assemblies ................ 8B-2
High-Mount Stoplamp Assembly ......... 88-3
Parking and Turn Signal Lamp
Assemblies ......................... 8B-3
Rear License Lamp Assembly ............ 8B-3
Rear Sidemarker Lamp Assemblies ........ 8B-3
Taillamp Assemblies ................... 8B-3
Turn Signal Lamp Flasher Assembly ...... 8B-3.
Interior Lighting ......................... 8B-3
Ashtray Lamp ........................ 8B-3
Automatic Transmission Indicator Lamp ... 8B-3
Console Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Dome and Reading Lamps ............... 8B-3
Front Side Door Courtesy Lamps ......... 8B-3
Heater and Air Conditioning Control
Lamp ............................. 8B-4
Instrument Panel Compartment Lamp ...... 8B-4
Rear Quarter Courtesy Lamps ............ 8B-4
Rear Compartment Lamp ................ 8B-4
Horn Assemblies ........................ 8B-4
Diagnosis ................................ 8B-4
Lighting System Troubleshooting ........... 8B-4
Horn Assemblies ........................ 88-4
Horn Tone Poor ....................... 88-4
On-Vehicle Service ........................ 88-4
Exterior Lighting ........................ 8B-4
Backup Lamps ........................ 8B-4
Daytime Running Lamps
(Canadian Only) . . . . . . . . . Refer to Section 8C
Front Fog Lamp Assemblies . . . . . . . . . . . . . 8B-4
Front Fog Lamp Aiming Procedure . . . . . . . . 8B-5
Front Sidemarker Lamp . . . . . . . . . . . . . . . . . 88-5
Hazard Lamp Flasher Assembly . . . . . . . . . . 8B-5
Headlamp Capsule Assemblies . . . . . . . . . . . 88-5
Headlamp Assemblies . . . . . . . . . . . . . . . . . . 8B-6
Headlamp Opening Door Actuator
Control Module Assembly . . . . . . . . . . . . . 8.8-8
Headlamp Aiming by Screen Method . . . . . . 8B-8
Headlamp Aiming Alternate Procedure .... SB-10
Headlamp Aiming After a Collision . . . . . . 8B- l l
High-Mount Stoplamp Assembly . . . . . . . . 88-11
Parking and Turn Signal Lamp
Assemblies ........................ 88-12
Rear License Lamp Assembly ........... 88-12
Rear Sidemarker Lamp Assemblies . . . . . . . 8B- l 3
Taillamp Assemblies . . . . . . . . . . . . . . . . . . 8B- l 3
Turn Signal Lamp Flasher Assembly ..... SB-14
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . 8B-14
Ashtray Lamp ....................... SB-15
Automatic Transmission Indicator
Lmnp ............................ 8B~I5
Console Lamp ....................... SB-16
Dome Lamp ......................... 8B-16
Front Reading Lamps .................. SB-16
Front Side Door Courtesy Lamps . . . . . . . . 8B- l 6
Heater and Air Conditioning Control
Lamp ............................ 8B-l 7
Instrument Panel Compartment Lamp . . . . . 8B- l 7
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB-17
CurrentAdjustment ................... 8B-l 7
Horn Assemblies ..................... SB-17
Horn Relay .......................... 8B-18
Specifications ............................ SB-18
Fastener Tightening Specifications . . . . . . . . . 8B-18
Bulb Usage Chart ....................... SB-19
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B- l 9
88-2 LIGHTING SYSTEMS AND HORNS
GENERAL DESCRIPTION
HALOGEN BULBS
Some bulbs in this vehicle may contain halogen gas.
CAUTION: Halogen bulbs contain a gas
under pressure. Handling a bulb
improperly could cau.se it to shatter
into flying glass fragments. To help
avoid personal injury:
• Turn off lamp assembly and allow
bulb to cool before changing
bulbs. Leave switch assembly off
until bulb change is complete.
• Always wear eye protection when
changing a halogen bulb.
• Handle bulb only by its base.
Avoid touching glass.
• Do not drop or scratch bulb. Keep
moisture away.
• Place used bulb in new bulb's
carton and dispose of it properly.
Keep halogen bulbs out of the
reach of children.
EXTERIOR LIGHTING
Backup Lamps
The backup lamps are part of the taillamp assem-
blies. They are located on the innermost side of the tail-
lamp assembly next to the taillamp filler. They will come
on when the transmission is shifted into "REVERSE."
On vehicles with an automatic transmission assembly, the
backup lamps are activated by the park/neutral position
switch assembly. On vehicles with a manual transmission,
they are activated by a backup lamp switch which is part
of the transmission assembly. For more information, refer
to SECTION 7 A or 7B.
Daytime Running Lamps (Canadian Only)
All Canadian vehicles are equipped with daytime
running lamps. The daytime running lamp system
includes a solid state module, a relay and a light sensor.
The system lights low-beam headlamps at reduced inten-
sity when the ignition switch is in the "RUN" position
during daylight. The daytime running lamp system is
designed to light the low-beam headlamps at full intensity,
and the parking and taillamps when low light conditions
are present.
Front Fog Lamp Assemblies
The fog lamp switch assembly is below the head-
lamp and instrument panel lamp dimmer switch assembly
to the left of the steering column assembly. To use the
front fog lamp assemblies, first turn on the headlamps or
parking lamps. Then push the right side of the fog lamp
switch to turn on the front fog lamp assemblies. Push the
left side of the switch to turn off the front fog lamp
assemblies.
The front fog lamp assemblies should not be used as
a substitute for the headlamps.
Switching to high-beam headlamps will turn off the
front fog lamp assemblies. Switching back to low-beam
headlamps will turn the front fog lamp assemblies on
again.
The front fog lamp assemblies must be aimed for
proper illumination of the road. Fog lamp aim should be
checked when a new bulb is installed or if service or
repairs in the front end area may have disturbed the fog
lamp mountings.
Front Sidemarker Lamps
The front sidemarker lamps are housed within the
parking and turn signal lamp assembly. They will come on
when the headlamps or parking lamps are on. The front
sidemarker lamps also have reflectors that will shine
when struck by light whether or not the vehicle's lamps
are on.
If the headlamps or parking lamps are off when a
turn is signalled, the appropriate front sidemarker lamps
will flash in unison with the front turn signal lamp on the
same side. If the headlamps or parking lamps are on when
a turn is signalled, the front sidemarker lamp and front
turn signal lamp will flash alternately.
Hazard Lamp Flasher Assembly
The hazard warning flashers are part of the turn
signal circuit. The hazard warning switch is on the right
side of the steering column assembly. Pressing in on the
hazard warning switch button causes the front and rear
turn signal lamps and front sidemarker lamps to flash.
Pulling on the hazard warning switch knob will turn off
the hazard warning flashers.
The hazard warning flashers will work with the
ignition switch in any position. When the hazard warning
flashers are "ON," the turn signals do not work. The
hazard lamp flasher assembly is in the convenience center
behind the instrument panel assembly on the knee bolster
bracket. For more information on the hazard warning
switch assembly, refer to SECTION 3F.
Headlamp Capsule Assemblies and
Headlamp Assemblies
The headlamp capsule assemblies (Chevrolet) and
headlamp assemblies (Pontiac) are controlled by the head-
lamp switch located on the headlamp and instrument
panel lamp dimmer switch assembly to the left of the
steering column assembly. They will come on with the
ignition switch in any position. Turning the headlamp
switch all the way to the right turns on the headlamps.
Turning the headlamp switch all the way to the left turns
off the headlamps.
Headlamp low beam and high beam are controlled
by the headlamp dimmer switch lever assembly on the left
side of the steering column assembly. When the head-
lamps are on, pulling the lever assembly toward the driver
until the switch clicks changes the lamp from low beam to
high beam, or from high beam to low beam. An indicator
lamp on the instrument cluster assembly will come on
when the high-beam headlamps are on.
The headlamps must be aimed for proper illumi-
nation of the road. Headlamp aim should be checked
whenever a new headlamp assembly is installed or service

repairs to the front end area may have disturbed the
headlamp assembly or its mountings.
m Important
• Some state and local laws specify requirements for
headlamp aim. These laws must be followed.
High-Mount Stoplamp Assembly
The high-mount stoplamp assembly is in the center
of the rear end spoiler assembly. It will illuminate when-
ever the brake pedal assembly is pushed down. The lamp
is powered separately from the taillamp assemblies
through a circuit in the stop lamp switch assembly.
Parking and Turn Signal Lamp Assemblies
The parking lamps can be turned on by turning the
headlamp switch to the first position on the right. The
parking lamps can be turned off by turning the headlamp
switch to the left. If the parking lamps are on and the igni-
tion switch is off, a warning tone will sound as a reminder
to turn the lamps off.
When the turn signals are activated, the appropriate
front parking lamps flash to signal a turn. The turn signal
works only when the ignition switch is on and the hazard
lamp flashers are turned off.
The turn signals are controlled by the turn signal
lever assembly on the left side of the steering column
assembly. Moving the lever all the way up or down (past
the detent) will turn on the turn signals. When the turn is
completed, the lever assembly will return to horizontal
and the turn signals will stop flashing.
For changing lanes or shallow turns where the steer-
ing wheel assembly does not turn far enough to cancel the
signal, move the signal only to the first detent and hold it
there. When the lever assembly is released, it will return
to horizontal and the turn signal will cancel. For more
information, refer to SECTION 8A.
Rear License Lamp Assembly
The rear license lamp assembly will come on when
the headlamps or parking lamps are on. The rear license
lamp assembly is mounted on the rear bumper fascia
above the license plate.
Rear Sidemarker Lamp Assemblies
The rear sidemarker lamp assemblies are mounted
on the rear bumper fascia.
The rear sidemarker lamp assemblies will come on
when the headlamps or parking lamps are on. The rear
sidemarker lamp assemblies also have reflectors that will
shine when struck by light whether or not the vehicle's
lamps are on.
Taillamp Assemblies
The taillamps, backup lamps and turn signal lamps
are part of the tail lamp assembly.
Turning on either the headlamps or parking lamps
will turn on the ta ill amps. When the brake pedal is pushed
down, the taillamps glow brighter to serve as stoplamps.
LIGHTING SYSTEMS AND HORNS 88·3
The turn signals are controlled by the turn signal
lever assembly on the left side of the steering column
assembly. Moving the lever all the way up or down (past
the detent) will turn on the turn signals. When the tum is
completed, the lever assembly will return to neutral and
the turn signals will stop flashing. If the brake pedal is
held down when a turn is signalled, one side will flash and
the other will stay on brightly.
For changing lanes or shallow turns where the steer-
ing wheel assembly does not tum far enough to cancel the
signal, move the lever assembly only to the first detent.
When the lever assembly is released, it will return to
neutral and the turn signals will cancel.
Turn Signal Lamp Flasher Assembly
The turn signal lamp flasher assembly is mounted
behind the instrument panel assembly on the driver knee
bolster bracket.
INTERIOR LIGHTING
For information on the warning/indicator lamps,
cluster lamps, etc., refer to SECTION 8C. For circuit
information, refer to SECTION 8A.
Ashtray Lamp
An ashtray lamp is available on vehicles with a
manual transmission. It is mounted beneath the ashtray
and it will come on when the parking lamps or headlamps
are turned on.
Automatic Transmission Indicator Larnp
The automatic transmission indicator lamp will
illuminate the automatic transmission control indicator
located on the front floor console assembly on vehicles
equipped with an automatic transmission. It will come on
when the parking lamps or headlamps are turned on.
Console Lamp
The console lamp is mounted on the front floor
console assembly. It lights when the console compartment
door is opened.
Dome and Reading Lamps
The dome lamp (not available on convertible mod-
els) is located on the roof above the rear seat assembly. It
will come on when a door is opened or when the inside
lamp is turned on. To turn on the interior lamps, rotate the
interior lights thumbwheel switch, located to the left of
the headlamp switch, full up.
The front reading lamps are part of the inside rear-
view mirror assembly. Use the switch to turn a reading
lamp on or off when the doors are closed. With the doors
open, the reading lamps are always on.
For more information on the dome and reading
lamps, refer to SECTION 10-9 and SECTION 10-2.
Front Side Door Courtesy Lamps
The front side door courtesy lamps are mounted
behind the front side door inside handle bezel assemblies.
They come on when the parking lamps or headlamps are
turned on to illuminate the door handles and controls.
88·4 LIGHTING SYSTEMS AND HORNS
Heater and Air Conditioning Control Lamp
The heater and air conditioning control lamp is
mounted on the back of the heater and air conditioning
control assembly. It will come on when the parking lamps
or headlamps are turned on to illuminate the heater and air
conditioning controls.
Instrument Panel Compartment Lamp
The instrument panel compartment lamp lights
when the instrument panel compartment door is opened.
Rear Quarter Courtesy Lamps
The rear quarter courtesy lamps are mounted in the
right and left quarter inner rear trim finishing panel
assemblies. They will come on when a door is opened or
when the interior lamps are turned on. For more informa-
tion on the rear quarter com1esy lamps, refer to SECTION
10-7.
Rear Compartment Lamp
The rear compartment lamp is located in the rear
compartment below the rear compartment lid latch assem-
bly. It will come on when the rear compartment lid is
opened. For more information on the rear compartment
lamp, refer to SECTION 10-8.
HORN ASSEMBLIES
Pushing the pads on the left-hand or right-hand
center of the steering wheel assembly sounds the horn
assemblies by closing the horn relay. For wiring and
circuit information, refer to SECTION 8A.
DIAGNOSIS
For wiring diagrams and other diagnosis informa-
tion on properly repairing wiring harnesses, connectors,
etc., refer to SECTION 8A.
LIGHTING SYSTEM TROUBLESHOOTING
Most lighting problems are caused by loose connec-
tors, open or shorted wiring, burned-out bulbs, bad switch
assemblies, an inadequate ground or blown fuses. Check
these items first and then refer to SECTION 8A.
HORN ASSEMBLIES
If the horn assemblies do not blow, or blow con-
stantly, follow the diagnostic procedures in SECTION 8A.
Horn Tone Poor
1. Horn tone poor - tighten horn bolts/screws in
mounting area, or coJTect poor connections or
ground.
2. Low-pitched moan - sounds like "mooing." Caused
by current too high. Adjust current. Refer to
"Horns" under "On-Vehicle Service" in this
section.
3. Weak tone - current too low. Correct poor connec-
tions or ground, or adjust current. Refer to "Horns"
under "On-Vehicle Service" in this section.
4. Weak, strained tone - remove foreign object in horn.
5. Harsh vibration - bend bracket so horn assembly is
not touching sheet metal.
ON-VEHICLE SERVICE
When replacing a part that requires a special pro-
cedure (such as a lens and housing assembly sealed
together), follow the instructions normally included in the
replacement parts package.
When removing a pai1 that requires special sealing
items (such as sealing washers), be sure to reinstall those
items when replacing the part. Also, if any body sealing
items (grommets, etc.) are disturbed, be sure to repair
them so the passenger compartment remains properly
sealed.
Take care to prevent waterleaks if sealing surfaces
are disturbed. Damaged gaskets must be replaced. If
necessary, use sealer (body caulking compound or equiva-
lent) in critical areas or any area where the gasket doesn't
seal properly.
CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
EXTERIOR LIGHTING
Backup Lamps
To replace a backup lamp bulb, refer to "Taillamp
Assemblies" under "On-Vehicle Service" in this section.
Front Fog Lamp Assemblies
Figure 1
!+-+! Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Front bumper fascia lower deflector. Refer to
SECTION I 0-4.
3. Bolts/screws (3) attaching front fog lamp assembly
(1) to front bumper impact bar (4).
4. Front fog lamp assembly (1) from front bumper
impact bar (4).
5. Nuts (2) from front bumper impact bar (4), if
necessary.
!++! Install or Connect
NOTICE: See "Notice" on page 8B-l of this
section.
1. Nuts (2) to front bumper impact bar ( 4 ), if removed.
!~I Tighten
• Nuts (2) to 10 N•m (89 lb. in.).
2. Front fog lamp assembly ( 1) to front bumper impact
bar (4).
3. Bolts/screws (3) attaching front fog lamp assembly
(1) to front bumper impact bar (4 ).
l~I Tighten
• Bolts/screws (3) to 10 N•m (89 lb. in.).
 LIGHTING SYSTEMS AND HORNS 88·5

4 I
I.
~
1
1 LAMP ASSEMBLY, FRONT FOG !VIEWA I
2
3
4
NUT, FRONT FOG LAMP, 10 N•m (89 LB. IN.)
BOLT/SCREW, FRONT FOG LAMP, 10 N•m (89 LB. IN.)
BAR, FRONT BUMPER IMPACT
1
'--~----3
'

PC2001-8B-f·RP

Figure 1 - Front Fog Lamp Assemblies (Typical)

4. Front bumper fascia lower deflector. Refer to

SECTION 10-4.
5. Lower vehicle.

Front Fog Lamp Aiming Procedure

Horizontal aim is not adjustable on this vehicle.
Vertical aim is done by an adjusting screw locatecl at the
top center of the front fog lamp assembly.
• Prepare vehicle: \
A. Make sure all components are in place, if other
service has been performed on vehicle.
B. Make sure vehicle has 1/2 tank of fuel or less.
C. Move vehicle to level area and park 7.6 m
(25 feet) away from target screen. A CONVENIENCE CENTER ~.....::;.,....
5 RELAY, HORN
D. Measure from center of front fog lamp 6 FLASHER ASSEMBLV, HAZARD LAMP
PC1002-8B-F-RP
assembly to ground line.
E. Turn front fog lamp assemblies on. Top edge of Figure 2 - Horn Relay and Hazard Lamp Flasher Assembly
high intensity zone to be 102 mm (4 inches)
below centerline of front fog lamp assembly. Headlamp Capsule Assemblies
F. Adjust front fog lamp assembly as required,
using adjusting screw at top center of front fog Chevrolet
lamp assembly.
Figure 3
Front Sidemarker Lamp
For replacement of front sidemarker lamp bulb, refer !++! Remove or Disconnect
to "Parking and Turn Signal Lamp Assemblies" under 1. Open hood assembly.
"On-Vehicle Service" in this section.
2. Bolts/screws (7).
Hazard Lamp Flasher Assembly 3. Headlamp mounting ring (8).
4. Electrical connector.
Figure 2
5. Headlamp capsule assembly (9).
!++! Remove or Disconnect !++! Install or Connect
• Hazard lamp flasher assembly (6) by pulling from
convenience center. NOTICE: See "Notice" on page 8B-1 of this sec-
tion.
!++! Install or Connect 1. Headlamp capsule assembly (9).
• Hazard lamp flasher assembly (6) to convenience 2. Electrical connector.
center. 3. Headlamp mounting ring (8).
88·6 LIGHTING SYSTEMS AND HORNS

A IVIEWA I

A HORIZONTAL ADJUSTMENT SCREW

B HORIZONTAL "0" (ZERO) INDICATOR
C VERTICAL LEVEL INDICATOR
D VERTICAL ADJUSTMENT SCREW
E VEHICLE WITH 1/2 TANK OF FUEL OR MORE
F VEHICLE WITH 1/4 TANK OF FUEL OR LESS
7 BOLT/SCREW, HEADLAMP
8 RING, HEADLAMP MOUNTING
9 CAPSULE ASSEMBLY, HEADLAMP
!VIEWS I PC1003-llB-F-RP

Figure 3 - Headlamp Capsule Assemblies - (Chevrolet)

• If replacing headlamp mounting ring (8), trans- 4. Headlamp bolts/screws attaching mounting ring to
fer undamaged vertical level indicator to new headlamp opening housing assembly (49).
headlamp mounting ring (8). 5. Headlamp mounting ring.
4. Bolts/screws (7). 6. Electrical connector.
• Tighten securely. 7. Sealed-beam headlamp assembly.
5. Close hood assembly.
!-++I Install or Connect
Headlamp Assemblies NOTICE: See "Notice" on page 8Bsl of this
section.
Pontiac 1. Sealed-beam headlamp assembly.
Headlamp Bulb Replacement 2. Electrical connector.
3. Headlamp mounting ring.
Figure 4
4. Headlamp bolts/screws attaching mounting ring to
!+-+I Remove or Disconnect
headlamp opening housing assembly (49).
• Tighten securely.
I. Open hood assembly.
5. Headlamp bezel (43).
2. Bolts/screws (44 ). • Top of headlamp bezel (43) must be flush to
3. Headlamp bezel (43). inner surface of headlamp opening door (42).
 LIGHTING SYSTEMS AND HORNS 88-7

41 BOLT/SCREW, HEADLAMP OPENING DOOR,

1.7 N•m (15 LB. IN.)
42 DOOR, HEADLAMP OPENING
43 BEZEL, HEADLAMP
44 BOLT/SCREW, HEADLAMP BEZEL, 1.7 N•m (15 LB; IN.)
45 BRACKET, HEADLAMP OPENING HOUSING
46 BOLT/SCREW, HEADLAMP OPENING DOOR BRACKET
47 BRACKET, HEADLAMP OPENING DOOR
48 BRACKET, HEADLAMP INTERMEDIATE 49
49 HOUSING ASSEMBLY, HEADLAMP OPENING
53 ACTUATOR ASSEMBLY, HEADLAMP
56 NUT, HEADLAMP OPENING HOUSING
57 BOLT/SCREW, HEADLAMP OPENING HOUSING

Figure 4 - Headlamp Assemblies - (Pontiac)

6. Bolts/screws (44 ). 5. Headlamp opening door (42).

!~! Tighten 6. Nuts (56) and bolts/screws (57) attaching headlamp

opening housing assembly (49) to headlamp open-
• Bolts/screws (44) to 1.7 N•m (15 lb. in.). ing housing bracket (45).
7. Close hood assembly. 7. Headlamp opening housing assembly (49) from
headlamp opening housing bracket (45).
Headlamp Opening Housing Assembly and
8. Bolts/screws (46).
Door Replacement
9. Opening door bracket (47).
Pontiac
10. Intermediate bracket (48).
Figure 4 11. Headlamp actuator assembly cap (58).

!++I Remove or Disconnect 12. Actuator assembly (53) from headlamp opening
housing bracket (45), if necessary, by removing
I. Raise headlamp manually by turning knob on head- attaching nut and bolts/screws.
lamp actuator assembly (53).
2. Bolts/screws (44 ). !++! Install or Connect
3. Headlamp bezel (43). NOTICE: See "Notice" on page 8B-1 of this
4. Bolts/screws (41 ). section.
88-8 LIGHTING SYSTEMS AND HORNS

1. Actuator assembly (53) to headlamp opening

housing bracket (45), if removed, by installing
attaching nut and bolts/screws.
2. Headlamp actuator assembly cap (58).
3. Intermediate bracket (48) to headlamp opening
housing assembly (49).
4. Opening door bracket (4 7) on top of intermediate
bracket (48).
5. Bolts/screws (46).

[e] Adjust
• Gaps and flushness of headlamp opening door
(42) to surrounding area using bolts/screws
(46).
• Tighten securely.
6. Headlamp opening housing assembly (49) to head-
lamp opening housing bracket (45).

[e] Adjust
• Gaps on headlamp opening housing assembly
(49) to surrounding area using the forward and A CONNECTOR, ELECTRICAL
rearward adjustment bolts/screws (60), or side- 50 MODULE ASSEMBLY, HEADLAMP OPENING DOOR
ACTUATOR CONTROL .
to-side adjustment bolts/screws (59). 51 BOLT/SCREW, HEADLAMP AUTOMATIC CONTROL
MODULE .
• Tighten securely.
52 DUCT, FRONT AIR INTAKE
7. Bolts/screws (57) and nuts (56) attaching headlamp
Figure 5 - Headlamp Opening Door Actwator Control Module
opening housing assembly (49) to headlamp open- Assembly - (Pontiac)
ing housing bracket (45).
• Tighten securely.
8. Headlamp opening door (42).
!++I Install or Connect
9. Bolts/screws (41 ). 1. Electrical connectors.
2. Door actuator module assembly (50) to air intake
l~I Tighten . duct (52).
3. Bolts/screws (51).
• Bolts/screws (41) to 1.7 N•m (15 lb. in.).
I 0. Headlamp bezel (43). 4. Front air intake duct. Refer to SECTION 6E3.
11. Bolts/screws (44 ). Headlamp Aiming by Screen Method

l~I Tighten
Figures 6, 7 and 8
Horizontal aim is corrected by an adjusting screw on
• Bolts/screws (44) to 1.7 N•m (I 5 lb. in.). the outer side of the headlamp capsule assembly (Chevro-
12. Lower headlamp. let) or headlamp assembly (Pontiac). Vertical aim is cor-
rected by an adjusting screw in the top center of the
Headlamp Opening Door Actuator Control assembly.
Module Assembly It is desirable to have a specific aiming area in a
darkened location. This area should be large enough to
Pontiac accommodate the vehicle, plus an additional 25 feet
measured from the face of the headlamp capsule assem-
Figure 5 blies to the front of the visual screen.
• The floor on which the vehicle rests must be flat
!+-+I Remove or Disconnect with the bottom of the screen. If the floor is not
1. Front air intake duct. Refer to SECTION 6E3. level, then compensation must be made.
2. Bolts/screws (51 ). • The aiming screen should be 5 feet high by .12 feet
wide with a matte white surface, well shaded from
3. Door actuator module assembly (50) from air intake outside light, and properly adjusted to the floor on
duct (52). which the vehicle stands. The screen must be
4. Electrical connectors. provided with a vertical center line, tw9 laterally
 LIGHTING SYSTEMS AND HORNS 88·9

3.66 m (12') MINIMUM

DISTANCE BETWEEN
HEADLAMPS

ADJUSTABLE
VERTICAL TAPES

ADJUSTABLE
HORIZONTAL TAPE

DIAGRAM OF LIGHT SCREEN

A CENTERLINE OF LAMPS, TRANSFER MEASUREMENT

FROM VEHICLE TO WALL/SCREEN
PC2006-88-F·RP
Figure 6 - Visual Headlamp Aiming Preparation

adjustable vertical tapes, and a vertically adjustable

horizontal tape. VERTICAL CENTERLINE
STRAIGHT AHEAD OF HORIZONTAL CENTERLINE
LAMPCENTER -------1 LOCATED AT LEVEL OF
[I) Important VERTICAL AIM-HIGH
INTENSITY ZONE
LAMP CENTER

CENTERED ON (HI
• For each vehicle checked, the horizontal lines LIMITS.
or tape on the screen must be adjusted.
Vehicles of the same model and year will have
different standing height for the headlamp cap-
sule assemblies.
• Provisions should be made for moving the screen, so LATERAL AIM-HIGH
INTENSITY ZONE
that it can be aligned parallel with the rear axle. This CENTERED ON (VI
will allow for a horizontal line drawn perpendicular LIMITS

from the center line of the screen to pass through the AIM INSPECTION FOR HIGH-BEAM HEADLAMP

center point between the two capsule assemblies.

VERTICAL CENTERLINE
• Once the screen has been set up in a permanent loca- STRAIGHT AHEAD OF
LAMP CENTER------...::r
tion, a reference line is to be painted on the floor to
identify the proper location of the headlamp capsule
assemblies (Chevrolet) or headlamp assemblies
(Pontiac) when they are being aimed (Figure 6).
- If a regular commercial aiming screen is not
available, the screen may consist of a vertical
wall having a clear uninterrupted area approxi-
mately 6 feet high by 12 feet wide, finished
with a washable non-gloss white paint.
I. Prepare vehicle for checking beam aim as follows:
AIM INSPECTION FOR LOW-BEAM HEADLAMP
A. Completely assemble all components on PC2008-88-F·RP
vehicle. Figure 7 - Visual Headlamp Aim Limits - (Pontiac)
B. Fuel load to be 1/2 tank or less.
88-10 LIGHTING SYSTEMS AND HORNS

- 51 mm (2 inches) ABOVE the horizontal

VERTICAL CENTERLINE
STRAIGHT AHEAD OF HORIZONTAL CENTERLINE
line.
LAMP CENTER - - - - - - - t LOCATED AT LEVEL OF
LAMP CENTER - 51 mm (2 inches) BELOW the horizontal
VERTICAL AIM· HIGH
INTENSITY ZONE line (Chevrolet).
CENTERED ON IHI
LIMITS. 64 mm (2.5 inches) BELOW the hori-
zontal line (Pontiac).
3. Switch headlamps on to low beam, and observe left
and top edges of high intensity zone on screen.

LATERAL AIM· HIGH

INTENSITY ZONE
CENTERED ON (VI
1£1 Adjust
LIMITS • Horizontal aim using horizontal adjusting
AIM INSPECTION FOR HIGH-BEAM HEADLAMP screw if left edge is more than:
VERTICAL CENTERLINE
- 102 mm (4 inches) RIGHT of straight
STRAIGHT AHEAD OF ahead.
LAMPCENTER------.::J
- 102 mm (4 inches) LEFT of straight
ahead.
• Vertical aim using vertical adjusting screw if
top edge is more than:
- 51 mm (2 inches) ABOVE the horizontal
line.
LATERAL AIM· LEFT EDGE
OF HIGH INTENSITY ZONE
AT(V)
51 mm (2 inches) BELOW the horizontal
LIMITS.-----""---..._;--: line (Chevrolet).
64 mm (2.5 inches) .BELOW the hori-
AIM INSPECTION FOR LOW-BEAM HEADLAMP zontal line (Pontiac).
PC1005·BB-F-RP

Figure 8 - Visual Headlamp Aim Limits - (Chevrolet)

Headlamp Aiming Alternate Procedure

• Only other load in vehicle is the driver.
C. Position vehicle so it is square with aiming
screen, and with the headlamp capsule assem-
blies (Chevrolet) or headlamp assemblies
(Pontiac) directly over reference line which
has been painted on floor.
D. Locate vertical line on aiming screen so that it
is in line with center of rear window and over
hood (Figure 6).
E. Mark center of front and rear windows with
narrow tape. Use these "sights" to locate cen-
ter of vehicle.
• Move the vehicle or the screen until the
center line of the screen comes into align-
ment with the two points.
F. Close doors.
G. Rock vehicle sideways to stabilize suspension.
2. With headlamps on high beam, observe center of
high intensity zone on screen.
[£] Adjust
• Horizontal aim using horizontal adjusting
screw if center is more than:
- 102 mm (4 inches) RIGHT of Straight
ahead.
- 102 mm (4 inches) LEFT of straight
ahead.
• Vertical aim using vertical adjusting screw if
center is more than:
Chevrolet
Figure 3
1. Prepare vehicle for checking beam aim as follows:
A. Completely assemble all components on
vehicle.
B. Place vehicle on level surface.
• Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
NOTICE: Horizontal aim of headlamp capsule
assembly must be done first. Adjusting vertical aim
first will result in incorrect headlamp aim.
2. Assure horizontal adjuster is set to "O" (zero) mark:
A. If vehicle has been damaged, refer to "Head-
lamp Aiming After a Collision" in the- follow-
ing procedure.
B. If horizontal pointer is not set at "O" (zero),
turn horizontal aiming adjustment screw until
pointer is lined up with "O" (zero).
3. Adjust vertical aim by turning vertical aiming screw
until bubble in level is centered at "O" (zero).
• If fuel tank is near empty to l /4 full, adjust aim
to center bubble at -0.4 degrees. This will
reduce the chance of raising the headlamp cap-
sule assemblies into oncoming driver's eyes
when the fuel tank is filled.

Pontiac
If a headlamp testing machine is used, it should give
results equivalent to those obtained using the screen
inethod. It should be in good repair and adjustment, and
should be used in accordance with the manufacturer's
instructions. The machine using a photoelectric cell or
cells to determine aim should also have a visual screen
upon which the beam pattern is projected proportional to
its appearance and aim on a screen at 25 feet. Such visual
screen should be plainly visible to the operator and should
have horizontal and vertical reference lines to permit
visual appraisal of the lamp beam.
Tool Required;
J 25300-B Headlamp Aimer
I. Prepare vehicle for checking beam aim as follows:
A. Completely assemble all components on
vehicle.
B. Place vehicle on level surface.
• Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
2. Install headlamp aimer J 25300-B to headlamp
assembly.
3. Calibrate mechanical aimers (conforming to SAE
1602):
A. Set master fixture to "O" U/D and "O" R/L.
B. Calibrate aimers on master fixture to read "O"
and "O" R/L.
~ Adjust
• Horizontal aim using horizontal adjusting screw.
- 102 mm (4 inches) left to 102 mm (4 inches)
right.
• Vertical aim using vertical adjusting screw.
- 51 mm (2 inches) up to 64 mm (2.5 inches)
down.
rn Important
• Aim-adjusting tools should be carefully
selected since one full turn of an adjusting
screw will move the aim approximately 89 mm
(3.5 inches) when measured at 25 feet.
Headlamp Aiming After a Collision
I. Prepare vehicle for checking beam aim as follows:
A. Completely assemble all components on
vehicle.
B. Place vehicle on level surface.
• Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
LIGHTING SYSTEMS AND HORNS 88·11
NOTICE: Horizontal aim of headlamp capsule
assembly (Chevrolet) or headlamp assembly (Pon-
tiac) must be done first. Adjusting vertical aim first
will result in incorrect headlamp aim.
2. Headlamp aim may be accomplished using a wall
and visual aiming. Refer to "Headlamp Aiming by
Screen Method" in this section.
3. It may be necessary to recalibrate horizontal adjuster
after a collision. This is done after completion of the
screen aiming procedure. Use a T-15 TORX® screw-
driver to reset horizontal indicator to "O" (zero)
(Chevrolet only).
High-Mount Stoplamp Assembly
Figure 9
!++I Remove or Disconnect
1. Bolts/screws (11) from stoplamp assembly (I 0).
2. Stoplamp assembly (10) from rear end spoiler
assembly (13).
3. Nut (12), if necessary.
4. Electrical connector.
5. Bulbs and sockets from stoplamp assembly (10).
6. Bulbs from sockets.
!++! Install or Connect
NOTICE: See "Notice" on page 8B-1 of this
section.
1. Bulbs to sockets.
.. A
CONNECTOR, ELECTRICAL
B
TAPE
10
STOPLAMP ASSEMBLY, HIGH-MOUNT
11
BOLT/SCREW, HIGH-MOUNT STOPLAMP,
1.7 N•m (15 LB. IN.)
12 NUT, HIGH-MOUNT STOPLAMP
13 SPOILER ASSEMBLY, REAR END
PC2007-IIB·F-RP
Figure 9 - High-Mount Stoplamp Assembly (Typical)
88-12 LIGHTING SYSTEMS AND HORNS

2. Bulbs and sockets to stoplamp assembly ( 10). 3. Parking and turn signal lamp assembly (14) to shelf
3. Electrical connector. on front bumper fascia.
4. Nut ( 12), if removed. 4. Bolts/screws (15) to parking and turn signal lamp
assembly (14).
5. Stop lamp assembly ( 10) to rear end spoiler
assembly (13).
6. Bolts/screws (11) to stoplamp assembly (10).
l~I Tighten
• Bolts/screws ( 15) to 1. 7 N •m (15 lb. in.).
l~I Tighten 5. Front bumper fascia lower deflector. Refer to
SECTION 10-4.
• Bolts/screws (11) to 1.7 N•111 (15 lb. in.), 6. Lower vehicle.
Parking and Turn Signal Lamp Assemblies
Rear License Lamp Assembly
Figure 10
Figure 11
!++I Remove or Disconnect j++I Remove or Disconnect
1. Raise and suitably support vehicle. Refer to SEC-
TION OA. 1. Bolts/screws (18) from rear license lamp assembly
2. Front bumper fascia lower deflector. Refer to (20).
SECTION 10-4. 2. Rear license lamp assembly (20) from rear bumper
fascia (25).
3. Bolts/screws ( 15) from parking and turn signal lamp
assembly (14 ). 3. Bulb (19) and socket from rear license lamp assem-
bly (20).
4. Parking and turn signal lamp assembly (14) from
shelf on front bumper fascia. 4. Bulb (19) from socket.
5. Front sidemarker lamp bulb (16), parking and turn
signal lamp bulb (17) and sockets from front parking
!++I Install or Connect
and turn signal lamp assembly (14). NOTICE: See "Notice" on page 8B-l of this
6. Front sidemarker lamp bulb ( 16) and parking and section.
turn signal lamp bulb ( 17) from sockets. 1. Bulb (19) to socket.
2. Bulb ( 19) and socket to rear license lamp assembly
j++I Install or Connect (20).
NOTICE: See "Notice" on page 8B-I of this 3. Rear license lamp assembly (20) to rear bumper
section. fascia (25).
1. Front sidernarker lamp bulb (16) and parking and 4. Bolts/screws (18) to rear license lamp assembly
turn signal lamp bulb ( 17) to sockets. (20).
2. Front sidemarker lamp bulb (16), parking and
signal lamp bulb ( 17) and sockets to parking
turn
and !~I Tighten
turn signal lamp assembly (14). • Bolts/screws (18) to 1.9 N•m (17 lb. in.).

!VIEWA I

A
14
15
16
17

PC2CJ08-88.F-RP
Figure 1 O - Parking and Turn Signal Lamp Assemblies (Typical)
 LIGHTING SYSTEMS AND HORNS 88-13

----
23

22

A SOCKET
,~11,. ~ 25
22 BOLT/SCREW, REAR
S.IDEMARKER LAMP, 1.4 N•m (12 LB. IN.)
23 LAMP ASSEMBLY, REAR SIDEMARKER
24 BULB, REAR SIDEMARKER LAMP
25 FASCIA, REAR BUMPER PC1009-8B-F-RP

Figure 12 - Rear Sidemarker Lamp Assemblies

A SOCKET
18 BOLT/SCREW, REAR LICENSE LAMP, 1.9 N•m (17 LB. IN.) Taillamp Assemblies
19 BULB, REAR LICENSE. LAMP
20 LAMP ASSEMBLY, REAR LICENSE
21 HARNESS ASSEMBLY, REAR LICENSE AND REAR Chevrolet
SIDEMARKER LAMP WIRING
25 FASCIA, REAR BUMPER
Figure 13
PC1008-BB-F-RP

Figure 11 - Rear License Lamp Assembly (Typical)

I+-+! Remove or Disconnect
1. Reposition rear compartment trim assembly.
2. Nuts ( 131) attaching taillamp assembly (126) to rear
end finishing panel assembly.
Rear Sidemarker Lamp Assemblies
3. Taillamp assembly (126) from rear end finishing
panel assembly.
Figure 12
4. Taillamp, turn signal and backup lamp bulbs (127,
j++j Remove or Disconnect 128, 129 and 130) and sockets from taillamp assem-
bly (126).
1. Bolts/screws (22) from rear sidemarker lamp
5. Taillamp, turn signal and backup lamp bulbs (127,
assembly (23).
128, 129 and 130) from sockets.
2. Rear sidemarker lamp assembly (23) from rear
bumper fascia (25). j++j Install or Connect
3. Bulb (24) and socket from rear sidemarker lamp NOTICE: See "Notice" on page 8B-1 of this sec-
assembly (23). tion.
4. Bulb (24) from socket. I. Taillamp, turn signal and backup lamp bulbs (127,
128, 129 and 130) to sockets.
j++j Install or Connect 2. Taillamp, turn signal and backup lamp bulbs (127,
NOTICE: See "Notice" on page 8B-1 of this 128, 129 and 130) and sockets to taillamp assembly
section. (126).
1. Bulb (24) to socket. • Rotate socket 90 degrees in taillamp assembly
2. Bulb (24) and socket to rear sidemarker lamp (126) to lock and secure.
assembly (23). 3. Taillamp assembly (126) to rear end finishing panel
3. Rear sidemarker lamp assembly (23) to rear bumper assembly.
fascia (25). 4. Nuts (131) attaching taillamp assembly (126) to rear
4. Bolts/screws (22) to rear sidemarker lamp assembly end finishing panel assembly.
(23).
l~.J Tighten
I~! Tighten • Nuts (131) to 4 N•m (35 lb. in.).
• Bolts/screws (22) to 1.4 N•m (12 lb. in.). 5. Position rear compartment trim assembly.
88-14 LIGHTING SYSTEMS AND HORNS

A BACKUP LAMP OPENING 126

B TURN SIGNAL LAMP OPENING
C TAILLAMP OPENING
D TAILLAMP OPENING
126 TAILLAMP ASSEMBLY
127 BULi;!, TAILLAMP
128 BULB, TURN SIGNAL
129 BULB, TAILLAMP
130 BULB, BACKUP LAMP
131 NUT, TAILLAMP, 4 N•m (35 LB. IN.)

FRTt

126

RC101D-88-F-RP

Figure 13 - Taillamp Assemblies - (Chevrolet)

Pontiac 3. Taillamp filler (40), if removed.

4. Taillamp assembly (26) to rear end panel assembly.
Figure 14
5. Nuts (31) attaching taillamp assembly (26) to rear
!+.+I Remove or Disconnect end panel assembly.

1. Reposition rear compartment trim assembly. !~I Tighten

2. Nuts (31) attaching taillamp assembly (26) to rear • Nuts (31) to 4 N•m (35 lb. in.).
end panel assembly.
6. Position rear compartment trim assembly.
3. Taillamp assembly (26) from rear end panel
assembly. Turn Signal Lamp Flasher Assembly
4. Taillamp filler (40), if necessary.
Figure 15
• Both taillamp assemblies (26) must be
removed to replace taillamp filler (40).
5. Taillamp, turn signal and backup lamp bulbs (27, 28
!++I Remove or Disconnect
and 30) and sockets from taillamp assembly (26). 1. Clip (33) from driver knee bolster bracket.
6. Taillamp, turn signal and backup lamp bulbs (27, 28 2. Electrical connector.
and 30) from sockets. 3. Flasher assembly (32) from clip (33), if necessary.

!++I Install or Connect !++I Install or Connect

NOTICE: See "Notice" on page 8B- l of this
section.
l. Taillamp, turn signal and backup lamp bulbs (27, 28
and 30) to sockets.
2. Taillamp, turn signal and backup lamp bulbs (27, 28
and 30) and sockets to taillamp assembly (26).
• Rotate socket 90 degrees in taillamp assembly
(26) to lock and secure.
1. Flasher assembly (32) to clip (33), if removed.
2. Electrical connector.
3. Clip (33) to driver knee bolster bracket.
INTERIOR LIGHTING
For information on warning/indicator lamps, instru-
ment cluster lamps, etc., refer to SECTION SC. For
circuit information, refer to SECTION 8A.
 LIGHTING SYSTEMS AND HORNS 88-15

26

A BACKUP LAMP OPENING

B TURN SIGNAL LAMP OPENING
C TAILLAMP OPENING
26 TAILLAMP ASSEMBLY
27 BULB, TAILLAMP
28 BULB, TURN SIGNAL
30 BULB, BACKUP LAMP
31 NUT, TAILLAMP, 4 N•m (35 LB. IN.)
40 FILLER. TAILLAMP PC2011-88-F-RP

Figure 14 - Taillamp Assemblies - (Pontiac)

Ashtray Lamp 2. Bulb and socket from front floor console transmis-
sion opening trim plate assembly.
Bulb Replacement 3. Bulb from socket.

'!++I Remove or Disconnect !++I Install or Connect

1. Open ashtray opening cover. 1. Bulb to socket.
2. Ashtray. 2. Bulb and socket to front floor console transmission
3. Pull bulb, socket and shield through opening in front opening trim plate assembly.
floor console assembly. 3. Front floor console transmission opening trim plate
4. Bulb and socket from shield. assembly.
S. Bulb from socket.

!++! Install or Connect

1. Bulb to socket.
2. Shield to bulb and socket.
3. Bulb, socket and shield to opening in front floor
console assembly.
4. Ashtray.
S. Close ashtray opening cover. CONNECTOR,
ELECTRICAL
32 FLASHER ASSEMBLY,
Automatic Transmission Indicator Lamp TURN SIGNAL LAMP
33 CLIP, TURN SIGNAL
Bulb Replacement LAMP FLASHER

!++I Remove or Disconnect PC1011-88-F·RP

1. Front floor console transmission opening trim plate Figure 15 - Turn Signal Lamp Flasher Assembly
assembly.
88-16 LIGHTING SYSTEMS AND HORNS

• Snap in place to secure.

!-++I Install or Connect
Console Lamp
Bulb Replacement
!+-+I Remove or Disconnect
1. Open front floor console compartment door.
2. Console lamp and retainer from front floor console
transmission shift opening trim plate assembly.
3. Bulb from socket.
4. Retainer from console lamp, if necessary.
NOTICE: See "Notice" on page 8B-1 of this
section.
l. Bulb (36) to dome lamp housing assembly (34).
2. Electrical connector.
3. Dome lamp housing assembly (34).
• Use locating pins to position dome lamp hous-
ing assembly (34) to headlining trim finish
panel assembly.
4. Bolts/screws (35).

!-++I Install or Connect !~! Tighten

1. Retainer to console lamp, if removed. • Bolts/screws (35) to 1.7 N•m (15 lb. in.).
2. Bulb to socket.
3. Lamp and retainer to opening in front floor consol.e Front Reading Lamps
transmission shift opening trim plate assembly until Bulb Replacement
retainer is seated.
4. Close front floor console compartment door. !+-+! Remove or Disconnect
l. Lamp lens from inside rearview mirror assembly,
Dome Lamp using a flat-bladed tool.
Figure 16 2. Bulb from socket, using a flat-bladed tool.
!+-+I Remove or Disconnect !-++! Install or Connect
I. Bolts/screws (35).
1. Bulb into socket.
• Loosen enough to pull dome lamp housing
assembly (34) from headlining trim finish 2. Lens to inside rearview mirror assembly by snap-
panel assembly. ping into place.
2. Dome lamp housing assembly (34) by pulling from
headlining trim finish panel assembly. Front Side Door Courtesy Lamps
3. Electrical connector. Bulb Replacement
4. Bulb (36) from dome lamp housing assembly (34).
!+-+I Remove or Disconnect
1. Front side door inside handle bezel bolt/screw.
2. Front side door inside handle bezel assembly.
3. Bulb and socket from front side door inside handle
bezel assembly.
4. Bulb from socket.

!-++I Install or Connect

NOTICE: See "Notice" on page 8B-1 of this sec-
tion.
1. Bulb to socket.
35-+~~A. 2. Bulb and socket to front side door inside handle
bezel assembly.
!VIEWA!
A CONNECTOR, ELECTRICAL
3. Front side door inside handle bezel assembly.
B PIN, LOCATING 4. Front side door inside handle bezel bolt/screw.
34 HOUSING ASSEMBLY, DOME LAMP
35 BOLT/SCREW, DOME LAMP, 1.7 N•m (15 LB. IN.)
36 BULB, DOME LAMP
PCZ013-88-f.RP
!~I Tighten
• Front side door inside handle bezel bolt/screw
Figure 16 - Dome Lamp Housing Assembly (Typical) to 1.4 N•m (12 lb. in.).
 UGHTING SYSTEMS AND HORNS 8B·f7

Heater and Air Conditioning Control Lamp

Bufb Replacement
'
!+-+I R_emove or Disconnect 55 SCREW, HORN ADJUSTMENT

I. Instrument panel c)uster trim plate bezel assembly.

Refer to SECTION SC.
2. Heater and air conditioning co~1trol bolts/screws.
3. Heater and a'ir conditioning control assembly.
4. Electrical connectors.
5. Bulbs and sockets from heater and air conditioning
control assembly.
6. Bulbs from sockets ..

!-++I Install or Connect

NOTICE: See "Notice" on page· SB-1 of this PC1017-8B-B-RP
section. Figure 17 - Horn Adjustment
1. Bulbs to sockets.
2. Bulbs. and sockets to heater al1d air conditioning current (more than 20 amperes) indicates an overheated
control assembly. winding or shorted horn assembly: replace the horn
... assembly. A currenfreading of about 18 amperes means
3. Electrical connectors.
contacting points are not open: adjust horn current.
4. Heater and air conditioning control assembly. No current reading indicates a broken connection or
5. Heater and air conditioning control bolts/screws. an open circuit due to a broken lead or overheated horn
assembly. An overheated horn assembly must be replacM.
!~I Tighten No current reading may also mean contact points are
open: adjust horn assembly.
• Heater and air conditioning control bolts/
screws to 1.9 N•m (17 lb. in.).
6. Instrument panel cluster trim plate bezel assembly.
1£1 Adjust
Refer to SECTION SC. f; Increase cmTent - turn adjustment screw (55)
· clockwise.
Instrument Panel Compartment Lamp 2. Decrease current· - furn adjustment screw • (55)
counterclockwise.
Bulb Replacement 3. Current adjustments should be made: 1/4 turn (90
degrees) at a time. ·
j+-+I Remove or Disconnect
Horn Assemblies
1. Open instrument panel compartment door.
Figure 18
2. Instrument panel compartment lamp and retainer
from instrument panel assembly.
3. Bulb from socket
!+-+I Remove or Disconnect
CAUTION: Refer to "Caution" lmd.er
4. Retainer from' instrument panel compartment lamp,
"Dtsconnecting the Battery Negative
if necessary. Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
!-++I Install or Connect 2. Raise and suitably support vehicle. Refer to SEC-
I. Retainer to instrument panel compartment lamp, if TION OA.
removed.
3. Front bumper fascia lower deflector. Refer to
2. Bulb to socket. SECTION 10-4.
3. Lamp and retainer to opening in instrument panel 4. Bolt/screw (39) from horn assembly (37 or 38).
assembly until retainer is seated. 5. Horn assembly (37 or 38) from right·hand engine
4. Close instrument panel compartment door. compartment side outer rail assembly.
HORNS 6. Electrical connector.

Current Adjustment !-++I Install or Connect

Figure 17 NOTICE: See "Notice" on page 88-1 of this
Current draw for a horn assembly while operating section.
should be 4.5 to 5.5 amperes at 11.5 to 12.5 volts. High I. Electrical connector.
88·18 LIGHTING SYSTEMS AND HORNS

2. Horn assembly (37 or 38) to right-hand engine

compartment side outer rail assembly.
• Use "F" and "A" designations on inboard side
of horn assembly (37 or 38).
3. Bolt/screw (39) to horn assembly (37 or 38).

l~I Tighten
• Bolt/screw (39) to 27 N•m (20 lb: ft.).
4. Front bumper fascia lower deflector. Refer to
SECTION 10-4.
5. Lower vehicle.
6. Battery negative cable assembly.

Horn Relay
A CONNECTOR, ELECTRICAL
37 HORN ASSEMBLY, F NOTE
38 HORN ASSEMBLY, A NOTE
Figure 2 39 BOLT/SCREW, HORN, 27 N•m (20 LB. FT.)
The horn relay (5) is in the convenience center, PC1014-88-f.RP

behind the instrument panel assembly on the driver knee Figure 18 - Horn Assemblies
bolster bracket.

l+.+I Remove or Disconnect 1-++I Install or Connect

• Horn relay (5) from convenience center. • Horn relay (5) to convenience center.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Dome Lamp Bolt/Screw ............................................. 1.7 N•m (15 lb. in.)
Front Fog Lamp Bolt/Screw ........................................... 10 N•m (89 lb. in.)
Front Fog Lamp Nut ................................................. 10 N•m (89 lb. in.)
Front Side Door Inside Handle Bezel Bolt/Screw ......................... 1.4 N•m (12 lb. in.)
Headlamp Bezel Bolt/Screw (Pontiac Only) ............................. 1.7 N•m (15 lb. in.)
Headlamp Opening Door Bolt/Screw (Pontiac Only) ...................... 1.7 N•m (15 lb. in.)
Heater and Air Conditioning Control Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
High-Mount Stoplamp Bolt/Screw ..................................... 1.7 N•m (15 lb. in.)
Horn Bolt/Screw .................................................... 27 N•m (20 lb. ft.)
Parking Lamp Bolt/Screw ............................................ 1.7 N•m (15 lb. in.)
Rear License Lamp Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Rear Sidemarker Lamp Bolt/Screw .................................... 1.4 N•m (12 lb. in.)
Taillamp Nut ........................................................ 4 N•m (35 lb. in.)
 LIGHTING SYSTEMS AND HORNS 88·19

BULB USAGE CHART

Exterior Lamps Trade No. Interior Lamps Trade No.

Backup (Chevrolet) 1151 Ashtray* 194
Backup (Pontiac) 1156 Automatic Transmission Indicator (PRNDL) 73
Front Fog 885 Cluster Illumination 161
Front Sidemarker 194 Console 194
Headlamp (Chevrolet) Dome 906
Low Beam H-4351 Front Reading 212-2
High Beam H-4352 Front Side Door Courtesy 74
Headlamp (Pontiac) H6545 Heater and Air Conditioning Control 37
High-Mount Stoplamp 921 Instrument Panel Compartment 194
Parking and Turn Signal 2397 Rear Compartment (Convertible Only) 562
Rear License 194 Rear Courtesy (Convertible Only) 562
Rear Sidemarker 194 Turn Signal Indicator 161
Taillamp 194 Warning/Indicator (Chevrolet) 161
Turn Signal 2057 Warning/Indicator (excluding Turn Signal
Indicator) (Pontiac) PC7t.

flC0001-8B·f·RP

SPECIAL TOOLS

J 25300-B

[!] HEADLAMP AIMER

MC0023-BB-F-RP
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·1

SECTION SC
INSTRUMENT PANEL, GAGES
AND CONSOLE
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repair.

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

CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Auxiliary Fuse Block . . . . . . . . . . . . . . . . . . . . . 8C-2
Controls
AM/FM Stereo and Clock Radio
Assembly . . . . . . . . . . . . . . Refer to Section 9A
Data Link Connector
(DLC) ................. Refer to Section 6E
Heater and Air Conditioning Control
Assembly ........ Refer to Section lBl or lC
Convenience Center . . . . . . . . . . . . . . . . . . . . . . 8C-2
Powertrain Control Module
(PCM) . . . . . . . . . . . . . . . . Refer to Section 6E
Daytime Running Lamps (DRL)
(Canadian Only) . . . . . . . . . . . . . . . . . . . . . 8C-2
Front Floor Console Assembly . . . . . . . . . . . . . 8C-2
Instrument Cluster Assembly . . . . . . . . . . . . . . . 8C-2
Gages ............................... 8C-3
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . 8C-4
Instrument Panel Switches . . . . . . . . . . . . . . . . . 8C-4
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly . . . . . . . . . . . . . 8C-4
Lid Release Switch Assembly . . . . . . . . . . . . 8C-4
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-4
Daytime Running Lamp (DRL) Ambient
Light Sensor (Canadian Only) .......... 8C-4
Cluster Warning/Indicator Lamps . . . . . . . . . . . 8C-4
"FASTEN SAFETY BELTS" Indicator
Lamp ............................. 8C-4
"HIGH BEAM" Indicator
Lamp . . . . . . . . . . . . . . . . . Refer to Section 8B
"TURN SIGNAL" Indicator Lamps . . . . . . . 8C-5
"AIR BAG" Indicator Lamp . . . . . . . . . . . . . 8C-5
"SERVICE ENGINE SOON"
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . 8C-5
"LOW COOLANT" Indicator (V8 On,ly) . . 8C-5
"LOW OIL" Indicator . . . . . . . . . . . . . . . . . . 8C-5
"BRAKE" Indicator Lamp .............. 8C-5
"ABS INOP" Indicator Lamp . . . . . . . . . . . . 8C-5
"ASR" Indicator Lamp . . . . . . . . . . . . . . . . . 8C-6
"CHECK GAUGES" Indicator Lamp 8C-6
"LOW TRAC" Indicator Lamp
(with ASR or TCS Systems) ........... 8C-6
"SECURITY" Indicator Lamp ........... 8C-6
"SKIP SHIFT" Indicator Lamp
(V8 Manual Only) . . . . . . . . . . . . . . . . . . . 8C-6
"TCS OFF" Indicator Lamp . . . . . . . . . . . . . 8C-6
Warning/Reminder Chimes . . . . . . . . . . . . . . . . 8C-6
Ignition Key Warning . . . . . . . . . . . . . . . . . . 8C-6
Fasten Seat Belt Assembly Warning . . . . . . . 8C-6
. Lig~ts-On Warning . . . . . . . . . . . . . . . . . . . . 8C-6
D1agnos1s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 8C-6
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 8C-7
Disabling the SIR System . . . . . . . . . . . . . . . 8C-7
Enabling the SIR System . . . . . . . . . . . . . . . . 8C-7
Handling Electrostatic Discharge (ESD)
Sensitive Parts ... , . . . . . . . . . . . . . . . . . . . . 8C-7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7
AM/FM Stereo and Clock Radio
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7
Heater and Air Conditioning
Control Assembly . . . . . . . . . . . . . . . . . . . 8C-9
Data Link Connector (DLC) .............. 8C-10
Daytime Running Lamp (DRL) Components
(Canadian Only) ...................... 8C-11
Daytime Running Lamp Ambient Light
Sensor Assembly . . . . . . . . . . . . . . . . . . . 8C-11
Daytime Running Lamp Ambient Light
Sensor Module Assembly ............ 8C-11
Driver Knee Bolster Assembly
and Deflector . . . . . . . . . . . . . . . . . . . . . . . . 8C-13
Engine Oil Level Indicator Control and
Low Engine Coolant Indicator
Module Assemblies . . . . Refer to Section 6B
Front Floor Console Assembly ............ 8C-14
Cigarette Lighter Assembly ............. 8C~15
Convertible Top Switch . . . . . . . . . . . . . . . . 8C-16
Compartment Lamp Switch ............. 8C-16
8C·2 INSTRUMENT PANEL, GAGES AND CONSOLE
Performance Switch (V8 Automatic)
Second Gear Start Switch
(V6 Automatic) .................. 8C-17
Traction Control Switches . . . . . . . . . . . • . . 8C-l 7
Storage Tray ......................... 8C-l 7
Transmission Plate Assembly . . . . . . . . . . . 8C-l 7
Heat, Ventilation and Air Conditioning
Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C- l 8
Air Distributor Assembly ............... 8C-18
Center Air Outlet Duct Assemblies ....... 8C-18
Defogger Outlet Duct Assembly ......... 8C-18
Floor Air Outlet Duct Assembly ....•.... 8C-18
Outer Air Outlet Duct Assemblies . . . . . . . . 8C-20
Heater and Air Conditioning Evaporator
and Blower Module Assembly . . . . . . . . . . 8C-20
Instrument Cluster Assembly ...............8C-21
Instrument Panel Carrier . . . . . . . . . . . . . . . . . 8C-22
Instrument Panel Insulator . . . . . . . . . . . . . . . . 8C-24
Instrument Panel Switches . . . . . . . . . . . . . . . . 8C-24
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly . . . . . . . . . . . . 8C-24
GENERAL DESCRIPTION
AUXILIARY FUSE BLOCK
The fuse block is a part of the body wiring harness
assembly. It is attached by a bracket on the left front hinge
pillar and is accessed through a removable panel on the
instrument panel carrier.
For diagnosis, refer to SECTION 8A.
CONVENIENCE CENTER
The convenience center is part of the body wiring
harness assembly. It is attached to a bracket located on the
cowl below the instrument panel carrier to the left of the
steering column assembly.
The audio alarm assembly, vehicle speed sensor
(VSS) buffer, and hazard lamp flasher are attached to the
convenience center. The tum signal lamp flasher is oppo-
site the convenience center to the right of the steering
column assembly and the knee bolster bracket.
For diagnosis of the convenience center and compo-
nents, refer to SECTION 8A.
DAYTIME RUNNING LAMPS {DRL)
{CANADIAN ONLY)
All Canadian vehicles are equipped with daytime
running lamps. The daytime running lamp system
includes a solid state control module assembly, a relay and
an ambient light sensor assembly. The system lights the
low-beam headlamps at a reduced intensity when the igni-
tion switch is in the "RUN" position during daylight. The
daytime running lamp system is designed to light the low-
beam headlamps at full intensity, and the parking lamps
and taillamps when low light conditions are present.
FRONT FLOOR CONSOLE ASSEMBLY
The console assembly fits over the tunnel in the floor
of the vehicle and extends from under the center of the
instrument panel assembly to the rear seat area. The con-
sole assembly consists of two major assemblies. The
Lid Release Switch Assembly ........... 8C-25
Instrument Panel Wiring Harness Assembly .. 8C-26
Auxiliary Fuse Block .................. 8C-26
Convenience Center ................... 8C-26
Odometer Repair Notice Label . . . . . . . . . . . . 8C-26
Sound Insulator Assembly . . . . . . . . . . . . . . . . 8C-28
Trim Panel Cluster Bezel Assembly, Upper
Trim Panel Assembly and Compartments .. 8C-29
Instrument Panel Cluster Trim Plate
Bezel Assembly .........•.......... 8C-29
Instr~ment Panel Compartment .......... 8C-30
Instrument Panel Fuse Block Access
Door Assembly .................... 8C-31
Instrument Panel Upper Trim Panel
Assembly ~ ........................• 8C-31
Passenger Side Inflator Module Assembly ... 8C-32
Warning/Reminder Chimes ............... 8C-32
Alarm Assembly ..................... 8C-32
Specifications ............................ 8C-33
Fastener Tightening Specifications ......... 8C-33
lower console assembly forms the side and rear walls of
the complete console structure, while the upper console
assembly forms the top of the structure.
The upper console assembly has a cigarette lighter
and an ashtray with a coinholder and mat, or a cassette
holder. The upper console assembly also houses the trans-
mission shift lever. For vehicles without the cassette
holder in the upper console area, the cigarette lighter and
ashtray are set just below the transmission shift lever in
the center of the console assembly. The parking brake is in
a recess in the right side of the console assembly.
Below the transmission shift lever, toward the rear
of the vehicle, is a cupholder with a mat. In the rear of the
console assembly is a storage compartment. The storage
compartment contains a tray for cassette tapes or compact
discs. The storage compartment has a padded door. that
serves as a front seat center armrest.
INSTRUMENT CLUSTER ASSEMBLY
The instrument cluster assembly is centered above
the steering column assembly in the instrument panel and
is removable from the rear of the panel (toward the steer-
ing wheel assembly). The instrument cluster assembly
contains instruments that provide the driver with vehicle
performance information.
The headlamp switch assembly, remote hatch
release and the optional foglamp switch assembly are
located on the left side of the cluster assembly.
Gages in the instrument cluster assembly include a
fuel gage, an engine coolant temperature gage, and a
voltmeter. A speedometer with an odometer and a trip
odometer is included, along with a tachometer.
The instrument cluster assembly has indicator lamps
for the headlamp high beam symbol, fasten seat belt
assembly, tum signal directional arrows and five lamps
for illumination.
The cluster assembly also contains warning indica-
tor lamps for "ABS INOP," "AIR BAG," "ASR"
(Acceleration Slip Regulation - Chevrolet V8 only),
"BRAKE," "CHECK GAUGES," "LOW COOLANT"

(V8 only), "LOW OIL," "LOW TRAC" (with ASR or
TCS systems), "SECURITY," "SERVICE ENGINE
SOON," "SKIP SHIFT" (V8 manual only) and "TCS
OFF" (Traction Control System - Pontiac V8 only).
Electric power is directed to the appropriate lamps
and gages of the instrument cluster assembly by a flexible
printed circuit attached to the back of the instrument
cluster case. Two multiple connectors and the snap-in
bulb sockets help to hold the printed circuit to the back of
the instrument cluster assembly.
The instrument cluster assembly is non-serviceable,
except as noted in this section, and must be replaced as a
unit.
When an instrument cluster assembly is replaced,
the law requires the odometer reading of the replacement
unit to be set to register the same mileage as the prior
odometer. If the same mileage cannot be set, the law
requires the replacement odometer to be set at zero and a
label be installed on the driver's door frame to show the
previous odometer reading and the date of replacement.
Refer to "Odometer Repair Notice Label" in this section.
Gages
Engine Coolant Temperature Gage
The coolant temperature sending unit is mounted to
the engine at a point where it is exposed to the coolant
being circulated through the engine cooling passages. The
sending unit contains a temperature~sensitive variable
resistor that senses and reacts to coolant temperature.
Resistance decreases as temperature increases.
When electric power is supplied to the engine cool-
ant temperature gage, a current flows through the gage to
the variable resistor and then to a ground at the engine.
The position of the gage pointer is determined by the
strength of the current flowing through the gage. When
the engine coolant is cold, resistance is high, the current
flow is low, and the pointer indicates a cold reading. As
coolant temperature increases, the resistance of the send-
ing unit resistor decreases and the pointer moves toward
the center of the gage. Prolonged driving or idling in very
hot weather may cause the pointer to move beyond this
point. An overheat condition exists if the pointer goes into
the red zone at the upper limit of the scale.
Dial calibrations go far above the normal boiling
point of water - 100°C (212°F) - because the cooling
system is pressurized. The increase in pressure also
increases the boiling temperature of the coolant, petmit-
ting it to reach temperatures above those possible with a
non-pressurized system without boiling. The higher oper-
ating temperature of the cooling system that results gives
greater cooling efficiency and other benefits.
Fuel Gage
The fuel gage sending unit is mounted on the top
surface of the fuel tank. The fuel level sender itself con-
sists of a float that rides on the surface of the fuel in the
tank, and a variable resistor controlled by the float arm.
When electric power is supplied to the fuel gage, current
flows through the gage to the variable resistor and then to
ground. The position of the gage pointer is determined by
the strength of the current flowing through the gage.
INSTRUMENT PANEL, GAGES AND CONSOLE 8C·3
If the tank is full, the resistance of the variable resis-
tor is high (90 ohms) and the current flow through the
gage is at a minimum. This causes the pointer to indicate
the "F" mark on the gage dial.
If the fuel level is low, the resistance of the variable
resistor is also low and current flow through the gage is
high. This causes the pointer to show a low fuel level
reading. Intermediate fuel levels cause the pointer to indi-
cate the corresponding position between "F" and "E."
Oil Pressure Gage
The oil pressure gage indicates the pressure of the
lubricating oil flow provided by the engine oil pump. The
oil pressure gage sending unit is a variable resistor
mounted to the engine block so it will sense the oil pres-
sure in a main oil passage just downstream from the
engine oil pump. When electric power is supplied to the
gage, current flows through the gage to the resistor in the
sending unit and then to grom;id at the engine block. The
position of the oil pressure gage pointer is determined by
the strength of the current flowing through the gage.
When oil pressure is low, the resistance of the send-
ing unit also is low and current flow through the gage is
high. This causes the gage indicator needle to show a low
pressure reading. As oil pressure increases, the resistance
of the sending unit resistor also increases and current flow
through the gage is reduced. Under normal conditions, the
oil pressure reading should be between 138 and 414 kPa
(20 and 60 psi). Engine oil pressure never should fall
below a reading of 28 kPa (4 psi), even at idle.
Speedometer
The electric speedometer does not have a speedome-
ter cable. The source of speed information is a small per-
manent magnet alternating current generator called a
vehicle speed sensor (VSS), mounted on the transmission
assembly. The shaft of the VSS fits into rotor teeth on the
transmission output shaft in the same manner as the
speedometer cable of a mechanical speedometer system.
The transmission output shaft rotates and turns the rotor
teeth near a magnetic pick-up within the vehicle speed
sensor. This generates an alternating current in the coil
with a frequency that is proportional to the speed of the
vehicle.
The alternating current from the VSS is sent to the
Powertrain Control Module (PCM).
The PCM modifies the current to a series of direct
current pulses at a frequency proportional to the speed of
the vehicle. These pulses form a vehicle speed signal that
is transmitted to the speedometer.
At the speedometer, a solid state circuit uses the
speed signal to regulate the distribution of current from
the fuse block to two electromagnetic coils at right angles
to each other near the base of the speedometer pointer
pivot. At the base of the speedometer pointer pivot is a
magnet that is acted upon by the magnetic fields of the
two coils. The relative strength of the two magnetic fields
determines the position of the magnet and accordingly, the
position of the speedometer pointer.
Pulses from the solid state circuit also are used to
drive a small electric stepper motor. The stepper motor
turns the numbered wheels of the odometer and the trip
odometer. The numbered wheels are geared so when any
ac~4 INSTRUMENT PANEL, GAGES AND CONSOLE
one wheel completes a revolution, the next wheel to the
left is turned one-tenth of a revolution. Every tenth of a
revolution advances the displayed number by one unit.
The trip odometer can be reset to zero at any time so the
driver can record the distance traveled from any selected
starting point.
Tachometer
The tachometer signal comes from the PCM.
Voltmeter
The voltmeter is an instrument that shows the volt-
age of the vehicle electrical system and indicates the abil-
ity of the charging system to keep the storage battery
assembly charged. The voltmeter is wired in parallel with
other circuits in the vehicle.
When the engine is running, the voltmeter indicates
charging system voltage. If the engine is not running and
the igni'tion switch is in the "RUN" or "START" posi-
tion, the voltmeter will show battery voltage. The voltme-
ter can be used as a first step in diagnosing many electrical
problems. Batt~ry voltage drop. ca~ be s~en while the
engine is crankmg. Afterthe engme 1s runnmg, generator
output voltage is indicated.
It is normal for the voltmeter to read between 11 and
13 volts du~ing extended idle or just after starting. As the
electrical load is increased, or in stop-and-go driving, the
pointer may rotate temporarily to the bottom of the scale.
A voltmeter reading continuously below 11 volts or above
16 volts indicates an electrical system problem.
INSTRUMENT PANEL
The instrument panel and related parts form a rigid
structure that encloses and supports many components on
or near the passenger compartment side of the cowl. The
top of the instrument panel is attached to the cowl next to
the base of the windshield near both outboard ends by
bolts/screws, and at the center by a support bracket. The
bottom of the instrument panel is attached to a stamped
metal tie bar that adds to the rigidity of the structure. A
sound insulator panel is attached to the support bracket
and the cowl on the passenger side of the panel to conceal
the components under the instrument panel and provide a
finished appearance.
· The steering column assembly is clamped in place at
the left side of the instrument panel. Below and to both
sides of the steering column assembly is an instrument
panel driver knee bolster assembly. An impact-absorbing
pad covers the top of the instrument panel. Trim covers
and trim plates accent the appearance of the exposed rear
face of the instrument panel.
The air conditioning module case is attached to the
cowl. Air ducts connect the case outlets to floor outlets,
windshield defroster outlets, side window defogger out-
lets and a high level outlet in the center of the instrument
panel. A high level air outlet is provided at each end of the
instrument panel. The air conditioning module and ducts
are concealed within the instrument panel structure.
Canadian vehicles equipped with daytime running
lamps have a headlamp automatic control ambient light
sensor assembly installed flush with the top surface of the
instrument panel upper trim panel assembly under the
windshield defroster nozzle grille assembly. ·
To the left of the steering column assembly, mounted
on the cowl, is the convenience center with the hazard
flasher unit, horn relay, audio alarm and turn signal flasher
unit. Attached to the convenience center is the vehicle
speed sensor buffer.
A headlamp switch with a thumbwheel dimmer con-
trol and an optional foglarnp switch are mounted in the
instrument panel to the left of the instrument cluster
assembly. The headlamp switch controls headlamps,
parking and sidemarker lamps, taillamps, interior lamps
and instrument panel lamps. The dimmer control regu-
lates the intensity of instrument panel illumination.
The instrument panel wiring harness assembly is
installed within the instrument panel area.
INSTRUMENT PANEL SWITCHES
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly .
The headlamp and instrument panel lamp dimmer
switch assembly may also contain a twilight sentinel
switch and a headlamp switch indicator lamp, if the
vehicle is equipped with a .twilight sentinel option.
For more information, refer .to SECTION 8B or
SECTION 9C.
Lid Release Switch Assembly
The lid release switch assembly releases the rear lid
of the vehicle automatically. The lid release switch assem-
bly is located on the left-hand side of the instrument panel
below the headlamp controls and foglamp switch assem-
bly.
SENSORS
Daytime Running Lamp (DRL) Ambient Light
Sensor (Canadian Only)
The headlamp automatic control ambient light (day-
light) sensor assembly is located to the right of the heat
and air conditioning duct in the center of the instrument
panel.
As the intensity of light reaching the sensor assem-
bly increases, the electrical resistance of the sensor assem-
bly decreases. When the DRL control module assembly
senses a low resistance in the sensor assembly, the module
assembly allows voltage to be applied to the DRL diode
assembly and then to the low-beam headlamps. Due to the
voltage drop across the diode assembly, the low-beam
headlamps are on a reduced intensity.
As the intensity of light reaching the sensor assem-
bly decreases, the electrical resistance of the sensor
assembly increases. When the DRL module. assem.bly
senses a high resistance in the sensor assembly, the mod-
ule assembly closes an internal relay and allows the low-
beam headlamps to come to fall intensity.
CLUSTER WARNING/INDICATOR LAMPS
"FASTEN SAFETY BELTS" Indicator Lamp
The "FASTEN SAFETY BELTS" indicator lamp
will always go on whenever the ignition switch is in

"RUN," "BULB TEST," or "START," if the driver's
seat belt assembly is unbuckled. It will remain on until the
driver's seat belt assembly is buckled.
For more information, refer to "Warning/Reminder
Chimes" in this section or SECTION 10-11.
"TURN SIGNAL" Indicator Lamps
The left or right tum indicator lamp will illuminate
when the multifunction lever on the left side of the steer-
ing column assembly is moved to signal a tum. The tum/
hazard switch in the steering column assembly receives an
on-and-off flashing current from the fuse block and the
tum signal flasher unit in the convenience center when the
ignition switch is in the "RUN," "START" or "BULB
TEST" position. The tum/hazard switch routes the cur-
rent to circuits that feed the left or right front tum signal
lamp, left or right rear tail/stop/tum signal lamps when the
multifunction lever is moved. The circuit to the left or
right front turn signal lamp, and cornering and sidemarker
lamps has a branch that feeds the appropriate turn indica-
tor lamp in the instrument cluster assembly, causing it to
flash when the exterior lamps are indicating a turn.
When the hazard warning button on the right side of
the steering column assembly is pressed in, the left and
right front tum signal lamps, cornering and sidemarker
lamps, and rear tail/stop/tum signal lamps all flash, and
both turn signal indicator lamps in the instrument cluster
flash. Power for the hazard warning system reaches the
turn/hazard switch from the fuse block and the hazard
flasher in the convenience center. Power is supplied with
the ignition switch in any position. When the hazard
warning system is flashing, the turn signal circuits are
inoperative.
"AIR BAG" Indicator Lamp
The "AIR BAG" indicator lamp will light to warn
the driver of a potential supplemental inflatable restraint
(SIR) system problem that could prevent the proper
deployment of the air bag in an accident. When the igni-
tion switch is first turned on, the lamp will flash seven
times to verify proper operation of the lamp circuit and the
diagnostic/energy reserve module (DERM). A Scan Tool
can be used to read diagnostic trouble codes (DTCs) in the
DERM and to clear all DTCs after repair. For additional
information, including service precautions, refer to SEC-
TION 9J.
"SERVICE ENGINE SOON" Indicator Lamp
The "SERVICE ENGINE SOON" indicator lamp
in the instrument cluster will come on when turning the
ignition on or the engine off to serve as a bulb and system
check. It should go off after the engine starts unless a
problem has been detected by the system.
The powertrain control module (PCM) performs a
continual self-diagnosis of certain control functions and
causes the "SERVICE ENGINE SOON" lamp to remain
on when the engine is running if a problem is detected. In
any event, the PCM will store in memory a 2-digit trouble
code if a problem is detected. When the data link connec-
tor (DLC) test connection is grounded, the PCM will
enable most outputs with the engine operating and termi-
nal "B" grounded at the DLC. When turning the ignition
INSTRUMENT PANEL, GAGES AND CONSOLE 8C·5
on or the engine off, the "SERVICE ENGINE SOON"
lamp will flash "FIELD SERVICE" which indicates an
open/closed loop. The PCM will not flash DTCs. Tech 1
must be used to retrieve DTCs.
"LOW COOLANT" Indicator (VS Only)
With a low coolant level, the circuit made by the low
coolant probe has very high resistance (over 50,000
ohms). The low engine coolant indicator module assem-
bly senses the voltage change at the low coolant level
input and provides ground to the "LOW COOLANT"
indicator and the indicator lights up. The "LOW COOL-
ANT" indicator is grounded for 1.5 seconds when the
ignition switch is initially turned "ON," causing the
"LOW COOLANT" indicator to light.
"LOW OIL" Indicator
The "LOW OIL" indicator ground is controlled by
the engine oil level indicator control module assembly. To
check for a low oil condition, the low oil module looks for
a ground through the oil level switch after the ignition
switch has been turned to "OFF" or "LOCK."
The low oil module assembly checks for a low oil
condition 32 minutes after the ignition switch is turned to
"OFF" or "LOCK," if the previous ignition cycle was
less than 12 minutes. If the previous ignition cycle was
longer than 12 minutes, the low oil module assembly
checks for a low oil condition 3 minutes after the ignition
switch is turned to "OFF" or "LOCK."
When the low oil module assembly loses the ground
through the oil level switch (oil level switch open indicat-
ing low oil level), the low oil assembly module grounds
the "LOW OIL" indicator for the duration of the next
ignition cycle.
When the low oil module assembly is grounded
through the oil level switch, the low oil module assembly
grounds the "LOW OIL" indicator for a bulb test when
the ignition switch is turned to "RUN" during the next
ignition cycle. The bulb test takes four to five seconds.
"BRAKE" Indicator Lamp
When the ignition switch is turned to "RUN," the
"BRAKE" indicator lamp will come on for approxi-
mately 3 seconds. If the parking brake is set, the lamp will
remain on. The lamp may also be illuminated by informa-
tion from the Electronic Brake Control Module (EBCM)
or Electronic Brake/Traction Control Module (EBTCM).
Additionally, with the ignition switch turned to
"RUN," "BULB TEST," or" START, "the lamp may be
activated by the brake combo valve. For more informa-
tion, refer to SECTION 8A-41 and SECTION 5El.
"ABS INOP" Indicator Lamp
The "ABS INOP" indicator lamp is part of the anti-
lock brake system. When the ignition switch is turned to
the "RUN" position, the "ABS INOP" lamp will turn on
for approximately 3 seconds and then turn off if no ABS
malfunction is detected. If a malfunction is detected, the
lamp will remain on.
If the "ABS INOP" indicator lamp comes on while
driving, there is a malfunction in the antilock brake sys-
tem. For more information, refer to SECTION 5El.
8C·6 INSTRUMENT PANEL, GAGES AND CONSOLE
"ASR" Indicator Lamp
Chevrolet VS Only
The Accelerated Slip Regulation (ASR) system lim-
its wheel spin if it senses that one or both of the rear
wheels are beginning to lose traction. When this happens,
the ASR system works the rear brakes and reduces engine
power to limit wheel spin.
The "ASR" indicator lamp will come on if there is a
system failure, if the system has been turned off by the
driver, or momentarily when starting the engine.
When the ignition switch is turned to the crank posi-
tion, the "ABS INOP," "ASR," and "TCS OFF" lamps
will come on. They will remain on if the switch is held in
the crank position.
"CHECK GAUGES" Indicator Lamp
The "CHECK GAUGES" indicator lamp alerts the
driver to check instrument cluster gages when any of the
following abnormalities are detected: coolant temperature
too high, generator voltage too high or too low, oil pres-
. sure too low.
The indicator lamp also comes on for about one
second after ignition "ON" as a bulb test.
"LOW TRAC" Indicator Lamp (with ASR or
TCS Systems)
On vehicles equipped with Accelerated Slip Regula-
tion (ASR) or Traction Control Systems (TCS), the
"LOW TRAC" indicator lamp comes on to indicate that
the system is active and is limiting wheel spin.
The "LOW TRAC" lamp will tum on during ABS
initialization, an ABS stop or a TCS event. It will remain
on for approximately 3 seconds and then turn off.
The "LOW TRAC" indicator lamp also comes on
when the Antilock Brake System (ABS) is adjusting brake
pressure to help avoid a skid.
"SECURITY" Indicator Lamp
The "SECURITY" indicator lamp is part of the
theft deterrent system. It will come on when the theft
deterrent module assembly is preventing the engine from
starting, or if the theft deterrent module assembly is not
properly programmed. It also comes on for about five
seconds during "BULB TEST."
"SKIP SHIFT" Indicator Lamp (V8 Manual
Only)
When the "SKIP SHIFT" indicator lamp is on, the
manual transmission can only be shifted from first to
fourth gear. For more information on skip shift, refer to
SECTION 6E3-C8.
"TCS OFF" Indicator Lamp
Pontiac VS Only
The Traction Control System (TCS), if equipped,
limits wheel spin if it senses that one or both of the rear
wheels are beginning to lose traction. When this happens,
the TCS works the rear brakes and reduces engine power
to limit wheel spin.
The "TCS OFF" indicator lamp will come on if
there is a system failure, if the system has been turned off
by the driver, or momentarily when starting the engine.
When the ignition switch is turned to the crank posi-
tion, the "ABS INOP," "ASR," and "TCS OFF" lamps
will come on. They will remain on if the switch is held in
the crank position.
WARNING/REMINDER CHIMES
The audio alarm module sounds a chime to bring
attention to one or more of several conditions. These
conditions are: 1) the lights are on and the ignition switch
is not in "RUN," "BULB TEST," or "START;" 2) the
ignition key is in the ignition switch when the driver's
door is open; 3) the seatbelt assembly is unbuckled when
the ignition switch is in "RUN," "BULB TEST," or
"START" and 4) the turn signal has been on for more
than a half mile. Voltage is applied at all times through the
fuse block to power the solid state audio alarm module.
Ignition Key Warning
Whenever the key is in the ignition switch and the
driver's door is open, the module is grounded. This
sounds the alarm.
Fasten Seat Belt Assembly Warning
With the ignition switch in "RUN," "BULB
TEST," or "START," voltage is applied through the fuse
block to the audio alarm module. With the driver's seat
belt assembly unbuckled, the module is grounded through
the seat belt switch and the alarm sounds. When the driv-
er's seat belt assembly is buckled, the alarm shuts off. If
the driver's seat belt assembly remains unbuckled, the
alarm times out after 4 to 8 seconds.
Lights-On Warning
When the headlamp switch is in "HEAD" or
"PARK," voltage is applied to the audio alarm module.
When the ignition switch is in "RUN," "BULB TEST,"
or "START," voltage is applied through the fuse block to
the module. These two voltages are sensed and the alarm
assembly is not sounded.
When the ignition switch is not in "RUN," "BULB
TEST" or "START," the module loses voltage. The
audio alarm module senses change. If voltage is still avail-
able, it is applied to sound the alarm. The alarm can be
turned off by turning the headlamp switch to "OFF." The
module no longer senses voltage from the headlamp
switch, so the alarm assembly does not sound.
DIAGNOSIS
For diagnosis of instrument panel, cluster, electrical
system (including individual wire color information and
applicable precautions for testing solid state electronic
devices and systems), refer to SECTION 8A.
ON-VEHICLE SERVICE
It may be necessary to color coat some replacement
components before installing them in the vehicle. For
information regarding this procedure, refer to SECTION
10-1.

SERVICE PRECAUTIONS
CAUTION: When performing service on
or around SIR components or SIR wir·
ing, follow the procedures listed below
to temporarily disable the SIR system.
Failure to follow procedures could
result in possible air bag deployment,
personal injury, or otherwise unneeded .
SIR system repairs.
The DERM in all Driver-Passenger SIR systems can
maintain sufficient voltage to cause a deployment for up
to 2 minutes after the ignition switch is turned "OFF," the
battery is disconnected, or the fuse powering the DERM is
removed.
Disabling the SIR System
!++! Remove or Disconnect
1. Turn steering wheel assembly so vehicle's tire and
wheel assemblies are pointing straight ahead.
2. Turn ignition switch to "LOCK."
3. "AIR BAG" fuse from fuse block.
4. Left-hand instrument panel sound insulator assem-
bly, refer to '' Sound Insulator Assembly" in this
section.
5. Connector position assurance (CPA) and yellow
two-way SIR harness connector at base of steering
column assembly.
6. Instrument panel compartment door assembly, refer
to "Instrument Panel Compartment" in this section.
7. Connector position assurance (CPA) and yellow
two-way SIR connector located near yellow 24-way
DERM connector on instrument panel wiring har-
ness assembly.
m Important
• With "AIR BAG" fuse removed and ignition switch
in "RUN," air bag indicator lamp on instrument
panel cluster assembly will light. This is normal
operation and does not indicate an SIR fault.
Enabling the SIR System
l++I Install or Connect
1. Turn ignition switch to "LOCK."
2. Yellow two-way SIR harness connector and connec-
tor position assurance (CPA) located near yellow
24-way DERM connector on instrument panel wir-
ing harness assembly.
3. Instrument panel compartment door assembly, refer
to "Instrument Panel Compartment" in this section.
4. Yellow two-way SIR connector and connector posi-
tion assurance (CPA) at base of steering column
assembly.
5. Left-hand instrument panel sound insulator, refer to
"Sound Insulator Assembly" in this section.
6. "AIR BAG" fuse to fuse block.
INSTRUMENT PANEL, GAGES AND CONSOLE 8C·7
7. Turn ignition switch to "RUN" and verify air bag
indicator flashes 7 times and then turns @ff. If indica-
tor does not respond as stated, refer to SECTION
9J-A.
NOTICE: The instrument panel and cluster contain
electrostatic discharge (ESD) sensitive parts. When
handling an electronic part that. is identified as being
ESD sensitive, the service technician should follow
the guidelines in SECTION OA. Following these
guidelines will reduce any possible electrostatic
charge buildup on the service technician's body and
the electronic part.
HANDLING ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE PARTS
NOTICE: When handling an electronic part that has
an BSD-sensitive sticker, refer to SECTION OA.
Follow these guidelines to reduce any possible
build-up of electrostatic charge:
• Do not open package until time when part is to be
installed.
• Avoid touching electrical terminals of part.
• Before removing part from its package, ground
package to known good ground on vehicle.
• Always touch known good ground before handling
part. This should be repeated while handling part.
Do it more often after sliding across seat, sitting
down from standing position, or walking a distance.
Not all parts that can be damaged by BSD have an
ESD label. Components that can be damaged by BSD are:
AM/FM stereo radio assembly/radio control
Antilock brake system EBCM assembly
Automatic day/night mirror
Cal Pak
Chime module
Cruise control module
Electronic automatic air conditioning control assem-
bly
Electronic spark control module
MEM-CAL (memory and calibration unit)
PROM (programmable read only memory) calibra-
tor
Supplemental inflatable restraint (SIR) DERM
Twilight sentinel amplifier
CONTROLS
AM/FM Stereo and Clock Radio Assembly
Chevrolet
Figures 1 and 2
l++I Remove or Disconnect
1. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this sec-
tion.
2. Trim plate assembly (15) and bolts/screws (16) from
instrument panel assembly.
8C·8 INSTRUMENT PANEL, G.AGES AND CONSOLE
3. Bolts/screws (67) attaching brackets (68) to instru-
ment panel carrier.
4. Brackets (68) and attached radio assembly (66) from
instrument panel carrier.
5. Instrument panel wiring harness electrical connec-
tors froin radio assembly (66).
6. Bolts/screws (65) and nuts (64) attaching radio
assembly (66) to brackets (68), if necessary.
7. Radio assembly (66) from brackets (68), if neces-
sary.
!++I Install or Connect
· NOTICE: See "Notice'' on page 8C-l of this sec-
tion.
1. Brackets (68) to radio assembly (66), if removed.
2. Bolts/screws (65) and nuts (64) attaching brackets
(68) to radio assembly (66), if removed.
l~I Tighten
• Nuts (64) to 2.8 N•m (25 lb. in.).
3. Instrument panel wiring harness electrical connec-
tors to radio assembly (66).
4. Brackets (68) and attached radio assembly (66) to
instrument panel carrier.
5. Bolts/screws (67) attaching brackets (68) to instru-
ment panel carrier.
l~I Tighten
• Bolts/screws (67) to 1.8 N•m (16 lb. in.).
6. Bo.Its/screws (16) attaching trim plate assembly (15)
to instrument panel assembly.
15 PLATE ASSEMBLY, INSTRUMENT PANEL ACCESSORY
TRIM
16 BOLT/SCREW, INSTRUMENT PANEL ACCESSORY TRIM
PLATE
PC1001-8C-F-RP
Figure 1 - Instrument Panel Accessory Trim Plate
Assembly - (Chevrolet)
7. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this sec-
tion.
Pontiac
Figures 3 and 4
l++I Remove or Disconnect
1. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this sec-
tion.
2. Trim plate assembly ( 15) from instrument panel
assembly (40).
3. Bolt/screw (63) from instrument panel tie bar
assembly, if necessary.
4. Retainer (62) and bolt/screw (65) from bracket (27).
5. Radio assembly (66).
6. Bolts/screws (67) attaching brackets (68) to instru-
ment panel carrier.
7. Brackets (68) and attached radio assembly (66) from
instrument panel carrier.
8. Instrument panel wiring harness electrical connec-
tors from radio assembly (66).
9. Bolts/screws (65) and nuts (64) attaching radio
assembly (66) to brackets (68), if necessary.
10. Radio assembly (66) from brackets (68), if neces-
sary.
l++I Install or Connect
NOTICE: See "Notice" on page 8C-1 of this sec-
tion.
1. Brackets (68) to radio assembly (66), if removed.
2. Bolts/screws (65) and nuts (64) attaching brackets
(68) to radio assembly (66), ifremoved.
l~I Tighten
• Nuts (64) to 2.8 N•m (25 lb. irt.).
3. Instrument panel wiring harness electrical connec-
tors to radio assembly (66).
4. Brackets (68) and attached radio assembly (66) to
instrument panel carrier. ··
5. Bolts/screws (67) attaching brackets (68) to instru-
ment panel carrier.
l~I Tighten
• Bolts/screws (67) to 1.8N•m (16 lb. in.).
6. Radio assembly ( 66) to instrument panel assembly
(40).
7. Retainer (62) and bolt/screw (65) to bracket (27).
8. Bolt/screw (63) to instrument panel tie bar assembly,
if removed.
l~I Tighten
• Bolt/screw (63) to 1.9 N•m (17 lb. in.).
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·9

A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS

ELECTRICAL
64 NUT, RADIO BRACKET, 2.8 N•m (25 LB. IN.)
65 BOLT/SCREW, RADIO
66 RADIO ASSEMBLY, AM/FM STEREO AND CLOCK
67 BOLT/SCREW, RADIO BRACKET, 1.8 N•m (16 LB. IN.)
68 BRACKET, RADIO
PC1002·8C·F·RP

Figure 2 - AM/FM Stereo and Clock Radio Assembly - (Chevrolet)

Heater and Air Conditioning Control

Assembly
Figure 5

l++I Remove or Disconnect

1. Bezel assembly. Refer to "Instrument Panel Cluster
Trim Plate Bezel Assembly" in this section.
2. Temperature control cable electrical connector and
vacuum wiring harness electrical connector from
over reinforcement (85).
3. Bolts/screws (81) attaching control assembly (82) to
panel assembly (40).
15 PLATE ASSEMBLY, INSTRUMENT PANEL ACCESSORY 4. Control assembly (82).
TRIM
40 PANEL ASSEMBLY, INSTRUMENT
PC2001 ·8C·F-RP
l++I Install or Connect
Figure 3 - Instrument Panel Accessory Trim Plate
NOTICE: See "Notice" on page 8C-1 of this sec-
Assembly - (Pontiac) tion.
1. Control assembly (82) to panel assembly (40).
2. Bolts/screws (81).

9. Trim plate assembly (15) to instrument panel assem-

l~I Tighten
• Bolts/screws (81) to 1.9 N•m (17 lb. in.).
bly (40).
3. Temperature control cable electrical connector and
10. Driver knee bolster assembly. Refer to "Driver vacuum wiring harness electrical connector through
Knee Bolster Assembly and Deflector" in this sec- hole in panel assembly (40) and over reinforcement
tion. (85).
8C-10 INSTRUMENT PANEL, GAGES AND CONSOLE

67

27 BRACKET, REAR RADIO

40 PANEL ASSEMBLY, INSTRUMENT
62 RETAINER, RADIO (PUSH-ON)
63 BOLT/SCREW, REAR RADIO BRACKET,
1.9 N•m (17 LB. IN.)
64 NUT, RADIO BRACKET, 2.8 N•m (25 LB. IN.)
65 BOLT/SCREW, RADIO
66 RADIO ASSEMBLY, AM/FM STEREO AND CLOCK
67 BOLT/SCREW, RADIO BRACKET, 1.8 N•m (16 LB. IN.)
68 BRACKET, RADIO '

PC2002-8C·f·RP

Figure 4 '-AM/FM Stereo and Clock Radio Assembly- (Pontiac)

4. Bezel assembly. Refer to "Instrument Panel Cluster 1. Three instrument panel bolts/screws attaching
Trim Plate Bezel Assembly" in this sectio!1. bracket (60) to instrument panel carrier, if removed.
DATA LINK CONNECTOR (DLC)
Figure 6
!~I Tighten
• Instrument panel bolts/screws to 1.9 N•m (17
The data link connector (DLC) is part of the instru- lb. in.).
ment panel wiring harness assembly. Refer to SECTION 2. Two bolts/screws (61) attaching DLC to bracket
8A. (60).
!+•I Remove or Disconnect !~I Tighten
I. Two bolts/screws (61) attaching DLC to bracket • Bolts/screws (61) to 1.5 N•m (13 lb. in.).
(60).
2. Three instrument panel bolts/screws attaching
bracket (60) to instrument panel carrier, if necessary.

l•+I Install or Connect

NOTICE: See "Notice" on page 8C-1 of this sec-
tion.
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·11

25
40

85

A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS

ENGINE CONTROL MODULE DATA LINK ELECTRICAL
A CONNECTOR, TEMPERATURE CONTROL CABLE
B CONNECTOR, INSTRUMENT CLUSTER TURN SIGNAL
ELECTRICAL
FLASHER ELECTRICAL
B CONNECTOR, VACUUM WIRING HARNESS ELECTRICAL
25 BAR ASSEMBLY, INSTRUMENT PANEL TIE
40 PANEL ASSEMBLY, INSTRUMENT
60 BRACKET, INSTRUMENT PANEL KNEE BOLSTER
81 BOLT/SCREW, HEATER AND AIR CONDITIONING
61 BOLT/SCREW, INSTRUMENT PANEL WIRING HARNESS
CONTROL, 1.9 N•m (17 LB. IN.)
ENGINE CONTROL MODULE DATA LINK CONNECTOR,
82 CONTROL ASSEMBLY, HEATER AND AIR
1.5 N•m (13 LB. IN.)
CONDITIONING
85 REINFORCEMENT, INSTRUMENT PANEL PC0004-8C-F-RP
PC2003·8C-F-RP .

Figure 5 - Heater and Air Conditioning Control Figure 6 - Data Link Connector (DLC)
Assembly (Typical)

• Snap into place.

DAYTIME RUNNING LAMP (DRL) Daytime Running Lamp Ambient Light

COMPONENTS (CANADIAN ONLY) Sensor Module Assembly

Daytime Running Lamp Ambient Light Figure 7

Sensor Assembly
!++I Remove or Disconnect
Figure 7 1. Module assembly (71) from heat and air condition-
!++I Remove or Disconnect ing duct assembly.
2. Instrument panel wiring harness electrical connec-
1. Grille (70) from instrument panel upper trim panel tors from module assembly (71) by depressing lock
assembly. retainers on daytime running lamp ambient light
• Gently unsnap grille (70). sensor module electrical connectors.
2. Sensor assembly (88) from grille (70). 3. Instrument panel wiring harness assembly from
under and behind bar assembly (25).
• Twist counterclockwise.
3. Sensor assembly (88) from instrument panel wiring
harness grille electrical connector.
!++I Install or Connect
1. Route instrument panel wiring harness assembly
!++I Install or Connect behind and under bar assembly (25).
2. Daytime running lamp ambient light sensor module
I. Sensor assembly (88) to instrument panel wiring electrical connectors to module assembly (7 l).
harness grille electrical connector.
• When connecting, push, click, then tug on day-
2. Sensor assembly (88) to grille (70). time running lamp ambient light sensor electri-
• Twist clockwise. cal connector, not wire.
3. Grille (70) to instrument panel upper trim panel 3. Slide module assembly (71) onto heat and air condi-
assembly. tioning duct assembly.
SC-12 INSTRUMENT PANEL, GAGES AND CONSOLE

71 71

IVIEWA I 70

,~~~~~~- A HARNESS ASSEMBLY, INSTRUMENT PANEL WIRING

B DUCT ASSEMBLY, HEAT AND AIR CONDITIONING
I' c C CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR GRILLE ELECTRICAL
D CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR MODULE ELECTRICAL
25 BAR ASSEMBLY, INSTRUMENT PANEL TIE
70 GRILLE, DAYTIME RUNNING LAMP AMBIENT LIGHT
SENSOR
71 MODULE ASSEMBLY, DAYTIME RUNNING LAMP
AMBIENT LIGHT SENSOR
75 CARRIER, INSTRUMENT PANEL
88 SENSOR ASSEMBLY, DAYTIME RUNNING LAMP
AMBIENT LIGHT

PC0005-IIC·F·RP

Figure 7 - Daytime Running Lamp Ambient Light Sensor Module Assembly

 INSTRUMENT PA~EL, GAGES AND CONSOLE 8C·13

DRIVER KNEE BOLSTER ASSEMBLY AND 2. Nuts (48) to studs (74).

DEFLECTOR 3. Bolts/screws (4) to bolster assembly (3) at deflect~r
(49) and instrument panel tie bar assembly.
Chevrolet
Figure 8 l~I Tighten
• Bolts/screws ( 4) to 1. 9 N •m ( 17 lb. in.).
!++I Remove or Disconnect Pontiac
1. Bolts/screws (4) from bolster assembly (3) at deflec-
tor (49) and instrument panel tie bar assembly. Figure 9
2. Nuts (48) from studs (74).
3. Deflector (49) from studs (74).
l++I Remove or Disconnect
1. Bolts/screws (4) from bolster assembly (3) at deflec-
!++I Install orConnect tor ( 49) and instrument panel tie bar assembly.
2. Bolster assembly (3) from dual lock retainers on
NOTICE: See "Notice" on page 8C-1 of this sec- instrument. panel carrier.
tion.
3. Nuts (48) from studs (74).
1. Deflector (49) to studs (74).
4. Deflector (49) from studs (74).

40

74 74

[j

~48

48____.
49
.___ 48
49 ----::::::::~~I
!VIEWA
A RETAINER, DUAL LOCK
3 BOLSTER ASSEMBLY, INSTRUMENT 3 BOLSTER ASSEMBLY, INSTRUMENT PANEL DRIVER
PANEL DRIVER KNEE KNEE
4 BOLT/SCREW, INSTRUMENT PANEL 4 BOLT/SCREW, INSTRUMENT PANEL DRIVER KNEE
DRIVER KNEE BOLSTER, 1.9 N•m (17 LB. IN.) BOLSTER, 1.9 N•m (17 LB. IN.)
40 PANEL ASSEMBLY, INSTRUMENT 40 PANEL ASSEMBLY, INSTRUMENT
48 NUT, INSTRUMENT PANEL DRIVER 48 NUT, INSTRUMENT PANEL DRIVER KNEE BOLSTER
KNEE BOLSTER DEFLECTOR DEFLECTOR
49 DEFLECTOR,JNSTRUMENT PANEL 49 DEFLECTOR, INSTRUMENT PANEL DRIVER KNEE
DRIVER KNEE BOLSTER BOLSTER
74 STUD, INSTRUMENT PANEL DRIVER 74 STUD, INSTRUMENT PANEL DRIVER KNEE BOLSTER
KNEE BOLSTER DEFLECTOR DEFLECTOR
RC1001-8C-F-RP PC2006-8C-F-RP

Figure 8 - Driver Knee Bolster Assembly Figure 9 - Driver Knee Bolster Assembly
and Deflector - (Chevrolet) and Deflector - (Pontiac)
8C~14 INSTRUMENT PANEL, GAGES AND CONSOLE

4. Console assembly (33).

!++I ·Install or Connect !++I Install or Connect
NOTICE: See "Notice" on page SC-I of this sec-
tion. NOTICE: See "Notice" on page 8C-1 of this sec-
I. Deflector (49) to studs (74). tion.
2. Nuts (48) to studs (74). I. Console assembly (33).
3. Bolster assembly (3) to dual lock retainers on instru- A. Route wiring connectors through appropriate
ment panel carrier. openings.
• Position bolster assembly (3) for best fit and B. Insert parking brake assembly through
apply pressure on retainers to secure. appropriate opening.
4. Bolts/screws (4) to bolster assembly (3) at deflector C. Locating pin on console assembly (33) into
(49) artd instrument panel tie bar assembly. hole in shifter bracket drive.

l~I Tighten D. Position console assembly (33) to floor of

vehicle.
• Bolts/screws (4) to 1.9 N•m (17 lb. in.). 2. Bolts/screws (36) attaching console assembly (33)
to bracket (37).
FRONT FLOOR CONSOLE ASSEMBLY
Figure 10
l~I Tighten
• Bolts/screws (36) to 8 N•m (71 lb. in.).
l++I Remove or Disconnect 3. Bolt/screw (35) attaching console assembly (33) to
instrument panel assembly.
I. Bolts/screws (34) attaching console assembly (33)
to instrument panel center support bracket and
manual floor console bracket. l~I Tighten
2. Bolt/screw (35) attaching console assembly (33) to • Bolt/screw (35) to 5.5 N•m (49 lb. in.).
instrument panel assembly. 4. Bolts/screws (34) attaching console assembly (33)
3. Bolts/screws (36) attaching console assembly (33) to instrument panel center support bracket and
to bracket (37). manual floor console bracket.

--
-----

35

..
"'· . '
,..
.. ''-
. . \.• ..
···, ........
·.,

33 CONSOLE ASSEMBLY, FRONT FLOOR

34 BOLT/SCREW, FRONT FLOOR CONSOLE,
8 N•m (71 LB. IN.)
35 BOLT/SCREW, INSTRUMENT PANEL,
5.5 N•m (49 LB. IN.)
36 BOLT/SCREW, FRONT FLOOR CONSOLE BRACKET,
8 N•m (71 LB. IN.)
37 BRACKET, FRONT FLOOR CONSOLE
PC1007-8C.F-RP

Figure 10 - Front Floor Console Assembly (Typical)

 INSTRUMENT PANEL, GAGES AND. CONSOLE BC-15

!~I Tighten
• Bolts/screws (34) to 8 N•m (71 lb. in.).

Cigarette Lighter Assembly

Chevrolet (without Switches)
Figure 11

l++I Remove or Disconnect 33

1. Cigarette lighter assembly from console assembly
(33).
2. Bezel assembly (32) from cigarette lighter bezel
wiring harness electrical connector.

!++I Install or Connect

I. Bezel assembly (32) to cigarette lighter bezel wiring
harness electrical connector.
2. Cigarette lighter assembly to appropriate opening in
console assembly (33).
• Snap into place.

Chevrolet (with Switches)

!VIEWA I
Figure 11

!++I Remove or Disconnect A

1. Switch assembly with cigarette lighter (98) from
console assembly (33).
2. Wiring harness electrical connector from cigarette
lighter assembly.
3. Cigarette lighter assembly from switch assembly
with cigarette lighter (98).

!++I Install or Connect

1. Cigarette lighter assembly to switch assembly with
cigarette lighter (98).
2. Wiring harness electrical connector to cigarette
lighter assembly.
3. Switch assembly with cigarette lighter (98) to con-
sole assembly (33).

Pontiac

!++l Remove or Disconnect A

1. Front floor console assembly. Refer to "Front Floor
Console Assembly" under "On-Vehicle Service" in
this section.
2. Cigarette lighter electrical connector from cigarette
lighter assembly.
B
CIGARETTE LIGHTER ELECTRICAL CONNECTOR
CONVERTIBLE TOP SWITCH ELECTRICAL CONNECTOR
C TRACTION CONTROL SWITCH ELECTRICAL CONNECTOR
30 TRAY, FRONT FLOOR CONSOLE TAPE/DISC STORAGE
32 BEZEL ASSEMBLY, CIGARETTE LIGHTER
33 CONSOLE ASSEMBLY, FRONT FLOOR
98 SWITCH ASSEMBLY, ELECTRONIC TRACTION CONTROL
AND FOLDING TOP (WITH CIGARETTE LIGHTER)

3. Cigarette lighter assembly from front floor console

assembly.

l++I Install or Connect RC1002-8C·F·RP

1. Cigarette lighter assembly to front floor console Figure 11 - Cigarette Lighter, Traction Control Switch and
assembly. Convertible Top Switch - (Chevrolet) (Typical)
8C·16 INSTRUMENT PANEL, GAGES AND CONSOLE

2. Cigarette lighter electrical connector to cigarette

lighter assembly.
3. Front floor console assembly. Refer to "Front Floor
Console Assembly" under "On-Vehicle Service" in
this section.

Convertible Top Switch

Chevrolet

Figure 11

!++I Remove or Disconnect

1. Folding top switch assembly (98) from console
assembly (33).

~
2. Convertible top switch connector from folding top
switch assembly (98).
3. Cigarette lighter electrical connector from cigarette
lighter assembly, if equipped.
4. Cigarette lighter assembly, if equipped, to folding 99
top switch assembly (98).

!++I Install or Connect 33

1. Cigarette lighter assembly, if equipped, to folding

top switch assembly (98).
2. Cigarette lighter electrical connector to cigarette
lighter assembly, if equipped.
3. Convertible top switch connector to folding top
switch assembly (98).
4. Folding top switch assembly (98) to console assem-
bly (33).

Pontiac

Figure 12

l++I Remove or Disconnect

1. Folding top switch assembly (99) from console
assembly (33).
2. Convertible top switch connector from folding top
switch assembly (99).

!++I Install or Connect

1. Convertible top switch connector to folding top
switch assembly (99).
A CONVERTIBLE TOP SWITCH ELECTRICAL CONNECTOR
2. Folding top switch assembly (99) to console assem- B TRACTION CONTROL AND PERFORMANCE SWITCH
bly (33). ELECTRICAL CONNECTOR
33 CONSOLE ASSEMBLY, FRONT FLOOR
99 SWITCH ASSEMBLY, FOLDING TOP
Compartment Lamp Switch 100 SWITCH ASSEMBLY, ELECTRONIC TRACTION CONTROL
(WITH AUTOMATIC TRANSMISSION SHIFT PROGRAM
Figure 13 SWITCH)

!++I Remove or Disconnect

1. Switch (93) and retainer (94) from opening in con- RC2001 ·8C-F-RP
sole assembly (33). Figure 12 - Convertible Top, Traction Control and
2. Retainer (94) from switch (93). Performance Switches - (Pontiac) (Typical)

I Traction Control Switches
~94
33 CONSOLE ASSEMBLY, FRONT FLOOR
93 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
94 RETAINER, INSTRUMENT PANEL COMPARTMENT
LAMP SWITCH
PC0009-8C-F-RP
Figure 13 - Compartment Lamp Switch
!++I Install or Connect
1. Retainer (94) to switch (93).
2. Switch (93) and retainer (94) down through opening
in console assembly (33).
• Be sure retainer (94) is seated in console
assembly (33).
Performance Switch (VS. Automatic)
Second Gear Start Switch (V6 Automatic)
Pontiac Only
Figure 12
l++I Remove or Disconnect
1. Automatic transmission shift program switch ( 100)
from console assembly (33).
2. Performance switch electrical connector from auto-
matic transmission shift program switch (100).
!++I Install or Connect
I. Performance switch electrical connector to auto-
matic transmission shift program switch (100).
2. Automatic transmission shift program switch (100)
to console assembly (33).
INSTRUMENT PANEL, GAGES AND CONSOLE 8C·17
ASR Switch - Chevrolet
TCS Switch - Pontiac
Figures 11 and 12
!+-+I Remove or Disconnect
1. Electronic traction control switch assembly (98 or
99) from console assembly (33).
2. Traction control switch electrical connector from
electronic traction control switch assembly (98 or
99).
3. Cigarette lighter electrical connector from cigarette
lighter assembly, if equipped.
4. Cigarette lighter assembly, if equipped, from trac-
tion control switch assembly (98).
!++I Install or Connect
1. Cigarette lighter assembly, if equipped, to traction
control switch assembly (98).
2. Cigarette lighter electrical connector to cigarette
lighter assembly, if equipped.
3. Traction control switch electrical connector to elec-
tronic traction control switch assembly (98 or 99).
4. Electronic traction control switch assembly (98 or
99) to console assembly (33).
Storage Tray
Figure 11
l+-+I Remove or Disconnect
• Tray (30) from console storage area.
• Depress dual lock fasteners on either side of
tray (30).
l,.+I Install or Connect
• Tray (30) into console storage area.
• Apply pressure to secure dual lock fasteners.
Transmission Plate Assembly
Figure 14
!++I Remove or Disconnect
1. Retainers attaching plate assembly (28 or 29) to con-
sole assembly (33).
2. Plate assembly (28 or 29).
!++I Install or Connect
1. Plate assembly (28 or 29) to console assembly (33).
• Position plate assembly (28 or 29) over shifter
stem, initially inserting forward end of plate
assembly (28 or 29) into console assembly
(33).
8C~18 INSTRUMENT PANEL1 GAGE$ AND CONSOL.E

4. Instrument panel carrier (75). Refer to "Instrument

29 28
Panel Carrier" in this section.

Center Air Outlet Duct Assemblies·

Chevrolet Only
B
B Figure 15
A
l++I Remove or Disconnect
1. Bolts/screws (57) attaching duct assembly (58 or 59)
to carrier (75).
2. Duct assembly (58 or 59).

A STEM, SHIFTER
!++I Install or Connect
B RETAINER NOTICE: See "Notice" on page 8C-1 of this sec-
28 PLATE ASSEMBLY, FRONT FLOOR CONSOLE tion.
TRANSMISSION (MANUAL) .
29 PLATE ASSEMBLY, FRONT FLOOR CONSOLE 1. Duct assembly (58 or 59) to carrier (75).
TRANSMISSION (AUTOMATIC) 2. Bolts/screws (57) attaching duct asse~bly (58 or 59)
33 CONSOLE ASSEMBLY, FRONT FLOOR
, , PC2011 ·BC-F-RP to carrier (7 5).
Figure 14 - Transmission Plate Assembly
!~I Tighten
• Bolts/screws (57) to 1.9 N•m (17 lb. in.).
2. Retainers attaching plate assembly (28 or 29) to con-
sole assembly (33).c Defogger Outlet Duct Assembly
• Apply pr:essm:e; snap into place and secure. Figures 15 and 16
HEAT, VENTILATION AND AIR
CONDITIONING DUCTS
l++I Remove or Disconnect
1. Duct assembly (56) from distributor assembly (54).'
2. Duct assembly (56) from carrier (75).
Air Distributor Assembly

Figures 15 and 16
!++I Install or Connect
NOTICE: See "Notice" on page 8C-1 of this sec-
!++I Remove or Disconnect tion.
1. Instrument panel carrier. Refer to "Instrument Panel 1. Duct assembly (56) to carrier (75).
Carrier" in this section. 2. Duct assembly (56) to distributor assembly (54).,
2. Bolts/screws (55) attaching distributor assembly
(54) to carrier (75). Floor Air Outlet Duct Assembly
3. Distributor assembly (54) from carrier (75). Figure 17

!++I Install or Connect !++I Remove or Disconnect

NOTICE: See "NOTICE" on page 8C-1 of this sec-
tion.
1. Distributor assembly (54) to carrier (75);
2. Route heater control cable assembly and vacuum
wiring harness assembly over reinforcement in car- l++l tnstall or Connect
rier (75).
• Align cable and wire assemblies with depres-
sion in distributor assembly (54).
3. Bolts/screws (55) attaching distributor assembly
(54) to carrier{75).
1. Bolts/screws (47) attaching duct assembly (46) to
module assembly ( 45).
2. Duct assembly (46).
NOTICE: See "Notice" on page 8C~l of this sec-
tion.
1. Duct assembly (46) to module assembly (45).
2. Bolts/screws (47) attaching duct assembly (46) to
module assembly (45).

l~I Tighten l~I Tighten

• Bolts/screws (55) to 1.9 N•m (17 lb. in.). • Bolts/screws (47) to 1.9 N•m (17 lb. in.).
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·19

54

I
I

58

75
59
!VIEWA I

A PIN, LOCATOR
52 DUCT ASSEMBLY, INSTRUMENT PANEL 6UTER AIR
OUTLET
53 BOLT/SCREW, INSTRUMENT PANEL OUTER AIR
OUTLET, 1.9 N•m (17 LB. IN.)
54 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
55 BOLT/SCREW, AIR DISTRIBUTOR DUCT,
1.9 N•m (17 LB. IN.)
56 DUCT ASSEMBLY, SIDE WINDOW DEFOGGER OUTLET
57 BOLT/SCREW, INSTRUMENT PANEL CENTER AIR 52
OUTLET DUCT, 1.9 N•m (17 LB. IN.)
58 DUCT ASSEMBLY, INSTRUMENT PANEL CENTER AIR
OUTLET
59 DUCT ASSEMBLY, INSTRUMENT PANEL CENTER AIR
OUTLET
75 CARRIER; INSTRUMENT PANEL
PC1011-IIC-F-RP

Figure 15 - Heat, Ventilation and Air Conditioning Ducts - (Chevrolet)

.sc.~20 INSTRUMENT PANEL, GAGES AND CONSOLE

56

,~~~ IVIEW A I
52 DUCT ASSEMBLY, INSTRUMENT PANEL OUTER AIR
OUTLET
53 BOLT/SCREW, INSTRUMENT PANEL OUTER.AIR
OUTLET, 1.9 N•m (17 LB. IN.) ..
54 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
55 BOLT/SCREW, AIR DISTRIBUTOR DUCT,
1.9 N•m (17 LB. IN.)
56 DUCT ASSEMBLY, SIDE WINDOW DEFOGGER OUTLET
75 CARRIER, INSTRUMENT PANEL
PC2012-8C-F·RP

Figure 16 - Heat, Ventilation and Air Conditioning Ducts - (Pontiac)

_outer Air Outlet Duct Assemblies HEATER AND AIR CONDITIONING

EVAPORATOR AND BLOWER MODULE
Figures 16 and 18 ASSEMBLY
!+-+I Remove or Disconnect Figure 17
I. Bolts/screws (53) attaching duct assembly (52) to
carrier (75). l+-+I Remove or D~sconnect
2. Duct assembly (52).
1. Bolts/screws (44) attaching module assembly (45) to
carrier (75). ·
~!-++I Install or Connect 2. Module assembly (45).
NOTICE: See "Notice" on page 8C-1 of this sec-
tion.
I. Duct assembly (52) to carrier (75).
!-++I Install.or Connect
NOTICE: See "Notice" on page 8C-l of this sec-
2. Bolts/screws (53) attaching duct assembly (52) to tion. ·
carrier (75).
I. Module assembly (45) to carrier (75).
l~I .Tighten 2. Bolts/screws (44) attaching module assembly (45) to
• Bolts/screws (53) to 1.9 N•m (17 lb. in.). carrier (75):
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·21

46

44 BOLT/SCREW, HEATER AND AIR CONDITIONING

EVAPORATOR AND BLOWER MODULE,
5.5 N•m (49 LB. IN.)
45 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING
EVAPORATOR AND BLOWER
47 IVIEWA I
46 DUCT ASSEMBLY, FLOOR AIR OUTLET
47 BOLT/SCREW, FLOOR AIR OUTLET DUCT,
1.9 N•m (17 LB. IN.)
75 CARRIER, INSTRUMENT PANEL PC0012-BC-F-RP
Figure 17 - Heater and Air Conditioning Evaporator and Blower Module Assembly

75

75

A LEFT SIDE
B RIGHTSIDE
52 DUCT ASSEMBLY, tNSTRUMENTPANEL OUTER AIR
B
OUTLET
53 BOLT/SCREW, INSTRUMENT PANEL OUTER AIR
OUTLET, 1.9 N•m (17 LB. IN.) 76
75 CARRIER, INSTRUMENT PANEL
76 BOLT/SCREW, INSTRUMENT PANEL OUTER AIR 77
OUTLET, 1.9 N•m (17 LB. IN.)
77 DUCT ASSEMBLY, INSTRUMENT PANEL OUTER AIR
OUTLET
PC1013-8C-F-RP

Figure 18 - Outer Air Outlet Duct Assemblies - (Chevrolet)

2. Bolts/screws (79) attaching cluster assembly (78) to

!~I Tighten carrier (75).
3. Cluster assembly (78) from carrier (75).
• Bolts/screws (44) to 5.5 N•m (49 lb. in.).
4. Instrument cluster wiring harness electrical connec-
tor from cluster assembly (78).
INSTRUMENT CLUSTER ASSEMBLY
!++I Install or Connect
Figure 19 NOTICE: See "Notice" on page 8C~l of this sec-
tion.
!++I Remove or Disconnect 1. Instrument cluster wiring harness electrical connec-
tor to cluster assembly (78).
I. Instrument panel upper trim panel assembly. Refer
to "Instrument Panel Upper Trim Panel Assembly" • When connecting, push, click, then tug on
in this section. electrical connector, not wire.
SC-22 INSTRUMENT PANEL, GAGES AND CONSOLE
A CONNECTOR, INSTRUMENT CLUSTER WIRING
HARNESS ELECTRICAL
75 CARRIER, INSTRUMENT PANEL
78 CLUSTER ASSEMBLY, INSTRUMENT
79 BOLT/SCREW, INSTRUMENT CLUSTER, A
2.2 N•m (20 LB. IN.)
Figure 19 - Instrument Cluster Assembly (Typical)
2. Cluster assembly (78) to carrier (75).
3. Bolts/screws (79) attaching cluster assembly (78) to
carrier (75).
l~I Tighten
• Bolts/screws (79) to 2.2 N•m (20 lb. in.).
4. Instrument panel upper trim panel assembly. Refer
to "Instrument Panel Upper Trim Panel Assembly"
in this section.
INSTRUMENT PANEL CARRIER
Figure 20
!++I Remove or Disconnect
CAUTION: See "Caution" on page 8C-1
of this section.
1. Sound insulator assembly from both sides of
vehicle. Refer to "Sound Insulator Assembly" in
this section.
2. Removable top assembly. Refer to SECTION 10-9.
3. Window rail trim panel assembly. Refer to SEC-
TION 10-6.
4. Knee bolster assembly and deflector. Refer to
"Driver Knee Bolster Assembly and Deflector" in
this section.
5. Disable SIR. Refer to "Disabling the SIR System"
in this section.
NOTICE: Remove stoplamp switch before fully
lowering the steering column assembly; Failure to
do so may cause the stoplamp switch to become
damaged or thrown out of adjustment resulting in a
malfunctioning stoplamp switch or premature brake
wear.
6. Stoplamp switch. Refer to SECTION 5.
7. Steering column assembly. Refer to SECTION 3F.
• Gently lower steering column assembly.
8. Trim panel assembly. Refer to "Instrument Panel
Upper Trim Panel Assembly" in this section.
78
PC1014-8C-F-RP
9. Trim plate assembly. Refer to "AM/FM Stereo and
Clock Radio Assembly" under "On-Vehicle Ser-
vice" in this section.
10. Bezel assembly. Refer to "Instrument Panel Cluster
Trim Plate Bezel Assembly" in this section.
11. Instrument cluster assembly. Refer t.o "Instrument
Cluster Assembly" under "On-Vehicle Service" in
this section.
12. Radio assembly. Refer to "AM/FM Stereo and
Clock Radio Assembly" under "On-Vehicle Ser-
vice" in this section.
13. Temperature control assembly. Refer to "Heater and
Air Conditioning Control Assembly" under "On-
Vehicle Service" in this section.
14. Left side duct assemblies. Refer to "Heat, Ventila-
tion, and Air Conditioning Ducts" in this section.
15. Transmission gear shift knob, cover and console
assemblies. Refer to "Front Floor Console Assem-
bly" under "On-Vehicle Service" in this section.
16. Fuse block. Refer to "Auxiliary Fuse Block" under
"Instrument Panel Wiring Harness Assembly" in
this section.
17. Assembly line data link connector. Refer to "Instru-
ment Panel Wiring Harness Assembly" in this sec-
tion.
18. Hazard and chime assembly. Refer to "Warning/Re-
minder Chimes" under "On-Vehicle Service" in
this section.
19. Upper bolts/screws (9).
20. Lower nuts (8).
21. Reposition carrier (75).
22. Air duct assembly. Refer to "Heat, Ventilation and
Air Conditioning Ducts" in this section.
23. Audio alarm assembly. Refer to "Alarm Assembly"
in this section.
24. Wiring harness assembly from carrier (75). Refer to
"Instrument Panel Wiring Harness Assembly" in
this section.
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·23

75

40

A . •

A WIRE ASSEMBLY, CROSS CAR WIRING HARNE~,

GROUND
-B
B WIRE ASSEMBLY, INSTRUMENT PANEL WIRING
HARNESS GROUND 8 NUT, INSTRUMENT PANEL, 25 N•m (18 LB. FT.)
C WIRE ASSEMBLY, INSTRUMENT PANEL WIRING 9 BOLT/SCREW, INSTRUMENT PANEL,
HARNESS GROUND 1.9 N•m (17 LB. IN.)
D WIRE ASSEMBLY, INSTRUMENT PANEL WIRING 40 PANEL ASSEMBLY, INSTRUMENT
HARNESS GROUND 75 . CARRIER, INSTRUMENT PANEL
PC1015-8C-F-RP

Figure 20 - Instrument Panel Assembly Mounting (Typical)

25. Carrier (75). 10. Fuse block. Refer to "Auxiliary Fuse Block" under
"Instrument Panel Wiring Harness Assembly" in
!++I Install or Connect this section.
11. Transmission gear shift knob, cover and console
NOTICE: See "Notice" on page 8C-1 of this sec- assemblies. Refer to "Front Floor Console Assem-
tion. bly" under "On-Vehicle Service" in this section.
1. Carrier (75). 12. Left side duct assemblies. Refer to "Heat, Ventila-
2. .Wiring harness assembly to carrier (75). Refer to tion and Air Conditioning Ducts" in this section.
"Instrument Panel Wiring Harness Assembly" in 13. Temperature control assembly. Refer to "Heater and
this section. Air Conditioning Control Assembly" under "On-
3. Audio alarm assembly. Refer to "Alarm Assembly" Vehicle Service" in this section.
in this section. 14. Radio assembly. Refer to "AM/FM Stereo and
4. Air duct assembly. Refer to "Heat, Ventilation and Clock Radio Assembly" under "On-Vehicle Ser-
Air Conditioning Ducts" in this section. vice" in this section.
5. Position carrier (75) 15. Instrument cluster assembly. Refer to "Instrument
6. Lower nuts (8). Cluster Assembly" under "On-Vehicle Service" in
this section.
l~I Tighten
16. Bezel assembly. Refer to "Instrument Panel Cluster
Trim Plate Bezel Assembly" in this section.
• Lower nuts (8) to 25 N•m (18 lb. ft.). 17. Trim plate assembly. Refer to "AM/FM Stereo and
7. Upper bolts/screws (9). Clock Radio Assembly" under "On-Vehicle Ser-
vice" in this section.
l~I Tighten 18. Trim panel assembly. Refer to "Instrument Panel
Upper Trim Panel Assembly" in this section.
• Upper bolts/screws (9) to 1.9 N•m (17 lb. in.).
19 .. Steering column assembly. Refer to SECTION 3F.
8. Hazard and chime assembly. Refer to "Warning/Re-
minder Chimes" under "On-Vehicle Service" in • Gently raise steering column assembly into
this section. place.
9. Assembly line data link connector. Refer to "Instru- 20. Stoplamp switch. Refer to SECTION 5.
ment Panel Wiring Harness Assembly" in this sec- CAUTION: Refer to "Caution" on page
tion. BC-1 of this section.
8C·24 INSTRUMENT PANEL, GAGES AND CONSOLE

21. Enable SIR. Refer to "Enabling the SIR System" in

this section.
22. Knee bolster assembly and deflector. Refer to
!++I Install or Connect
"Driver Knee Bolster Assembly and Deflector" in 1. Insulator (26) to tape (24) that is attached to carrier
(75).
this section.
2. Retainers (7) attaching insulator (26) to carrier (75).
23. Window rail trim panel assembly. Refer to SEC-
TION 10-6.
INSTRUMENT PANEL SWITCHES
24. Removable top assembly. Refer to SECTION 10-9.
25. Sound insulator assembly. Refer to "Sound Insula- Headlamp and Instrument Panel Lamp
tor Assembly" in this section. Dimmer Switch Assembly
INSTRUMENT PANEL INSULATOR Chevrolet
Figure 21 Figure22

j++I Remove or Disconnect j++I Remove or Disconnect

1. Retainers (7) attaching insulator (26) to carrier (75). 1. Switch assembly (83) from bezel assembly (5).
2 .. Insulator (26) from tape (24) that is attached to car- 2. Instrument panel wiring harness electrical connec-
rier (75). tors from switch assembly (83).

7 RETAINER, INSTRUMENT PANEL INSULATOR

24 TAPE, INSTRUMENT PANEL INSULATOR FASTENER
26 INSULATOR, INSTRUMENT PANEL
75 CARRIER, INSTRUMENT PANEL

PC0016-8C-F-RP

Figure 21 - Instrument Panel Insulator

A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS 5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER
FOG LAMP ELECTRICAL TRIM PLATE
B CONNECTOR, INSTRUMENT PANEL WIRING HARNESS 75 CARRIER, INSTRUMENT PANEL
ELECTRICAL 83 SWITCH ASSEMBLY, HEADLAMP AND INSTRUMENT
C CONNECTOR, INSTRUMENT PANEL WIRING HARNESS PANEL LAMP DIMMER
DIMMER SWITCH ELECTRICAL
PC1017-8C-F-RP

Figure 22 - Headlamp and Instrument Panel Lamp Dimmer Switch Assembly - (Chevrolet)

!++! Install or Connect
NOTICE: When installing switch assembly, do not
put pressure on switch knob or dimmer thumbwheel.
Failure to follow these instructions may result in
damage to the switch assembly.
I. Switch assembly (83) to instrument panel wiring
harness electrical connectors.
2. Switch assembly (83) to bezel assembly (5).
Pontiac
Figure 23
!++I Remove or Disconnect
1. Switch assembly (83) from carrier (75).
2. Instrument panel wiring harness electrical connec-
tors from switch assembly (83).
!++! Install or Connect
NOTICE: When installing switch assembly, do not
put pressure on switch knob or dimmer thumbwheel.
Failure to follow these instructions may result in
damage to the switch assembly.
I. Switch assembly (83) to instrument panel wiring
harness electrical connectors.
2. Switch assembly (83) to carrier (75).
A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL
B CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL
75 CARRIER, INSTRUMENT PANEL
83 SWITCH ASSEMBLY, HEADLAMP AND INSTRUMENT
PANEL LAMP DIMMER
PC2017·8C-F-RP
Figure 23 - Headlamp and Instrument Panel Lamp Dimmer
Switch Assembly - (Pontiac)
INSTRUMENT PANEL, GAGES AND CONSOLE SC-25
Lid Release Switch Assembly
Chevrolet
Figure 24
!++! Remove or Disconnect
1. Switch assembly (31) from instrument panel carrier
(75) inside instrument panel compartment door.
2. Instrument panel wiring harness electrical connector
from switch assembly (31).
!++! Install or Connect
1. Instrument panel wiring harness electrical connector
to switch assembly (31).
2. Switch assembly (31) to instrument panel carrier
(75) inside instrument panel compartment door.
Pontiac
Figure 25
!++! Remove or Disconnect
I. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this sec-
tion.
2. Switch assembly (31) from instrument panel wiring
harness electrical connector.
3. Switch assembly (31) from bolster assembly (3).
!,.+I Install or Connect
1. Switch assembly (31) to bolster assembly (3).
2. Switch assembly (31) to instrument panel wiring
harness electrical connector.
~31
A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
31 SWITCH ASSEMBLY, REAR COMPARTMENT LID RELEASE
75 CARRIER, INSTRUMENT PANEL
RC1003-8C-F-RP
Figure 24 - Lid Release Switch Assembly - (Chevrolet)
8C·26 INSTRUMENT PANEL, GAGES AND CONSOLE

2. Auxiliary fuse block.

(t+l tnstall or Connect

NOTICE: See "Notice" on page 8C-1 of this sec-
tion.
1. Auxiliary fuse block to carrier (75).
2. Bolt/screw (86).
A
l~I Tighten
• Bolt/screw (86) to 1.5 N•m (13 lb. in.).

Convenience Center
Figure29
A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL .
3 BOLSTER ASSEMBLY, INSTRUMENT PANEL DRIVER
l++I Remove or Disconnect
KNEE 1. Bolts/screws (87) attaching convenience center to
31 SWITCH ASSEMBY, REAR COMPARTMENT LID tie bar assembly (25).
RELEASE
75 CARRIER, INSTRUMENT PANEL 2. Convenience center.
PC201B·BC-F-RP.

Figure 25 - lid Release Switch Assembly - {Pontiac) .. l++l tnstall or Connect

NOTICE: See "Notice" on page 8C-1 of this sec-
3. Driver knee bolster assembly. Refer to "Driver tion.
Knee Bolster Assembly and Deflector" in this sec-
tion. 1. Convenience center to tie bar assembly (25).
2. Bolts/screws (87).
INSTRUMENT PANEL WIRING HARNESS
ASSEMBLY !~I Tighten
Refer to Figures 26 and 27 for instrument panel wir- • Bolts/screws (87) to 1.5 N•m (13 lb. in.).
ing harness assembly routing.
ODOMETER REPAIR NOTICE LABEL
Auxiliary Fuse Block
Figure 30
Figure 28

l++l Remove or Disconnect

m Important
• When repairing an instrument cluster assembly, the
1. Bolt/screw (86) connecting auxiliary fuse block to law requires the odometer reading of the replace-
carrier (75). ment unit to be set to register the same mileage as the

PC1019-8C-F-RP

Figure 26 - Instrument Par1el Wiring Harness Routing - {Chevrolet)

 INSTRUMENT PANEL; GAGES AND CONSOLE 8C·27

PC2020-8C-F-RP

Figure 27 - Instrument Panel Wiring Harness Routing - (Pontiac)

r"' 75

86
'<
.A

87 25

A FUSE BLOCK, INSTRUMENT PANEL WIRING HARNESS A CONVENIENCE CENTER, INSTRUMENT PANEL WIRING
AUXILIARY HARNESS
75 CARRIER, INSTRUMENT PANEL 25 BAR ASSEMBLY, INSTRUMENT PANEL TIE
86 BOLT/SCREW, INSTRUMENT PANELWIRING HARNESS 75 CARRIER, INSTRUMENT PANEL
FUSE BLOCK 1.5 N•m (13 LB. IN.) 87 BOLT/SCREW, INSTRUMENT PANEL WIRING HARNESS
CONVENIENCE CENTER, 1.5 N•m (13 LB. IN.)

RC0001-8C·F-RP PC0021-8C·F-RP

Figure 28 - Auxiliary Fuse Block Figure 29 - Convenience Center

• A copy of the label must be retained in compliance

with the retention requirement~ specified in the
"Guidelines for General Motors Odometer Policy."
prior odometer. If the same mileage cannot be set,
the law requires that the replacement odometer be
set to zero and a label be installed on the driver's
!++I Install or Connect
door frame to show the previous reading and the date I. Clean area around left B-pillar where odometer
of replacement. repair notice label is to be attached.
8C·28 INSTRUMENT PANEL, GAGES AND CONSOLE

• Label area is to be clean and free from plastisol SOUND INSULATOR ASSEMBLY
or any foreign material that could affect adhe-
sion of odometer repair notice label. Figure 31
2. Properly fill out all necessary information on odom- Left Side
eter repair notice label.
• Sign and date odometer repair notice label. !++I Remove or Disconnect
3. Remove backing and attach odometer repair notice 1. Retainer (13) from instrument panel carrier.
label to left B-pillar. 2. Insulator assembly (14) from instrument panel car-
rier.
A. Unhook flange on insulator assembly (14)
from side kick panel assembly.

""fOOOAlfTl,iOJI '"""'tl"ICl.lwasat

____ ........
,....a -o rua-to uc:a ro llJIO o-
"'"'' Nl'UCID • " ' Aft OOO'llllrt,l SU
"'' ZPO. -.uca ,._ ro ,..,.... 111
IUCIMUtr...,...
_ _ _ _ u ..Olllqq

oa:w ..~....· • • ~ - -
"-----
......._,,
, ........ l,AW . . . . . ., . .........
011-..r11Mrow•n.su,-..

A LABEL, ODOMETER REPAIR NOTICE PC2023.SC·F·RP

Figure 30 - Odometer Repair Notice Label

c
A LEFTSIDE A
B RIGHTSIDE
C FLANGE
D TAB 12
10 INSULATOR ASSEMBLY, INSTRUMENT PANEL SOUND
11 RETAINER, INSTRUMENT PANEL SOUND INSULATOR
12 RETAINER, INSTRUMENT PANEL SOUND INSULATOR
13 RETAINER, INSTRUMENT PANEL SOUND INSULATOR
14 INSULATOR ASSEMBLY, INSTRUMENT PANEL SOUND PC2024-8C-F-RP

Figure 31 - Sound Insulator Assembly (Typical)

 INSTRU.MENT PANEL, GAGl:S AND CONSO~E ~C~29

.B. Detach tab OQ insulator assembly (.14) from

retainer on instrument panel carri,er. · 75

j++l !nstall or Connect .

1. Insulator assembly (14) to instrument panel carrier.
A. Attach tab on insulator assembly (14) to
retainer on instrument panel carrier. . .
B. Hook flange on ins{!lator assembly (1'4) to side
kick panel assembly. ·
2. Retainer (13) to instrument panel carrier.

Right Side..

l++I Remove or Disconnect

1. Retainer ( 11) from boss 9n .heate.r and air condition-
ing module assembly. ·
2. Retainer (12) from insulator assembly (10),
3. Insulator assembly ( 10) from instrument panel car-
rier. 5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER
· A. Detach forward flange on insulator assembly TRIM PLATE
6 BOLT/SCREW, INSTRUMENT PANEL CLUSTER TRIM
( 10) from boss on heater and air conditioning PLATE, 1.9 N•m (17 LB. IN.) .
module assembly. 75 CARRIER, INSTRUMENT PANEL
B. Unhook flange on insulator assembly (10)
from under side kick panel assembly•. ·

!++I .Install or Connect PC1024-8C-f..RI'

Figure 32 - Instrument Panel Cluster Trim Plate Bezel

1. Insulator assembly (10) to instrument panel carrier. Assembly - (Chevrolet)
A. Hook flange on insulator assembly (10) over
side kick panel assembly.
B. Attach forward flange on insulator assembly
( 10) to boss on heater and air conditioning A. Position bezel assembly (5) over instrument
module assembly. cluster assembly.
2. Reta\per (12) to insulator assembly (10).
B. Align hoks on bezel assembly (5) with holes
3. Retai"ner (11) to boss on heater and air conditioning on carrier.(75).
module assembly.
2. Four bolts/screws (6) attaching bezel assembly (5)
TRIM PANEL Cl..USTER BEZEL ASSEMBLY, to carrier (75).
'
UPPER TRIM PANEL ASSEMBLY AND
COMPARTMENTS .,l~J Tighten
• Bolts/screws (6) to 1.9 N•m (17 lb. in.).
Instrument Panel Cl.uster Trim Plate Bezel
Assembly
Pontiac
Chevrolet
Figure 33
!Figure 32

!++I Remove or Oisconn'ect l++I Remove or Disconn~ct

1. Locator pins attachit)g bezel assembly (5) to carrier
1. Four bolts/screws (6) attaching bezel assembly (5) (75). .
to carrier (75).
2. Bezel assembly (5) from carrier (75). 2 .. Bezel assembly (5) f;orn carrier (75).: ·'

l++I Install or Connect l++I Install or Con~ect

· NOTICE: See "Notice" on page 8C-l of this sec- 1. Bezel assembly (5) onto carrier (75).....
tion. ·· 2. Locator pins attaching beZel assembly (5) to carriet
1. Bezel assembly (5) onto carrier (75). (75).
SC·.30 INSTRUMENT PANEL, GAGES ANO CONSOLE

wiring harness assembly. For further information, refer to

75 SECTION 8B.

Instrument Panel Compartment Door Assembly

Figure 34

!++I Remove or Disconnect

1. Bolts/screws (20 and 90) attaching hinge to instru-
ment panel carrier.
2. Open door assembly (89).
A
3. Door assembly (89) from instrument panel carrier.

!++I Install or Connect

A PIN, LOCATOR NOTICE: See "Notice" on page 8C-1 of this sec-
5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER tion.
TRIM PLATE
75 CARRIER, INSTRUMENT PANEL 1. Door assembly (89) onto instrument panel carrier.
2. Close door assembly (89).
PC2025·8C·f·RP 3.. Bolts/screws (20 and 90) attaching hinge to instru-
Figure 33 - Instrument Panel Cluster Trim Plate Bezel m.ent panel carrier.
. Assembly- (Pontiac) ·
• Align hinge.
Instrument Panel Compartment
The instrument panel compartment is part of the l~I Tighten
instrument panel carrier. The door, lock assembly and • Bolts/screws (20 and 90) to 2.8 N•m (25 lb.
lamp are serviceable. The lamp S\\'.itch is part of the body in.).

91

'~ !VIEWA I
~20 91

'"-----_j 89

18 MODULE ASSEMBLY, INFLATABLE RESTRAINT

INSTRUMENT PANEL .
20 BOLT/SCREW, INFLATABLE RESTRAINT CONTROL
!VIEWB I
MODULE BRACKET, 2,.8 N•m (25 LB. IN.)
89 DOOR ASSEMBLY, INSTRUMENT PANEL
COMPARTMENT
90 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT
DOOR, 2.8 N•m (25 LB.IN.) '
91 LOCK ASSEMBLY, INSTRUMENT PANEL
COMPARTMENT DOOR
92 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT
DOOR LOCK

Figure 34 - Instrument Panel Compartment Door and Lock Assembly

 INSTRUMENT PANEL, .GAGES AND. CONSOLE 8C·31

Instrument Panel Compartment Door Lock

Assembly
Figure 34

l++I Remove or Disconnect

1. Open door assembly (89).
2. Three bolts/screws (92) attaching lock assembly
(91) to door assembly (89).
3. Lock assembly (91) from door assembly (89).

l++f tnstall or Connect

I. Lock assembly (91) to doo.r assembly (89).
2. Three bolts/screws (92) attaching lock assembly
75 CARRIER, INSTRUMENT PANEL
(91) to door assembly (89). 95 RETAINER, INSTRUMENT PANEL COMPARTMENT
• Align and tighten bolts/screws (92). LAMP SWITCH
96 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
3. Close door assembly (89).

Instrument Panel Compartment Lamp Switch PC2027-8C-F-RP

Figure 35 - Instrument Panel Compartment Lamp Switch

Figure 35 (Typical)

l++I Remove or Disconnect

· 1. Switch (96) and retainer (95) from carrier (75).
2. Retainer (95) from switch (96).

!++I Install or Connect 75

1. Retainer (95) to switch (96).
2. Switch (96) and retainer (95) down through opening 0
_________// [
in carrier (75).
• Be sure retainer (95) is seated into carrier (75).

Instrument Panel Fuse Block Access Door \ -

Assembly
Figure 36
A LOCK ASSEMBLY, DUAL

l++I Remove or Disconnect 2. DOOR ASSEMBLY, INSTRUMENT PANEL FUSE BLOCK

ACCESS
75 CARRIER, INSTRUMENT PANEL
• Door assembly (2) from carrier (75).
PC2028-8C-F-RP

!++I Install or Connect Figure 36 - Instrument Panel Fuse Block Access Door
Assembly (Typical)
• Door assembly (2) to carr.ier (75).
A. Align taqs on door assembly (2) with front
edge of carrier (75).
B. Align locator pins on door assembly (2) with
holes on carrier (75) and apply pressure.
!++I Install or Connect
1. Panel assembly (1) to carrier (75).
Instrument Panel Upper Trim Panel A. Align panel assembly (1), using locator pins.
Assembly
B. Apply pressure to rear of pane~ assem_bly (1),
Figure 37 engaging dual lock fasteners with matmg sur-
face.
l++I Remove or Disconnect 2. Panel assembly (1) to lower windshield support.
1. Panel assembly (1) from lower windshield support. • Engage dual lock fasteners with mating sur-
2. Panel assembly (1) from carrier (75). face.
SC-32 INSTRUMENT PANEL, GAGES AND CONSOLE

18 19

17 BOLT/SCREW, INFLATABLE RESTRAINT INSTRUMENT

PANEL MODULE, 2.8 N•m (25 LB. IN.)
75
18 MODULE ASSEMBLY, INFLATABLE RESTRAINT
INSTRUMENT PANEL
19 BRACKET ASSEMBLY, INFLATABLE RESTRAI.NT
INSTRUMENT PANEL MODULE
A PIN, LOCATOR
PC0030-8C·F·RP
B FASTENER,DUALLOCK
C SUPPORT, LOWER WINDSHIELD Figure 38 - Passenger Side Inflater Module Assembly
1 PANEL ASSEMBLY, INSTRUMENT PANEL UPPER TRIM
75 CARRIER, INSTRUMENT PANEL
PC2029·8C-F·RP 5. Enable the SIR system. Refer to "Enabling the SIR
Figure 37 - Instrument Panel Upper Trim Panel Assembly System" in this section.
(Typical)
WARNING/REMINDER CHIMES
PASSENGER SIDE INFLATOR MODULE
ASSEMBLY Alarm Assembly
Figures 34 and 38 Figure 39
CAUTION: See "Caution" on page 8C-1
of this section. l+-tl Remove or Disconnect
!+-ti Remove or Disconnect • Alarm assembly (97) from convenience center.

1. Disable SIR system. Refer to "Disabling the SIR

System" in this section.
1-++I Install or Connect
2. Bolts/screws (20) attaching bracket assembly (19) to • Alarm assembly (97) to convenience center.
instrument panel carrier.
3. Bracket assembly (19) from instrument panel car-
rier.
4. Bolts/screws (17) attaching module assembly (18) to
75
bracket assembly ( 19).
5. Module assembly (18).

!-++I Install or Connect

NOTICE: See "Notice" on page 8C-l of this sec-
tion. A
l. Module assembly (18) into bracket assembly (19).
2. Bolts/screws ( 17) attaching module assembly ( 18) to
bracket assembly ( 19).

l~I Tighten
• Bolts/screws (17) to 2.8 N•m (25 lb. in.).
A CONVENIENCE CENTER, INSTRUMENT PANEL WIRING
3. Bracket assembly ( 19) to instrument panel carrier. HARNESS
4. Bolts/screws (20) attaching bracket assembly (19) to 75 CARRIER, INSTRUMENT PANEL
97 ALARM ASSEMBLY, SEAT BELT AND IGNITION KEY
instrument panel carrier.

l~I Tighten
RC0002·8C·F·RP

Figure 39 - Seat Belt and Ignition Key and Alarm Assembly

• Bolts/screws (20) to 2.8 N•m (25 lb. in.).
 INSTRUMENT PANEL, GAGES AND CONSOLE 8C·33

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Air Distributor Duct Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Floor Air Outlet Duct Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Front Floor Console Bolt/Screw ......................................... 8 N•m (71 lb. in.)
Front Floor Console Bracket Bolt/Screw .................................. 8 N•m (71 lb. in.)
Heater and Air Conditioning Control Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N •m (17 lb. in.)
Heater and Air Conditioning Evaporator and Blower Module Bolt/Screw ...... 5.5 N•m (49 lb. in.)
Inflatable Restraint Control Module Bracket Bolt/Screw .................... 2.8 N•m (25 lb. in.)
Inflatable Restraint Instrument Panel Module Bolt/Screw ................... 2.8 N•m (25 lb. in.)
Instrument Cluster Bolt/Screw ........................................ 2.2 N•m (20 lb. in.)
Instrument Panel Bolt/Screw (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Instrument Panel Bolt/Screw (Lower) .................................. 5.5 N•m (49 lb. in.)
Instrument Panel Center Air Outlet Duct Bolt/Screw ....................... 1.9 N•m (17 lb. in.)
Instrument Panel Cluster Trim Plate Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Instrument Panel Compartment Door Bolt/Screw ......................... 2.8 N•m (25 lb. in.)
Instrument Panel Driver Knee Bolster Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 N•m (17 lb. in.)
Instrument Panel Nut ................................................ 25 N•m (18 lb. ft.)
Instrument Panel Outer Air Outlet Bolt/Screw ............................ 1.9 N•m (17 lb. in.)
Instrument Panel Wiring Harness Convenience Center Bolt/Screw ............ 1.5 N•m (13 lb. in.)
Instrument Panel Wiring Harness Engine Control Module Data Link
Connector Bolt/Screw ............................................. 1.5 N•m (13 lb. in.)
Instrument Panel Wiring Harness Fuse Block Bolt/Screw ................... 1.5 N•m (13 lb. in.)
Radio Bracket Bolt/Screw ............................................ 1.8 N•m (16 lb. in.)
Radio Bracket Nut .................................................. 2.8 N•m (25 lb. in.)
Rear Radio Bracket Bolt/Screw ....................................... 1.9 N•m (17 lb. in.)

SECTION SE
WINDSHIELD WIPER/WASHER SYSTEM
(PULSE)
NOTICE: Refer to Battery Disconnect Caution in Section OA.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or
system damage could result.
CONTENTS
General Description ....................... 8E-1
Circuit Operation ....................... 8E-1
Diagnosis ............................... 8E-3
Component Locations ................... 8E-3
Troubleshooting Hints ................... 8E-3
System Diagnosis ...................... 8E-3
On-Vehicle Service ....................... 8E-10
Washer Pump Replacement .............. 8E-10
Washer Reservoir Replacement ........... 8E-10
Wiper Arm Replacement ................. 8E-10
Wiper Blade Assembly Replacement ....... 8E-11
Wiper Blade Element Replacement ........ 8E-13
Windshield Washer ..................... 8E-13
GENERAL DESCRIPTION
Figure 1
The windshield wiper/washer system consists .of
a permanent magnet depressed park wiper motor
assembly, wiper linkage assemblies, wiper arm and
blade assemblies, a washer pump mounted on a washer
fluid reservoir and a wiper/washer switch assembly
· (Figure 1).
Pulse and timing functions, along with the de-
mand wash function, are controlled by a printed circuit
'board in the wiper motor cover assembly. The wiper
motor also is equipped with RFI (radio frequency
interference) suppression.
Depressed park positioning is accomplished by
an external drive mechanism on the wiper motor
assembly.
Figure 1 - Wiper/Washer Switch Assembly
WINDSHIELD WIPER/WASHER SYSTEM SE-1
Wiper Motor Assembly Replacement ....... 8E- l 3
Wiper Linkage Assembly Replacement ..... 8E-14
Off-Vehicle Service ....................... 8E-15
Wiper Motor Cover Assembly Replacement .8E-15
Wiper Chatter Repair ..................... 8E- l 6
Windshield Glass Cleaning ............... 8E-l6
Blade Element Cleaning ................. 8E-l6
Wiper Arm Tip Pressure Check ........... 8E-l6
Blade Element Set Check ................ 8E-17
Specifications ........................... 8E-18
Fastener Tightening Specifications ......... 8E-18
Special Tools ............................ 8E-18
CIRCUIT OPERATION
Figure2
Wiper Operation
In addition to the features of a conventional (non-
pulse) wiper system (mist, low and high speeds), the
pulse type windshield wiper/washer system includes
an operating mode in which the wipers make single
sweeps with an adjustable time interval between
sweeps. The time interval is controlled by a solid state
timer in the wiper motor cover assembly. The duration
of the delay interval is determined by the delay resis-
tor in the wiper/washer switch assembly.
When the wiper switch is turned OFF, the wiper
motor returns the wipers to end of sweep (inner wipe)
position, the wiper motor reverses and activates its
external depressed park mechanism to lower the wip-
ers to park position.
Pulse Operation
With the wiper S\\'.itch in DELAY (pulse), battery
voltage is applied to the wiper motor connector at ter-
minal "B" through CKT 143. Voltage also is applied
to terminal "D" through CKT 113 and terminal "E"
through CKT 112.
The length of delay time between sweeps is con-
trolled by the variable pulse delay resistor. The delay
is adjustable from 1 to 22 seconds, nominally.
BE-2 WlNOSHIELD WIPER/WASHER SYSTEM

- - - ~ - - - ~ ~1/P

ACCY
,-
·, FUSE
BLOCK

._ _______ _ --~ (NOT USED) 1

I

1 YEL

143
WIPER/WASHER
SWITCH ASSEMBLY

WASHER
HI
SWITCH MIST MIST
•, ~
OFF e e e • e • LO
PULSE
360 Q

.8 PNK 94 WIPER/
WASHER
WIPERS
DELAY
1------------'
REQUEST INPIJT
INPUT
WIPER
INTERLOCK 1--------------. (PTC)

r
INPUT ,,......~-..~-+-~LOW T2
,. '
• WIPERS - - - - - - - - ,
ENABLE END OF
SPEED
RELAY

T1
SWEEP
ISOlA-~ SWITCH
TION
(OPEN AT
•DIODE
(WIPERS) SOLID END OF
STATE "SWEEP"
AND

• PARK
POSITION
"PARK"
POSITION)
1--=---=--+------.
r
'
I
I
----------------

r--t~~-t~~PARK
INPUT I RELAY
PARK
.8 RED 228 SWITCH
(CLOSED
UNTIL WIPERS
IN "PARK")
PARK
WIPERS-----
GROUND CONTROL

WIPER lo10T0R ·
ASSEMBLY

.8BLK SEE GROUND

DISTRIBUTION
150 SECTION8A

Figure 2 - Wiper/Washer System Electrical Schematic

 WINDSHIELD WIPER/WASHER SYSTEM SE-3
Low Speed Operation DIAGNOSIS
In the LO position of the wiper switch, battery
voltage is applied to the wiper motor connector at ter- COMPONENT LOCATIONS
minal "B" through CKT 143 and terminal "E" through
CKT 112, with voltage applied to terminal "D" through • Refer to Figure 4 for a list of component locations.
CKT 113.
The circuit board supplies power to the wiper TROUBLESHOOTING HINTS
motor, which runs continuously through the low speed
relay. Figure2

High Speed Operation • Make the following checks before beginning Sys-
tem Diagnosis.
In the HI position of the wiper switch, battery
1. Check fuse 14. If open, check for short to ground
voltage is applied at terminals "B", "C" and "E" of
through CKT 143 and replace fuse.
the wiper motor assembly through CKTs 143, 92 and
2. Check that all system connectors are mated firmly.
112. Voltage also is applied to terminal "D" through
3. If washer does not operate, check that:
CKT 113.
- Washer reservoir is filled.
- Hoses are correctly attached.
Park Position Operation - Hoses are not cut, kinked or pinched.
When turned OFF from any position, the wipers - Nozzles are not clogged.
complete the last sweep and park. When the wiper - Connector seal at washer pump is not damaged
switch is in OFF, the wiper motor assembly has bat- or missing.
tery voltage applied to terminal "B" only, from CKT 4. Check for binding or broken wiper arm linkage.
143. When the end of sweep switch opens, the control • Refer to System Diagnosis.
circuit reverses the wiper motor which activates the
external depressed park mechanism. The wiper motor
continues to run until the park switch opens.
SYSTEM DIAGNOSIS
• Perform the System Check (Figure 5), then refer to
Washer Operation the Symptom Table (Figure 6) for the appropriate
When the washer switch is turned to ON, battery diagnostic procedures.
voltage is applied to terminal "D" of the wiper motor
assembly through CKT 113. The washer switch also
applies voltage to terminal "A" which turns ON the
washer pump through CKTs 94 and 228. The wiper
motor has voltage applied through the low speed relay
and operates at low speed for 2 to 4 wipes.
When the washer switch is held ON, the wiper
motor circuit board will keep the washer pump ON
only as long as the washer switch is held ON.
If the wipers had been in DELAY, LO or HI,
they would return to that operation after the wash cycle.
If in OFF, they then return to park position after 2 to 4
wipes.
A BLK
Mist Operation B YEL
When the wiper switch is moved to MIST and C PPL
D DK GAN
released, the wipers make one sweep at low speed and
E GAY
return to park position. If the wiper switch is held in
MIST, the wipers will continue to operate until the
switch is released. The circuit operation is the same as Figure 3 - Wiper Motor Wiring Harness Connector
that of low speed.
SE-4 WINDSHIELD WIPER/WASHER SYSTEM'

SECTION
COMPONENT LOCATION SA-201-PG FIG.
I/P Fuse Block .......... . LH side of I/P carrier, on the side . . . . . . . . . . . . . . . . . . 8 . . . . . . . . 15
Isolation Diode (Wipers) .. . Approx. 20 cm (8 in.) from C215 ................... 35 ........ 64
Washer Pump ........... . Front of vehicle, below engine hood latch . . . . . . . . . . . . 25 . . . . . . . . 46
Wiper Motor Assembly Rear of LH shock tower, mounted to dash
panel below LH wiper mount ................... . 10 ........ 18
Wiper/Washer Switch
Assembly ............ . In left side of steering column, actuated by
multi-function lever .......................... . 3 ........ 5
C200B (18 cavities) ...... . Part of forward lamp harness, between LH
kick panel and steering column ................. . 25 ........ 49
C200D (48 cavities) ...... . Part of I/P harness, between LH kick panel
and steering column .......................... . 25 . ....... 49
C215 (11 cavities) ....... . Near base of steering column ..................... . 35 . ....... 64
G106 .................. . Near top LH side of radiator, in top of T-bar ......... . 19 . ....... 35
PlOO .................. . Left side in dash panel, engine to passenger
compartment ................................ . 19 . ....... 36
Sll3 Forward lamp harness, approx. 13 cm (5 in.)
from electrical center breakout

Figure 4 - Component Locations

SYSTEM CHECK
ACTION NORMAL OPERATION

[11
• Turn ignition switch to RUN. Wipers operate at LO speed. Washer sprays wind-
• Press washer switch to ON. shield as long as washer switch is held in ON posi-
tion. After releasing switch, washer stops and wipers
return to park position after 2 to 4 sweeps.

[2]
• Turn wiper switch to DELAY (pulse mode). Wipers make one complete sweep, then pause for 1
to 22 seconds before making next sweep. The pause
time is adjusted by turning the wiper switch through
the delay range.

[3]
• Wiper switch in DELAY. Washer sprays windshield as long as washer switch
• Press washer switch ON. is held ON. Wipers run at low speed while spraying
and continue for 2 to 4 sweeps after washer switch is
released. Wipers then return to pulse operation.

[4]
• Turn wiper switch to LO. Wipers run continuously at low speed.

[5]
• Turn wiper switch to HI. Wipers run continuously at faster speed.

[6]
• Turn wiper switch to OFF. Wipers return to park position at low speed.

[7]
• Turn wiper switch to MIST, then release. Wipers make one complete sweep, then return to park
position.

Figure 5 - Wiper/Washer System Check

 WINDSHIELD WIPER/WASHER SYSTEM SE-5

SYMPTOM PROCEDURE PAGE

Wipers do not operate in any mode. Chart 1 8E-5
Wipers run when switch is "OFF." Chart 2 8E-6
No low speed mode. Replace wiper/washer switch -
assembly.
No high speed mode. Chart 3 8E-7
Wipers operate only when switch is in HI position, Check for open or poor connection in -
but run at low speed. CKT 143 between wiper/washer
switch CONN C215 TERM "D" and
wiper motor CONN TERM "8". If OK,
replace wiper motor assembly.
Low speed, pulse delay and mist modes inoperative Chart 4 8E-7
(high speed mode OK).
Pulse delay operates incorrectly or not at all. Chart 5 8E-8
Wipers stop randomly and do not park when switch is Chart 6 8E-8
moved to "OFF."
Wipers do not operate when washer switch is activated. Chart 7 8E-9
Washer does not operate. Chart 8 8E-9
Figure 6- Symptom Table

CHART 1
WIPERS DO NOT OPERATE IN ANY MODE
• IGNITION SWITCH TO "RUN."
• BACKPROBE WITH A TEST LIGHT FROM WIPER/WASHER SWITCH
CONN C215 TERM "D" TO GROUND.
IS TEST LIGHT "ON"?

• WIPER SWITCH TO "HI". REPAIR OPEN OR POOR CONNECTION IN CKT 143 TO WIPER/
• CONNECT TEST LIGHT FROM CONN C215 TERM "G" TO GROUND. WASHER SWITCH ASSEMBLY. IF FUSE 14 IS OPEN, CHECK
IS TEST LIGHT "ON"? FOR SHORT TO GROUND IN RELATED CKTS. RELATED CKTS
WILL DEPEND ON WHETHER FUSE BLOWS BEFORE OR
AFTER SYSTEM OPERATION.

• DISCONNECT WIPER MOTOR CONNECTOR. CHECK FOR POOR CONNECTION AT CONN C215 TERM "D"
• CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO OR OPEN IN PIGTAIL (CKT 143) TO WIPER/WASHER SWITCH
GROUND. ASSEMBLY.
IS TEST LIGHT "ON"? IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.

(CONTINUED ON NEXT PAGE)

BE-6 WINDSHIELD WIPER/WASHER SYSTEM
(CONTINUED FROM PREVIOUS PAGE)

• CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO REPAIR OPEN OR POOR CONNECTION IN CKT 92 BETWEEN
TERM "A". CONN C215 AND WIPER MOTOR ASSEMBLY.
IS TEST LIGHT "ON"? THEN, CONTINUE DIAGNOSIS IN OPPOSITE BOX OF CHART.

CHECK FOR POOR CONNECTION TO WIPER MOTOR ASSEMBLY. REPAIR OPEN OR POOR CONNECTION IN GROUND CKT150.
IF OK, RELACE WIPER MOTOR ASSEMBLY.

CHART2
WIPERS RUN WHEN SWITCH IS "OFF"

• IGNITION SWITCH TO "RUN."

• WIPER SWITCH "OFF."
• DISCONNECT WIPER/WASHER SWITCH CONN C215 .

•
• I
WIPER MOTOR KEEPS RUNNING I WIPER MOTOR PARKS I
I I
• USING A DVM, MEASURE VOLTAGE FROM CONN C215 CHECK FOR SHORTED WIRES IN PIGTAIL TO WIPER/WASHER
(VEHICLE SIDE} TERM "E" TO GROUND.
I SWITCH ASSEMBLY.
IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY .

• I
MORE THAN 1 VOLT I LESS THAN 1 VOLT (APPROX. 0 VOLT}
I I
• RECONNECT WIPER/WASHER SWITCH CONN C215. • RECONNECT WIPER/WASHER SWITCH CONN C215.
• DISCONNECT WIPER MOTOR CONNECTOR. • DISCONNECT WIPER MOTOR CONNECTOR.
• USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR • USING THE DVM, MEASURE VOLTAGE FROM WIPER
CONN TERM "D" TO GROUND. MOTOR CONN TERM "C" TO GROUND.
I I
• • •
MORE THAN 1 VOLT
I
I LESS THAN 1 VOLT
I
I OVOLT
I
I [;]
REPAIR B+ CONNECTION REPLACE WIPER MOTOR REPLACE WIPER MOTOR REPAIR SHORT TO B+ IN
TO CKT 113. COVER ASSEMBLY. COVER ASSEMBLY. CKT92.
 WINDSHIELD WIPER/WASHER SYSTEM 8E-7
CHART3
NO HIGH SPEED MODE

DO WIPERS OPERATE AT ALL WITH WIPER SWITCH IN "HI"?

• IGNITION SWITCH TO "RUN". REPLACE WIPER/WASHER SWITCH ASSEMBLY.

• WIPER SWITCH TO "HI".
• CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "G" AND GROUND.
IS TEST LIGHT "ON"?

• DISCONNECT WIPER MOTOR CONNECTOR. CHECK FOR POOR CONNECTION AT CONN C215 OR FOR OPEN
• CONNECT TEST LIGHT BETWEEN HARNESS TERM "C" AND IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
GROUND. IF OK, REPLACE WIPER/WASHER SWITCH .ASSEMBLY.
IS TEST LIGHT "ON"?

CHECK FOR POOR CONNECTION TO WIPER MOTOR REPAIR OPEN IN CKT 92.
ASSEMBLY.
IF OK, REPLACE WIPER MOTOR ASSEMBLY.

CHART4
LOW SPEED, PULSE DELAY AND MIST MODES INOPERATIVE
(HIGH SPEED MODE OK)

• IGNITION SWITCH TO "RUN."

• WIPER SWITCH TO "LO."
• USING A DVM, MEASURE VOLTAGE FROM WIPER/WASHER
SWITCH CONN C215 TERM "E" TO GROUND.
I
•
MORE THAN 1 VOLT I •
LESS THAN 1 VOLT (APPROX. 0 VOLT)

I I
• DISCONNECT WIPER MOTOR CONNECTOR. CHECK FOR POOR CONNECTION AT CONN C215 OR FOR
• USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR OPEN IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
CONN TERM "D" TO GROUND . IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.

•
• • I
MORE THAN 1 VOLT I LESS THAN 1 VOLT (APPROX. 0 VOLT)
I I
REPLACE WIPER MOTOR COVER ASSEMBLY. I REPAIR OPEN IN CKT 113.1
SE-8 WINDSHIELD WIPER/WASHER SYSTEM
CHART 5
PULSE DELAY OPERATES INCORRECTLY OR NOT AT ALL

• IGNITION SWITCH "OFF".

• DISCONNECT WIPER/WASHER SWITCH CONN C215.
• WIPER SWITCH TO "DELAY".
• WITH A DIGIT AL MULTl METER SET TO OHMS SCALE, MEASURE
RESISTANCE THROUGH WIPER/WASHER SWITCH ASSEMBLY
FROM CONN C215 TERM "D" TO TERM "F".
• MOVE WIPER SWITCH THROUGH ENTIRE DELAY RANGE, ONE
NOTCH AT A TIME.
DOES RESISTANCE VARY FROM APPROXIMATELY 39 kf! TO
680 kn? (SEE FIGURE 2.)

• RECONNECT WIPER/WASHER SWITCH CONN C215. REPLACE WIPER/WASHER SWITCH ASSEMBLY.

• DISCONNECT WIPER MOTOR CONNECTOR.
• IGNITION SWITCH TO "RUN".
• USING A DVM, MEASURE VOLTAGE FROM WIPER
MOTOR CONN TERM "E" TO GROUND.

APPROX. 0 VOLT

REPLACE WIPER MOTOR COVER ASSEMBLY. CHECK CKT 112 FOR OPEN OR POOR CONNECTION.
IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY.

CHARTS
WIPERS STOP RANDOMLY AND DO NOT PARK WHEN SWITCH IS MOVED TO "OFF"

• IGNITION SWITCH TO "RUN".

• WIPER SWITCH "OFF."
• DISCONNECT WIPER/WASHER SWITCH CONN C215.
DO WIPERS PARK?

• USING A DVM, MEASURE VOLTAGE FROM CONN C215 REPLACE WIPER/WASHER SWITCH ASSEMBLY.
(VEHICLE SIDE) TERM "E" TO GROUND.

• RECONNECT WIPER/WASHER SWITCH CONN C215. REPLACE WIPER MOTOR COVER ASSEMBLY.
• DISCONNECT WIPER MOTOR CONNECTOR.
• USING THE DVM, MEASURE VOLTAGE FROM CONN TERM "D
TO GROUND.

REPAIR SHORT TO B+ IN CKT 113. REPLACE WIPER MOTOR COVER ASSEMBLY.

 WINDSHIELD WIPER/WASHER SYSTEM SE-9
CHART7
WIPERS DO NOT OPERATE WHEN WASHER SWITCH 15 ACTIVATED

• IGNITION SWITCH TO "RUN."

• CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "E" AND GROUND.
• ACTIVATE WASHER SWITCH AND OBSERVE TEST LIGHT.
IS TEST LIGHT "ON"?

CHECK FOR OPEN IN CKT 113 OR FOR POOR CONNECTION AT CHECK FOR OPEN IN WIPER/WASHER SWITCH ASSEMBLY
CONN C215 OR AT WIPER MOTOR ASSEMBLY. PIGTAIL AND CONNECTION.
IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY. IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.

CHARTS
WASHER .DOES NOT OPERATE

• DISCONNECT WASHER PUMP CONNECTOR.

• CONNECT A TEST LIGHT BETWEEN TERMINALS "A" AND "B"
OF PUMP CONNECTOR.
• ACTIVATE WASHER SWITCH.
IS TEST LIGHT "ON"?

• CONNECT THE TEST LIGHT BETWEEN WASHER PUMP CONN CHECK FOR POOR CONNECTION TO WASHER PUMP.
TERM "A" AND GROUND. IF OK, REPLACE WASHER PUMP.
IS TEST LIGHT "ON"?

• CONNECT THE TEST LIGHT BETWEEN WIPER/WASHER REPAIR OPEN IN CKT 150.
SWITCH CONN C215 TERM "H" AND GROUND.
IS TEST LIGHT "ON"?

CHECK FOR POOR CONNECTION AT CONN C215 TERM "H". CHECK FOR OPEN IN CKT 94, CKT 228 OR ISOLATION DIODE.
IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.
8E-10 WINDSHIELD WIPER/WASHER SYSTEM
ON-VEHICLE SERVICE
WASHER PUMP REPLACEMENT
Figure 8

!••! Remove or Disconnect

1. Negative battery cable.

2. Electrical connector (3).
3. Place drain pan under vehicle.
4. Washer pump (4) from reservoir (2) using suit-
able pliers.
5. Washer hose assembly (5) from pump. 1 SCRIVET (4) 2 RESERVOIR, WASHER

!••! Install ~r Connect Figure 7 - Washer Reservoir (Top Front View)

1. Washer hose assembly (5).

2. Washer pump (4) in washer reservoir (2) using
pliers.

rn Important

• Make sure washer pump is pushed all the

way into washer reservoir seal.
3. Electrical connector (3).
4. Refill washer reservoir.
5. Negative battery cable.
A GUARD, SPLASH
2 RESERVOIR, WASHER
WASHER RESERVOIR REPLACEMENT 3 CONNECTOR, ELECTRICAL
4 PUMP, WASHER
Figures 7 and 8 5 HOSE ASSEMBLY, WASHER

!••! Remove or Disconnect Figure 8 - Washer Reservoir Removal

1. Washer fluid.
2. Two scrivets (1, Figure 7) from top of washer 3. Washer reservoir with 2 scrivets (1, Figure 7) at
reservoir (2). bottom of reservoir.
3. Drive vehicle onto rack. 4. Splash guard with mounting screws.
4. Negative battery cable. 5. Lower vehicle on rack.
5. Raise vehicle on rack. 6. Negative battery cable, then drive vehicle off rack.
6. Splash guard and mounting screws. 7. Two scrivets (1) at top of washer reservoir.
7. Two scrivets ( 1) from bottom of washer reservoir. 8. Washer fluid.
8. Washer reservoir and pump (4, Figure 8).
9. Electrical connector (3) and washer hose assem-
WIPER ARM REPLACEMENT
bly (5).
10. Washer pump from reservoir. Figures 9 through 11

!••! Install or Connect

!••! Remove or Disconnect
NOTICE: See "Notice" on page 8E-1 of this Tool Required:
section. J 39637 Wiper Arm Puller
1. Washer pump (4, Figure 8) in washer reser- 1. Operate wipers at lowest DELAY setting, then
voir (2). shut off wipers at inner wipe (end of sweep) po-

rn Important
sition. At tip of blade assembly, mark windshield
to aid at installation. See Figure 11 for wipe pat-
tern and inner wipe positions.
• Make sure washer pump is pushed all the 2. Raise hood (Chevrolet only).
way into washer reservoir seal.
3. Lift wiper arm nut cover and remove nut (7,
2. Washer hose assembly (5) and electrical connec-
Figure 9).
tor (3).
 WINDSHIELD WIPER/WASHER SYSTEM SE-11

rn Important

• Do not grasp plastic spoiler of wiper arm.

!L !
f.> 1nspect
• Run wipers and checlc for proper wipe pat-
4. Wiper arm (6, Figure 10) from linkage drive shaft tern (Figure 11).
using J 39637. • Shut off wipers and ch.eek for correct park
5. Wiper blade assembly, if required. See "Wiper position.
Blade Assembly Replacement."

!••! Install or Connect WIPER BLADE ASSEMBLY REPLACEMENT ·

NOTICE: See "Notice" on page 8E-1 of this Figures 12 and 13

section.
!••! Remove or Disconnect

rn
1. Wiper blade assembly, if removed. See "Wiper
Blade Assembly Replacement."
2. Wiper arm (6) on linkage drive shaft, with tip of Important
blade assembly aligned with mark made at
removal. • Do not grasp plastic spoiler of wiper arm.

rn Important
1. If wiper arms have not been removed, lift wiper
arm (6, Figure 12) until it locks into service-up
position.
• If wipers could not be stopped at inner wipe
position for wiper arm removal, position
blade tip(s) according to dimensions given
rn Important

• Use care when removing or installing a blade

in Figure 11.
3. Nut (7, Figure 9) on linkage drive shaft. assembly (8). Inadvertent bumping can cause

rn Important

• It may be necessary to allow for some move-

2.
the wiper arm to toggle back and strike the
windshield.
Press down on locking tab of blade pivot, then
pull blade assembly downward to disengage it
ment of a wiper arm when its nut is being from hook of wiper arm.
tightened. If wiper arm moves away from
desired alignment mark, loosen nut (7) and !••! Install or Connect
reposition wiper arm. 1. Position pivot of blade assembly (8, Figure 13)
,~1 Tighten
in hook of wiper arm (6), then pull blade assem~
bly upward until locking tab of blade pivot en 1
• Nut (7) to 32 N•m (24 lb. ft.) while holding gages slot in arm hook.
wiper arm. 2. Carefully lower wiper arm and blade assembly
4. Close nut cover. onto windshield.
5. Close hood (Chevrolet only).

A COVER, NUT
6 ARM, WIPER
7 NUT, 32 N•m (24 LB. FT.) 6 ARM, WIPER

Figure 9 - Wiper Arm Nut Removal Figure 10 - Wiper Arm Removal

SE-12 WINDSHIELD WIPER/WASHER SYSTEM

A PAINT LINE E BLADE TIP

B LH BLADE INNER WIPE POSITION F RH BLADE INNER WIPE POSITION
C 95-125 mm (3-3/4 - 5 IN.) G 87-117mm(3-1/2-4-1/21N.)
D TOP EDGE OF MOLDING

Figure 11 - Wipe Pattern and Inner Wipe Positions

A HOOK, ARM A SLOT, HOOK

B TAB, LOCKING B TAB, LOCKING
C PIVOT, BLADE c PIVOT, BLADE
D SPOILER, PLASTIC D SPOILER; PLASTIC
6 ARM, WIPER 6 ARM, WIPER
8 BLADE 8 BLADE
ASSEMBLY, ASSEMBLY,
WIPER WIPER

Figure 12 - Wiper Blade Assembly Removal Figure 13 - Wiper Blade Assembly Installation
 WINDSHIELD WIPER/WASHER SYSTEM 8E-13
WIPER BLADE ELEMENT REPLACEMENT
Figures 14 and 15

!••! Remove or Disconnect PULL

1. Wiper blade assembly from wiper arm. See
"Wiper Blade Assembly Replacement."
2. Blade element (9, Figure 14) has two notches at
one end which are engaged by the bottom claw B
•
set of blade assembly. At notched end, pull blade
element from blade assembly.
A HEEL END OF BLADE ASSEMBLY
!••! Install or Connect B
C
NOTCH (2)
CLAW SET
NOTICE: The heel end of the wiper blade assem- 9 ELEMENT, BLADE
bly is the end nearest to the base of the wiper arm.

rn
Figure 14 - Wiper Blade Element Removal

Important

• Replacement blade elements have three plas-

tic caps which retain the two metal flexor
strips. Do not remove these caps before the
element is installed.
1. At heel end of blade assembly, slide blade ele-
ment (9, Figure 15), notched end last, into blade
claw sets. The plastic retainer caps will be forced
off as element is fully inserted.
2. Be certain that the two element notches are en- 9
gaged by last claw set and that all other claws are
properly engaged in slots of element on both sides.
3. Wiper blade assembly on wiper arm. See "Wiper A CAP, RETAINING (3)
Blade Assembly Replacement." 9 ELEMENT, BLADE

WINDSHIELD WASHER
Figures 11 and 16

A correctly operating windshield wiper/washer -B

system has a spray pattern that cleans 75% of the wipe
pattern (Figure 11) within ten wiper cycles.
If a washer nozzle ( 10, Figure 16) becomes
plugged, apply air pressure. If a nozzle remains plugged,
the nozzle must be replaced.
B CLAW ENGAGED IN NOTCH
WIPER MOTOR ASSEMBLY RIGHT WRONG
REPLACEMENT
Figures 16 through 19

!••I Remove or Disconnect

Tool Required: D E
J 39232 Wiper Linkage Separator
1. Wiper arm and blade assemblies. See "Wiper Arm
Replacement." C SLOT
D CLAW IN ELEMENT SLOT
2. Negative battery cable.
E CLAW AGAINST METAL FLEXOR
3. LH cowl panel and hood seal.
4. Washer hose assembly (11, Figure 16) from LH Figure 15 - Wiper Blade Element Installation
cowl panel.
SE-14 WINDSHIELD WIPER/WASHER SYSTEM
5. Electrical connector from wiper motor assembly
(l 7, Figure 17). A
6. Screw (14) and nut (20).
7. Socket of RH linkage assembly (13) from ball of A
LH linkage assembly ( 15) using J 39232 (see Fig-
ure 18).
(
8. LH linkage assembly.
9. Screw (19, Figure 17).
10. Pull wiper motor assembly free from slots of
bracket (16).
11. Socket of RH linkage assembly from crank arm
ball of wiper motor assembly using J 39232 (see
Figure 18).

!••! Install or Connect

Tool Required:
J 39529 Wiper Linkage Installer

NOTICE: See "Notice" on page 8E-1 of this A SCRIVET (8)

section.

rn
B PANEi:., RH COWL
C PANEL, LH COWL
Important 10 NOZZLE, WASHER (2)
11 HOSE ASSESMBLY, WASHER
• When installing wiper motor assembly, make
certain that the crank arm is in inner wipe Figure 16 - Cowl Panels and Washer Components
position as shown in Figure 17 .. The crank
arm drive pin must be engaged in the cam
pocket. ' WIPER LINKAGE ASSEMBLY
1. Press socket of RH linkage assembly (13) into REPLACEMENT
engagement with crank arm ball of wiper motor Figures 16 through 19
assembly (17) using J 39529 (see Figure 19).
2. Wiper motor assembly (17, Figure 17) with two
locator pads (18) pressed fully into slots of bracket !••I Remove or Disconnect
(16). Tool Required:
3. Screw (19). J 39232 Wiper Linkage Separator

1~1 Tighten 1. Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
• Screw (19) to 10 N•m (7.5 lb. ft.). 2. LH cowl panel and hood seal.
4. LH linkage assembly (15) without attaching parts. 3. Washer hose assembly (11, Figure 16) from LH
5. Press socket of RH linkage assembly into en- cowl panel.
gagement with ball of LH linkage assembly using 4. Screw (14, Figure 17) and nut (20).
J 39529 (see Figure 19). 5. Socket of RH linkage assembly (13) from ball of
6. Attach LH linkage assembly with screw (14, LH linkage assembly (15) using J 39232 (see Fig-
Figure 17) and nut (20). ure 18).

l~l Tighten
6.
7.
8.
LH linkage assembly.
Three screws (12, Figure 17).
Socket of RH linkage assembly from crank arm
• Screw (14) and nut (20) to 10 N•m (7.5 lb. ball of wiper motor assembly (17) using J 39232
ft.). (see Figure 18).
7. Electrical connector to wiper motor assembly. 9. RH linkage assembly from slotted plenum access
8. Washer hose assembly (l l, Figure 16) to LH cowl hole.
panel and washer nozzle (10).
9.
10.
LH cowl panel and hood seal.
Negative battery cable.
!••I Install or Connect

11. Wiper arm and blade assemblies. See "Wiper Arm Tool Required:
Replacement." J 39529 Wiper Linkage Installer
NOTICE: See "Notice" on page 8E-1 of this
section.
 WINDSHIELD WIPER/WASHER SYSTEM SE-15
1. RH linkage assembly (13, Figure 17) through OFF-VEHICLE SERVICE
slotted plenum access hole.
2. Three screws (12) finger tight. WIPER MOTOR COVER ASSEMBLY
3. Align RH linkage assembly. REPLACEMENT
4. Press socket of RH linkage assembly into en-
gagement with crank arm ball of wiper motor Figures 20 and 21
assembly (17) using J 39529 (see Figure 19).
5. LH linkage assembly (15, Figure 17) without at-
taching parts.
l••! Remove or Disconnect
6. Press socket of RH linkage assembly into en- 1. Three screws (21, Figure 20) using Torx screw-
gagement with ball of LH linkage assembly us- driver.
ing J 39529 (see Figure 19). 2. Cover assembly (22).
7. Screw (14, Figure 17) and nut (20).

,~, Tighten
!••! Install or Connect

NOTICE: See "Notice" on page 8E-l of this

• Screw (14), nut (20) and three screws (12) section.
to 10 N•m (7.5 lb. ft.).
1. Cover assembly (22, Figure 20).
8. Washer hose assembly to LH cowl panel and
washer nozzle (10). [I] Important
9. LH cowl panel and hood seal.
• Before installing the cover assembly, make
10. Wiper arm and blade assemblies. See "Wiper Arm
certain that the inner wipe cam is positioned
Replacement."
as shown in Figure 21.
2. Three screws (21, Figure 20).

19

A CRANK ARM DRIVE PIN IN CAM POCKET 16 BRACKET, WIPER MOTOR

12 SCREW (3), 10 N•m (7.5 LB. FT.) 17 MOTOR ASSEMBLY, WIPER
13 LINKAGE ASSEMBLY, RH 18 PAD, LOCATOR (2)
14 SCREW, 10 N•m (7.5 LB. FT.) 19 SCREW, 10.N•m (7.5 LB. FT.)
15 LINKAGE ASSEMBLY, LH 20 NUT, 10 N•m (7.5 LB. FT.)

Figure 17 - Linkage and Wiper Motor Assemblies

SE-16 WINDSHIELD. WIPER/WASHER SYSTEM

Figure 18 - J 39232 Wiper Linkage Separator (Typical Usage) Figure 19 - J 39529 Wiper Linkage Installer (Typical Usage)

!~! Tighten

• Screws (21) to 2 N•m (18 lb. in.).

21
WIPER CHATIER REPAIR
Some vehicles may exhibit a condition where the
windshield wipers chatter and/or wipe unevenly. Sev-
eral items may contribute to this condition. To com-
pletely repair this condition ALL items listed should
be checked and repaired as necessary.

WINDSHIELD GLASS CLEANING

Clean windshield with windshield cleaner, GM
PN 1050011 or equivalent. The cleaner used should be
one which will not harm paint finish or scratch glass. ,
The glass is clean when water no longer "beads", but
"sheets" across entire glass surface.

BLADE ELEMENT CLEANING

Lift each blade assembly off windshield and clean
element with a cloth saturated in full strength washer
solution. Rinse blade assemblies with water.
CAUTION: Avoid prolonged skin contact with washer
solution.

21 SCREW (3), 2 N•m (18 LB. IN.)

WIPER ARM TIP PRESSURE CHECK
22 COVER ASSEMBLY
23 MOTOR, WIPER
1. Run wipers at lowest DELAY setting, then shut
wipers off at inner wiper (end of sweep} position. Figure 20 - Wiper Motor Cover Assembly Replacement
 WIN~SHIELD WI.F>ER/WASl::IER SYSTEM SE-17
2. Remove blade assemblies from wiper an;ns, pro-
A CAM, INNER WIPE
viding protection for windshield surface. ·
3. Attach a scale to wiper arm hook and measure
the force required to lift wiper arm perpendicular
to windshield to normal working height (height
with blade assembly attached).
4. If the force required is not within the specifi-
cations given belaw, · the wiper arm should be
replaced.
Tip Pressure - RH Wiper Arm - 9-11 N -D
(32.5-39.5 oz.)
LH Wiper Arm-10-12 N
(36.0-43.0 oz.)

BLADE ELEMENT SET CHECK

Figure22
Remove wiper blade assemblies from wiper arms. .A
Look down the length of the blade element. The rub-
ber element which contacts the glass must be on the Figure 21 - Inner Wipe Cam Position for
center line of the blade assembly ::t 15 degrees. Re- Cover Assembly Installation
place the element if necessary.

A BLADE ELEMENT SHOULD NOT BE BENT

MORE THAN 15° IN EITHER DIRECTION
FROM CENTER LINE
9 ELEMENT, BLADE
Figure 22 - Blade Element Set Check
SE-18 WINDSHIELD WIPERiWASHER· SYSTEM,
SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Linkage Assembly Nut (20) ....•. J.............................. lO N•m (7.5 lb;,:ft.)

Linkage Assembly Screws {12 and 14) .......... , .... i ..•.......•.. ; 10N•m.J(7.5 lb. ft.)
Wiper Arm Nuts (7) .......... '. •....... :..........•........ r,.... 32.Ntm,(24 lb.. ft.)·
Wiper MotorAssembly Sc;::r~w (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (7.5 lb. ft.)
Wiper Motor Cover Assembly Screws (21)' ..................... '... 2 N~ll? (18 lb. in.)

SPECIAL TOOLS

2.

J 39637 J 39232 J 39529

1. WIPER ARM PULLER

2. WIPER LINKAGE SEPARATOR
3. WIPER LINKAGE INSTALLER
 ACCESSORIES 9·1

SECTION 9
ACCESSORIES
CONTENTS
Audio Systems ........................................................... Section 9A
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9B
Theft Deterrent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9D
Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9E
Supplemental Inflatable Restraint (SIR) System .................................. Section 9J
Remote Keyless Entry ...................................................... Section 9K
 AUDIO SYSTEMS 9A·1

SECTION 9A

AUDIO SYSTEMS
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTION.S .could result in possible air bag deployment, personal
injury or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description ........................ 9A- I
Speaker Systems ......................... 9A-I
Base Audio System (UQO) .............. 9A- l
Delco®-GM/Bose® Music Systems ........ 9A-2
Optional Audio System ................. 9A-2
Radio Fixed Antenna Assembly ............ 9A-2
Radio Assemblies ........................ 9A-2
FM Stereo ........................... 9A-3
AMAX Stereo Certification .............. 9A-3
Radio Assembly Controls ................. 9A-3
ETR AM/FM Stereo/Cassette. (UN6) ......... 9A-4
Radio Assembly Operation .............. 9A-4
Cassette Tape Player ................... 9A-4
Delco®-GM/Bose® Music System/
Cassette (UU8) ........................ 9A-5
Radio Assembly Operation ............ '. . 9A-5
Cassette Tape Player ................. ': . 9A-5
Delco®-GM/Bose® Music System/
Compact Disc (UlT) ................... 9A-6
Radio Assembly Operation .............. 9A-6
Compact Disc Player . . . . . . . . . . . . . . . . . . . 9A-6
ETR AM/FM Stereo/Compact Disc
Player (UIC) ......................... 9A-7
Radio Assembly Operation .............. 9A-7
Compact Disc Player ................... 9A-7
ETR AM/FM Stereo/Cassette Tape
Player (UN6) ......................... 9A-8
Radio Assembly Operation .............. 9A-8
AMAX Stereo Certification .............. 9A-8
Cassette Tape Player ................... 9A-8
ETR AM/FM Stereo/Cassette Tape Player
with Graphic Equalizer (UT6) ............ 9A-9
Radio Assembly Operation .............. 9A-9
AMAX Stereo Certification .............. 9A-9
Cassette Tape Player .................. 9A-10
ETR AM/FM Stereo/Compact Disc Player
(UIC) .............................. 9A-10
Radio Assembly Operation ............. 9A-10
AMAX Stereo Certification ............. 9A-10
Compact Disc Player .................. 9A-11
ETR AM/FM Stereo/Compact Disc Player
with Graphic Equalizer (UP3) ........... 9A-ll
Radio Assembly Operation ............. 9A-ll
AMAX Stereo Certification ............. 9A-ll
Compact Disc Player .................. 9A-12
Setting Radio Anti-Theft Feature .......... 9A·l2
Unlocking Secured Radio Assembly ........ 9A-13
Unlocking Secured Radio Assembly after
Power Loss ..........•............... 9A-13
Determining Factory Backup Unlocking Code
for Secured Radio Assembly ............ 9A-14
Diagnosis ............................... 9A-14
Audio System Diagnosis . . . . . . Refer to Section SA
Radio Fixed Antenna Assembly Diagnosis ... 9A-14
On-Vehicle Service ....................... 9A-14
Tape Player and Cassette Care ............. 9A-14
Compact Disc Care ..................... 9A-15
Radio Assembly . . . . . . . . . . . . . Refer to Section SC
Speaker Assemblies ..................... 9A-15
Radio Suppression Equipment ............. 9A- I 5
Radio Fixed Antenna Assembly ........... 9A-15
Specifications ............................ 9A-16
Fastener Tightening Specifications ......... 9A-16
Special Tools ............................ 9A-16

GENERAL DESCRIPTION SPEAKER SYSTEMS

All radio assemblies have electronic memory for
preselected station function.
Base Audio System (UQO)
There are two front speaker assemblies, one in each
front side door, an.d two rear speaker assemblies mounted
in the rear panel. These speaker locations allow for a full,
high fidelity sound.
9A-2 AUDIO SYSTEMS

Standard radio front side door speaker assemblies

are 6 inches round and 4 ohms. Radio rear speaker assem-
blies are 6 inches round and IO ohms.
High performance extended range speaker assem-
blies are standard with full electronically tuned receiver
(ETR) system.
Chevrolet convertibles are equipped with (U62)
sound systems which include two door coax speakers and
two "B" pillar coax speakers.

Delco®-GM/Bose® Music Systems

Chevrolet PC1001-8A..f.RP
Figure 1 - UN6 Radio - (Chevrolet)
The speaker system for the Delco®-GM/Bose®
Music Systems (UU8 and UIT) includes three speaker
assemblies. There are two front speaker assemblies, one
in each front side door, and one rear speaker assembly,
mounted in the left rear cargo compartment trim. The 111.IME TREB

~~
Bose® amplifier is part of the rear speaker assembly.

Optional Audio System ........

Pontiac
The premium speaker system is available on the
UT6 and UP3 radio assemblies. It consists of four front
;~@AM-Fiia
speaker assemblies, two in each front side door, and six
rear speaker assemblies, two mounted in the rear sail
PC1002·9A·F..flP
panel, and four mounted in the rear compartment trim
panel assembly. The amplifier is located under the right Figure 2 - UU8 Radio - (Chevrolet)
rear armrest assembly.
Pontiac convertibles are equipped with (U62-base)
sound system which includes two door coax speakers and
two "B" pillar coax speakers. Pontiac convertibles also ( •OIAl
=j
.... 00 ~~
(C!KD
~~
can be equipped with (UW6-uplevel), a sound system
which includes two door high-sensitivity speakers, two
! llt-8.B
~-'.0\ ~~·:!•!:'f!~::...
door dome tweeters and two "B" pillar coax speakers.
ullll,. G!~
TUNU0FADE
~
~~ GJ mm m w me u....
RADIO FIXED ANTENNA ASSEMBLY
In-N. CIII• RDM REV FWD 11:AM PREV 1111 I
The fixed antenna assembly is designed to provide
good radio omni-directional reception in moderate fringe \... AM·FM .a.
,E. ·D ,
areas.

RADIO ASSEMBLIES PC1003-9A·F·RP

All 2000 (Chevrolet) and 2001 (Pontiac) series radio Figure 3 - UH Radio - (Chevrolet}
assemblies feature ETR tuning, vacuum fluorescent dis-
play, AM-FM stereo, seek and scan tuning, and digital
clock display. Eight radio assemblies are available.

~ G8
Chevrolet
Figures 1 through 4
[)LA ~oLOBAL
~ [[RcLI] .GJ8 i~rn=,~~!,~ \, L .................... , \

POWER fi Cll!lEEiJ
• AM/FM Stereo/Cassette (UN6) with dynamic noise
reduction and Automatic Program Search. ~AT~DE ~L COMP ADM RIV FWD ICAN PAIV NIXT I
• Delco®-GM/Bose® Music System with Cassette ~ 0CD00GJC!J~[-..
AM-FM.a.
110 u
Tape Player (UU8), dynamic noise reduction and
Automatic Program Search.
• Delco®-GM/Bose® Music System with Compact RC1001·9A·F·RP
Disc Player (UlT) and Delco®-Loc II.
Figure 4 - U1 C Radio - (Chevrolet Convertible}
• AM/FM Stereo/Compact Disc (U IC) with scan and
directional seek and Delco®-Loc II (convertible).
 AUDIO SYSTEMS 9A·3

Pontiac
Figures 5 through 8
AUTO
REVERSE \ ~
:\\!!
• AM/FM Stereo/Cassette (UN6) with Theftlock. \\ EJECT
• AM/FM Stereo/Cassette Equalizer (UT6) with
Steering Wheel Radio Controls with Theftlock.
-BASS-
• AM/FM Stereo/Compact Disc Player (U 1C) with TUNE ( g,
VOLUMDD
Theft lock.
0
BAL FADE

• AM/FM Stereo/Compact Disc/Equalizer (UP3) with POWER

PUSN
( THU'TI.OCK Q)
~~00
Steering Wheel Radio Controls.
All Pontiac radios are equipped with dual directional
seek and Dolby®. RC2002·9A·F-RP

Pontiac Firebird models have a new family of radio Figure 5 - UN6 Radio - (Pontiac)
assemblies (2001 series) available featuring new styling
(flush front design) and steering wheel controls on up-
level radios. Some assemblies are available with or with-
out a graphic equalizer. [6§:) PONTIAC
( TAPE/PLAY
The Pontiac optional audio system (UT6 and UP3) 10.n n
11.rO.O
uses ten speakers and an amplifier: four speaker assem- FM1 ST

blies mounted in the front side doors, two speaker assem-

blies in the rear sail panel and four speaker assemblies in
the rear compartment trim panel assembly. The amplifier
AM/FM

VO LUM o ·
RECALL

TUNE @~@~~@ij
is under the right rear armrest assembly.

FM Stereo
POWER 0
I THl'FTlOC,C 01 OOao
All factory-equipped sound systems with an FM
RC2003-9A·F-RP
stereo radio assembly will switch to stereo operation
whenever an FM stereo broadcast is being received, and Figure 6 - UT6 Radio - (Pontiac)
an indicator in the dial will light. Stereo operation means
the radio is separating a stereo broadcast back into the
original two channels, called "left" and "right." Stereo
sound is noticeably more realistic to the ear. (]i§] s:>ONTIAC
Although FM is normally static-free, reception can
be limited by terrain, atmospheric conditions, station 11.1·!..1.u
Ii.I-OU
FM1 ST
~
-.
-
( CO/PLAY II .f!HJECT)
SEEK
strength and distance from the transmitter. Buildings or -TREBLE-~

other obstructions can cause momentary static, flutter or c;;;;;T~ :;-: I• I I

station swapping. If reception is poor, tuning to a stronger BAL FADE

station will bring improvement.
00 ((DU)
AMAX Stereo Certification
All optional radio assemblies are AMAX ce1tified.
These receivers can reproduce the fidelity sound now RC2004-9A·F-RP

transmitted by all AM stations but not received on all AM Figure 7 - U1 C Radio - (Pontiac)
radio assemblies.
Some improvements are high fidelity, adjustable
receiver band width (wide for high fidelity or narrow to
cut out any interference), noise cancellation, full stereo
(]i!ii] PONTIAC
sound, new frequencies received and external antenna
assembly capability. ( CO/PLAY ~ ) ~EJECT)

The range of most AM stations is greater than FM,

especially at night. The longer range, however, can cause
stations to interfere with each other. AM is also subject to

0
VOLUMOE
BAL FADE
noise pick-up from storms, power lines, etc. AMAX
certification reduces many of these problems. POWER

"''" I THEFTLOCI< 01
0)000
RADIO ASSEMBLY CONTROLS
When the radio assembly is first turned on, the fre- RC2005-9A·F-RP

quency will appear on the display for five seconds, and Figure 8 - UP3 Radio - (Pontiac)
then the display will return to the time display. To recall
the frequency, simply push in the upper knob or the
9A-4 AUDIO SYSTEMS
"RCL" button while the radio assembly is turned on. The
frequency will appear on the display for five seconds.
When the ignition lock cylinder is in the "LOCK" or
"OFF" position, the radio display is blank. To display the
time when the ignition lock cylinder is in the "OFF" or
"LOCK" position, simply push the upper knob or the
"RCL" button.. The time will display for five seconds.
Then the display will turn blank.
ETR AM/FM STEREO/CASSETIE (UN6)
Chevrolet
Figure 1
Radio Assembly Operation
Upper Knob
This knob turns the radio assembly on and off.
Rotate knob to control volume. The control ring behind
the knob is the balance control.
Turn the ring clockwise to move speakei· balance to
the right and counterclockwise to move speaker balance
to the 1eft. Press the knob to select the other side of the
tape when playing a cassette.
Lower Knob
Turn the knob to manually select radio stations.
When the radio assembly is on and the tape player is off,
press the knob to choose either the AM or the FM band.
The control ring behind the lower knob fades the
sound between the front and rear speaker assemblies.
Bass and Treble Controls
Slide the "TREB" lever up to increase treble and
down to decrease treble. Slide the "BASS" lever up to
increase bass and down to decrease bass.
If a station is weak and noisy, move the "TREB"
lever down to reduce the noise.
Push Buttons
To preset four AM stations and four FM stations:
I. Tune in desired station.
2. Press "SET." Within five seconds, press a station
button.
To preset three additional AM stations and three
additional FM stati. ons:
l. Tune in desired station.
2. Press "SET." Within five seconds, press any two
adjacent buttons simultaneously.
The radio will tune to the preselected station when
the push button or button pair is pressed.
Button pairing allows for seven AM and seven FM
stations to be preset for a total of fourteen preset stations.
If electrical power is interrupted by a blown fuse or a
discharged battery, the stations must be reset.
Clock
To set the clock display on a 2000 series radio
assembly, the ignition lock cylinder must be in the
"ACCESSORY" or "RUN" position and the radio
assembly must be off. To set the clock:
I. Push "SET."
2. Within five seconds, push and hold "SEEK T"
until the correct hour appears.
3. Then press and hold "SEEK A," until the correct
minute appears.
Seek and Scan Feature
The 2000 series radio assemblies have "SEEK" and
"SCAN" features for electronic station tuning up and
down the band.
Push the "SEEK A, or T " and the radio will tune to
next higher or lower station with enough signal strength to
be heard clearly, and stay there.
"SCAN" is a two-button sequence. To "SCAN" to
the next higher station, press "SEEK A." and hold it there
while you press "SEEK T-" To "SCAN" to the next
lower station, press "SEEK T " and hold it there while
you press "SEEK A, . " The radio will move to the next
strong station. It will pause there a few seconds, then
move to the next strong station. When the radio reaches
the end of the band, it will return to the other end of the
band and continue to "SCAN." This will continue until
the "SCAN" mode is terminated. To terminate the
"SCAN" mode, press both buttons again or press the
upper knob.
Cassette Tape Player
To play a tape, the ignition lock cylinder must be
in the "ACCESSORY" or "RUN" position and the
receiver/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cas-
sette first. When the tape is fully inserted, the radio will
turn off and the tape will begin playing.
To advance the tape, press the " ..,.,, (forward)
button. To reverse the tape, press the " ..... " (reverse)
button. To resume tape play from fast forward or reverse,
press the "STOP-EJECT" button lightly. When the tape
reaches the end of a side, it will automatically reverse and
play the other side of the tape. To resume listening to the
radio or to eject the tape, push the "STOP-EJECT"
button.
The cassette player is turned off by ejecting the tape,
turning the power knob (upper knob) or rotating the igni-
tion lock cylinder to "LOCK," "OFF" or "START."
When this occurs, the tape player will either eject the
cassette automatically or the internal tape drive and roller
will retract automatically. This is to protect the tape player
and cassette tape.
For the best operation of the cassette player do
not use cassette tapes longer than 60 minutes per side.

Tape Direction Indicators
The direction the tape is being played is indicated by
indicator arrows. When the indicator arrow on the left side
is on, the tape direction is to the left. When the indicator
arrow on the right side is on, the tape direction is to the
right.
Reversing Sides
Press the upper knob to play the other side of the
tape. When the end of tape is reached, it automatically
reverses direction and plays the other side.
"APS" (Automatic Program Search)
PL1sh "APS" to go to the beginning of a new selec-
tion.
To go forward to the beginning of the next selection,
push" ...... " To go back to the beginning of the current
selection, push " ...... " Push " ..... " again to go to the begin-
ning of the previous selection.
Tape Eject Button
Press "STOP-EJECT" to eject tape or stop tape and
switch to radio.
DELCO®-GM/BOSE® MUSIC
SYSTEM/CASSETTE (UU8)
Chevrolet
Figure 2
Radio Assembly Operation
Upper Knob
This knob turns the radio assembly on and off.
Rotate knob to control volume. Press the knob to select
the other side of the tape when playing a cassette.
Lower Knob
Turn the knob to manually select radio stations.
When the radio assembly is on and the tape player is off,
press the knob to choose either the AM or the FM band.
The control ring behind the lower knob fades the
sound between the front and rear speaker assemblies.
Bass and Treble Controls
Slide the "TREB" lever up to increase treble and
down to decrease treble. Slide the "BASS" lever up to
increase bass .and down to decrease bass.
If a station is weak and noisy, move the "TREB"
lever down to reduce the noise.
Balance
The speaker assemblies are electronically balanced
on the Delco®-GM/Bose® Music System.
Push Buttons
To preset four AM stations and four FM stations:
1. Tune in desired station.
2. Press "SET." Within five seconds, press a station
button.
AUDIO SYSTEMS 9A·5
To preset three additional AM stations and three
additional FM stations:
I. Tune in desired station.
2. Press "SET." Within five seconds, press any two
adjacent buttons simultaneously.
The radio will tune to the preselected station when
the push button or button pair is pressed.
Button pairing allows for seven AM and seven FM
stations to be preset for a total of fourteen preset stations.
If electrical power is interrupted by a blown fuse or a
discharged battery, the stations must be reset.
Clock
To set the clock display on a 2000 series radio
assembly, the ignition lock cylinder must be in the
"ACCESSORY" or "RUN" position and the radio
assembly must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK T"
until the correct hour appears.
3. Then press and hold "SEEK.._,, until the correct
minute appears.
Seek and Scan Feature
The 2000 series radio assemblies have "SEEK" and
"SCAN" features for electronic station tuning up and
down the band.
Push the "SEEK .._ or T " and the radio will tune to
next higher or lower station with enough signal strength to
be heard clearly, and stay there.
"SCAN" is a two-button sequence. To "SCAN" to
the next higher station, press "SEEK.._,, and hold it there
while you press "SEEK T," To "SCAN" to the next
lower station, press "SEEK T " and hold it there while
you press "SEEK .._ . " The radio will move to the next
strong station. It will pause there a few seconds, then
move to the next strong'station. When the radio reaches
the end of the band, it will return to the other end of the
band and continue to "SCAN." This will continue until
the "SCAN" mode is terminated. To terminate the
"SCAN" mode, press both buttons again or press the
upper knob.
Cassette Tape Player
To play a tape, the ignition lock cylinder must be
in the "ACCESSORY" or ''RUN" position and the
receiver/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cas-
sette first. When the tape is fully inserted, the radio will
turnoff and the tape will begin playing.
To advance the tape, press the " .,.,, (forward)
button. To reverse the tape, press the ....... " (reverse)
button. To resume tape play from fast forward or reverse,
press the "STOP-EJECT" button lightly. When the tape
reaches the end of a side, it will automatically reverse and
play the other side of the tape. To resume listening to the
radio or to eject the tape, push the "STOP-EJECT"
button.
The cassette player is turned off by ejecting the tape,
turning the power knob (upper knob) or rotating the igni-
tion lock cylinder to "LOCK," "OFF" or "START."
9A-6 AUDIO SYSTEMS
.When this occurs, the tape player will either eject the
cassette automatically or the internal tape drive and roller
will retract at1tomatically. This is to protect the tape player
and cassette tape.
For the best operation of the cassette player do
not use cassette tapes longer than 60 minutes per side.
Tape Direction Indicators
The direction the tape is being played is indicated by
indicator arrows. When the indicator arrow on the left side
is on, the tape direction is to the left. When the indicator
a1Tow on the right side is on, the tape direction is to the
right.
Reversing Sides
Press the upper knob to play the other side of the
tape. When the end of tape is reached, it automatically
reverses direction and plays the other side.
"APS" (Automatic Program Search)
Push "APS" to go to the beginning of a new selec-
tion.
To go forward to the beginning of the next selection,
push" ....... " To go back to the beginning of the current
selection, push " ..... " Push " .... " again to go to the begin-
ning of the previous selection.
Tape Eject Button
Press "STOP-EJECT" to eject tape or stop tape and
switch to radio.
Tape Equalization Button
Select the 70 µsec (chrome or metal) tape by
pressing "Cr02" button in, or 120 µsec (standard) by
leaving "Cr02" button out.
DELCO®-GM/BOSE® MUSIC
SYSTEM/COMPACT DISC (U1 T)
Chevrolet
Figure 3
Radio Assembly Operation
Upper Knob
This knob turns the radio assembly on and off.
Rotate knob to control volume. Press knob to silence the
sound. The control ring behind the knob is the balance
control. Turn the ring clockwise to move speaker balance
to the right and counterclockwise to move speaker bal-
ance to the left.
Lower Knob
Rotate knob to tune radio stations manually. Press
knob to alternately select AM or FM (FM 1 or FM2) band.
Rotate control behind lower knob to adjust the sound
between front and rear speaker assemblies.
Bass and Treble Controls
Push "BASS A" to hear more bass and "BASS T"
to hear less bass. ·
Push "TREB A" to hear more treble and "TREB
T" to hear less treble.
For the clearest sound, keep both of these adjusted
all the way up.
If a station is weak and noisy, push "TREB T" to
reduce the noise.
Push Buttons
To preset five AM stations, five FMI stations and
five FM2 stations, use the following procedure:
1. Tune in desired station.
2. Push "SET." Within five seconds, push one of the
five push buttons.
3. Repeat these steps for each push button.
Clock
To set the clock display, the ignition lock cylinder
must be in the "ACCESSORY" or "RUN" position and
the radio assembly must be off. To set the clock:
1. Push "SCAN."
2. Within five seconds, push and hold "SEEK .... "
until the correct hour appears.
3. Then push and hold ''SEEK ..,.,, until the correct
minute appears.
"SEEK"
Press "SEEK .,.... or .... " and the radio will tune to
the next higher or lower station with enough signal
strength to be heard clearly, and stay there.
"SCAN"
Push "SCAN" to hear each station for a few
seconds. To stop scanning, push "SCAN" again or the
upper knob.
Compact Disc Player
With the radio assembly on, insert disc into slot,
label side up (player pulls it in). "CD" will appear on the
display and track 1 will begin to play. If disc comes back
out and "ERR" appears on display, check to see if:
• Disc is upside down.
• Disc is dirty, scratched or wet.
• Too much moisture is in the air.
• Temperature is too hot or too cold.
"RCL" (Recall)
Press "RCL" to see current track number. Press
"RCL" again within five seconds to see time elapsed in
current track on the display.
"PREV" (Previous)
Press "PREY" to play track again. If held or pressed
more than once, the disc will return to previous track. If
"PREY'.' is pressed within eight seconds from start of
track, the disc will go to the beginning of the previous
track and begin to play. If "PREY" button is pressed after
eight seconds into the track, the· disc will go to the begin-
ning of the current track and begin to play.

"NEXT"
Press "NEXT" when you want to hear the next track
now (before the present track is finished). If "NEXT" is
held or pressed more than once, the disc will advance
farther.
"FWD" (Forward)
Press and hold "FWD" to quickly advance within a
track. Release it to resume playing.
"REV" (Reverse)
Press and hold "REV" to return quickly to a favorite
passage on the disc. Release it to resume playing.
"SCAN"
Press "SCAN" to listen to each track for about 10
seconds. To stop scanning, push "RDM" or "SCAN."
"RDM" (Random)
Press this button and the player chooses a random
order of tracks to play. When the final random track has
been played, the disc will play the same random selection
again. Press "RDM" again for a different selection of
tracks.
"COMP" (Compression)
Push "COMP" to make loud and soft passages more
nearly equal in volume.
"ST-PL" (Stop/Play)
Press "ST-PL" to stop disc from playing. The radio
will resume playing. "ST-PL" will also restart the disc.
The disc will resume playing at the point where it stopped.
"EJCT" (Eject)
Push "EJCT" to eject disc and resume radio play.
ETR AM/FM STEREO/COMPACT DISC
PLAYER(U1C)
Chevrolet Convertible
Figure4
Radio Assembly Operation
Upper Knob
This knob turns the radio assembly on and off.
Rotate knob to control volume. Press knob to silence the
sound. The control ring behind the knob is the balance
control. Turn the ring clockwise to move speaker balance
to the right and counterclockwise to move speaker .bal-
ance to the left.
Lower Knob
Rotate knob to tune radio stations manually. Press
knob to alternately select AM or FM (FM I or FM2) band.
Rotate control behind lower knob to adjust the sound
between front and rear speaker assemblies.
AUDIO SYSTEMS 9A·7
Bass and Treble Controls
Push "BASS A" to hear more bass and "BASS T"
to hear less bass.
Push "TREB A" to hear more treble and "TREB
T" to hear less treble.
For the clearest sound, keep both of these adjusted
all the way up.
If a station is weak and noisy, push "TREB T" to
reduce the noise.
Push Buttons
To preset five AM stations, five FMI stations and
five FM2 stations, use the following procedure:
1. Tune in desired station.
2. Push "SET." Within five seconds, push one of the
five push buttons.
3. Repeat these steps for each push button.
Clock
To set the clock display, the ignition lock cylinder
must be in the "ACCESSORY" or "RUN" position and
the radio assembly must be off. To set the clock:
1. Push "SCAN."
2. Within five seconds, push and hold "SEEK • . until
the correct hour appears.
3. Then push and hold "SEEK ..,..,, until the correct
minute appears.
"SEEK"
Press "SEEK ..... or •• and the radio will tune to the
next higher or lower station with enough signal strength to
be heard clearly, and stay there.
"SCAN"
Push "SCAN" to hear each station for a few
seconds. To stop scanning, push "SCAN" again or .the
upper knob.
Compact Disc Player
With the radio assembly on, insert disc into slot,
label side up (player pulls it in). "CD" will appear on the
display and track 1 will begin to play. If disc comes back
out and "ERR" appears on display, check to see if:
• Disc is upside down.
• Disc is dirty, scratched or wet.
• Too much moisture is in the air.
• Temperature is too hot or too cold.
"RCL" (Recall)
Press "RCL" to see current track number. Press
"RCL" again within five seconds to see time elapsed in
current track on the display.
"PREY" (Previous)
Press the "PREY" to play track again. If held or
pressed more than once, the disc will return to previous
track. If "PREY" is pressed within eight.seconds from
start of track, the disc will go to the beginning of the pre-
vious track and begin to play. If "PREY" button is
9A·8 AUDIO SYSTEMS
pressed after eight seconds into the track, the disc will go
to the beginning of the current track and begin to play.
"NEXT"
Press "NEXT" when you want to hear the next track
now (before the present track is finished). If "NEXT" is
held or pressed more than once, the disc will advance far-
ther.
"FWD" (Forward}
Press and hold "FWD" to quickly advance within a
track. Release it to resume playing.
"REV" (Reverse}
Press and hold "REV" to return quickly to a favorite
passage on the disc. Release it to resume playing.
"SCAN".
Press "SCAN" to listen to each track for about 10
seconds. To stop scanning, push "RDM" or "SCAN."
"ROM" (Random)
Press this button and the player chooses a random
order to tracks to play. When the final random track has
been played, the disc will play the same random selection
again. Press "RDM" again for a different selection of
tracks.
"COMP" (Compression}
Push "COMP" to make loud and soft passages more
equal in volume.
"ST-PL" (Stop/Play)
Press "ST-PL" to stop disc from playing. The radio
will resume playing. "ST-PL" will also restart the disc.
The disc will resume playing at the point where it stopped.
"EJCT" (Eject}
Push "EJCT" to eject disc and resume radio play.
ETR AM/FM STEREO/CASSETTE TAPE
PLAYER (UNG)
Pontiac
Figure 5
Radio Assembly Operation
Volume Knob
Push the "VOLUME" knob to turn the radio on or
off. Rotate the knob to adjust sound.
"AM/FM"
Press "AM/FM" to receive either AM/FM! or
FM2. The lighted display shows the selection.
Tune Knob
Press the "TUNE" knob to release the knob. Turn
the knob to choose desired radio stations. Push the
"TUNE" knob back in to store it when not in use.
"RECALL"
Press "RECALL" to recall the station being played
or the clock display. Press "RECALL" also to display the
time when the ignition is off.
"SEEK"
Press "SEEK T" or"•" and the radio will tune to
the next lower or higher station and stay there.
Bass and Treble Controls
Slide the "TREBLE" lever to the right to incr~ase
treble and to the left to decrease treble. Slide the "BASS"
lever to the right to increase bass and to the left to decrease
bass.
If a station is weak and noisy, move the "TREBLE"
lever to the left to reduce the noise.
AMAX Stereo Certification
With an AMAX-certified receiver, the radio can pro-
duce quality AM sound comparable to FM stereo. AMAX
reduces noise without reducing the high frequencies
needed for the best sound. In addition to improved sound
quality, AMAX includes more stations on the AM band.
You don't have to do anything to a Delco® GM radio
because AMAX is automatic.
Clock
To set the clock display on the radio assembly, the
ignition may be off. To set the clock:
1. Press and hold "HR" (hour) until the correct hour
appears.
2. Press and hold "MIN" (minute) until the correct
minute appears.
There will be a two-second delay before the clock
goes into the time-set mode.
Push Buttons
To preset six AM stations and six FMl stations or six
FM2 stations:
1. Tune in desired station.
2. Press and hold one of the six push buttons until the
display shows "SET." Whenever pressing that but-
ton, the preset station will return.
Repeat these steps for each push button.
Speaker Adjustment
Balance Knob: Press "BAL" knob to release knob.
Turn the knob to move the sound between the right and
left speakers. Push "BAL" knob back in to store it when
not adjusting.
Fade Knob: Press "FADE" knob to release the
knob. Turn the knob to move the sound between the front
and rear speakers. Push "FADE" knob back in to store it
when not adjusting.
Cassette Tape Player
The tape player is built to work best with tapes that
are 30 minutes long on each side. Tapes longer than that
are so thin they may not work well in this player.
To play a tape, the ignition lock cylinder must be in
the "ACCESSORY" or "RUN" position and the receiv-

er/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cas-
sette first. If you hear nothing or hear just garbled sound, it
may not be in squarely. Press "EJECT" to remove the
tape and start over. A cassette symbol will appear in the
upper left hand corner of the display whenever a tape is
inserted. When the tape is fully inserted, the radio will
turn off and the tape will begin playing.
Once the tape is playing, use "VOLUME," "BAL,"
"FADE," "TREBLE" and "BASS" just as for the radio.
The arrow shows which side of the tape is playing.
To rapidly advance the tape, press "FWD" (for-
ward). Press "PROG" (program) or "REV" (reverse) to
stop this process. The radio will play during this opera-
tion. To rapidly reverse the tape, press "REV" (reverse).
Press "PROG" (program) or "REV" (reverse) again to
stop this process. The radio will play during this opera-
tion.
To play the next selection, press "NEXT" or
"SEEK A" (instead of waiting until the current selection
is finished). For "NEXT" to work properly, your tape
must have at least three seconds of silence between each
selection. The radio will not play during this operation.
To replay the current selection, press "PREY" or
"SEEK T." For "PREY" to work properly, your tape
must have at least three seconds of silence between each
selection. The radio will not play during this operation.
To switch from one side of the tape to the other or to
stop the tape from searching, press the "PROG" (pro-
gram) knob.
To reduce tape noise, press [Dolby®] symbol. This
symbol will appear in the display.
To stop the tape player do any of the following:
• Turn the power off or turn the ignition key off. The
cassette stays in the player and will resume playing
at the point where it stopped.
• Press AM/FM to stop playing the cassette and
switch to radio. Press "TAPE/PLAY" to restart the
cassette at the point where it stopped.
• Press "EJECT" to remove the cassette or stop the
cassette and switch to radio. "EJECT" will work
with the ignition on or off.
ETA AM/FM STEREO/CASSETTE TAPE
PLAYER WITH GRAPHIC EQUALIZER (UT6)
Pontiac
Figure 5
Radio Assembly Operation
Volume Knob
Push the "VOLUME" knob to turn the radio on or
off. Rotate the knob to adjust sound.
"AM/FM"
Press "AM/FM" to receive either AM/FM I or
FM2. The lighted display shows the selection.
AUDIO SYSTEMS 9A·9
Tune Knob
Press the "TUNE" knob to release the knob. Turn
the knob to choose desired radio stations. Push the
"TUNE" knob back in to store it when not in use.
"RECALL"
Press "RECALL" to recall the station being played
or the clock display. Press "RECALL" also to display the
time when the ignition is off.
"SEEK"
Press "SEEK T" or "A" and the radio will tune to
the next lower or higher station and stay there.
AMAX Stereo Certification
With an AMAX-certified receiver, the radio can pro-
duce quality AM sound comparable to FM stereo. AMAX
reduces noise without reducing the high frequencies
needed for the best sound. In addition to improved sound
quality, AMAX includes more stations on the AM band.
You don't have to do anything to a Delco® GM radio
because AMAX is automatic.
Clock
To set the clock display on the radio assembly, the
ignition may be off. To set the clock:
1. Press and hold "HR" (hour) until the correct hour
appears.
2. Press and hold "MIN" (minute) until the correct
minute appears.
There will be a two-second delay before the clock
goes into the time-set mode.
Push Buttons
To preset six AM stations and six FM l stations or six
FM2 stations:
I. Tune in desired station.
2. Press and hold one of the six push buttons until the
display shows "SET." Whenever pressing that but-
ton, the preset station will return.
Repeat these steps for each push button.
Speaker Adjustment
Balance Knob: Press "BAL" knob to release the
knob. Turn the knob to move the sound between the right
and left speakers. Push "BAL" knob back in to store it
when not adjusting.
Fade Knob: Press "FADE" knob to release the
knob. Turn the knob to move the sound between the front
and rear speakers. Push "FADE" knob back in to store it
when not adjusting.
Steering Wheel Controls
Vehicles equipped with this radio have steering
wheel controls for the audio system. With steering wheel
controls, use the buttons on the steering wheel to:
1. Turn the radio on or off.
2. Adjust the volume.
3. Choose AM, FMl or FM2.
4. Use the "SEEK" and "RECALL" functions.
9A·10 AUDIO SYSTEMS
5. Choose one of the preset stations.
Setting the Graphic Equalizer
Use the levers to set the bass, midrange and treble
unti I you get the sound you want. The 40, 100, 250 and
625 levers adjust the bass; I .6K is midrange, and 4K and
I 2K control the treble. The l .6K lever may be set in the
middle position and then the other levers may be moved
up or down until a satisfactory amount of bass and treble
is achieved.
Cassette Tape Player
The tape player is built to work best with tapes that
are 30 to 45 minutes long on each side. Tapes longer than
that are so thin they may not work well in this player.
To play a tape, the ignition lock cylinder must be in
the "ACCESSORY" or "RUN" position and the receiv-
er/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cas-
sette first. If you hear nothing or hear just garbled sound, it
may not be in squarely. Press "EJECT" to remove the
tape and start over. A cassette symbol will appear in the
upper left hand corner of the display whenever a tape is
inserted. When the tape is fully inserted, the radio will
turn off and the tape will begin playing.
Once the tape is playing, use "VOLUME," "BAL,"
"FADE," "TREBLE" and "BASS" just as for the radio.
The arrow shows which side of the tape is playing.
To rapidly advance the tape, press "FWD" (for-
ward). Press "PROG" (program) or "REV" (reverse) to
stop this process. The radio will play during this opera-
tion. To rapidly reverse the tape, press "REV" (reverse).
Press "PROG" (program) or "REV" (reverse) again to
stop this process. The radio will play during this opera-
tion.
To play the next selection, press "NEXT" or
"SEEK •" (instead of waiting until the current selection
is finished). For "NEXT" to work properly, your tape
must have at least three seconds of silence between each
selection. The radio will not play during this operation.
To replay the current selection, press "PREY" or
"SEEK T." For "PREY" to work properly, your tape
must have at least three seconds of silence between each
selection. The radio will not play during this operation.
To switch from one side of the tape to the other or to
stop the tape from searching press the "PROG" (pro-
gram) knob.
To reduce tape noise, press [Dolby®] symbol. This
symbol will appear in the display.
To stop the tape player do any of the following:
• Turn the power off or turn the ignition key off. The
cassette stays in the player and will resume playing
at the point where it stopped.
• Press AM/FM to stop playing the cassette and
switch to radio. Press "TAPE/PLAY" to restart the
cassette at the point where it stopped.
• Press "EJECT" to remove the cassette or stop the
cassette and switch to radio. "EJECT" will work
with the ignition or radio off.
ETR AM/FM STEREO/COMPACT DISC
PLAYER (U1C)
Pontiac
Figure 7
Radio Assembly Operation
Volume Knob
Push the "VOLUME" knob to turn the radio on or
off. Rotate the knob to adjust sound.
"AM/FM"
Press "AM/FM" to receive either AM/FMl or
FM2. The lighted display shows the selection.
Tune Knob
Press the "TUNE" knob to release the knob. Turn
the knob to choose desired radio stations. Push the
"TUNE" knob back in to store it when not in use.
"RECALL"
Press "RECALL" to recall the station being played
or the clock display. Press "RECALL" also to display the
time when the ignition is off.
"SEEK"
Press "SEEK T" or "•" and the radio will tune to
the next lower or higher station and stay there.
AMAX Stereo Certification
With an AMAX-certified receiver, the radio can pro-
duce quality AM sound comparable to FM stereo. AMAX
reduces noise without reducing the high frequencies
needed for the best sound. In addition to improved sound
quality, AMAX includes more stations on the AM band.
You don't have to do anything to a Delco® GM radio
because AMAX is automatic.
Bass and Treble Controls
Slide the "TREBLE" lever to the right to increase
treble and to the left to decrease treble. Slide the "BASS"
lever to the right to increase bass and to the left to decrease
bass.
If a station is weak and noisy, move the "TREBLE"
lever to the left to reduce the noise.
Clock
To set the clock display on the radio assembly, the
ignition may be off. To set the clock:
I. Press and hold "HR" (hour) until the correct hour
appears.
2. Press and hold "MIN" (minute) until the correct
minute appears.
There will be a two-second delay before the clock
goes into the time-set mode.
Push Buttons
To preset six AM stations and six FM 1 stations or six
FM2 stations:
1. Tune in desired station.

2. Press and hold one of the six push buttons until dis-
play shows "SET." Whenever pressing that button,
the preset station will return.
Repeat these steps for each push button.
Speaker Adjustment
Balance Knob: Press "BAL" knob to release the
knob. Turn the knob to move the sound between the right
and left speakers. Push "BAL" knob back in to store it
when not adjusting. · • Turn the power off or turn the ignition key off. The
Fade Knob: Press "FADE" knob to release the
knob. Turn the knob to move the sound between the front
and rear speakers. Push "FADE" knob back in to store it
when not adjusting.
Compact Disc Player
With the radio assembly on, insert the disc into the
slot, label side up (player pulls it in). "CD" will appear on
the display and track I will begin to play. If the disc comes
back out and "ERR" appears on display, check to see if:
• Disc is upside down.
• Disc is dirty, scratched or wet.
• Too much moisture is in the air.
• Temperature is too hot or too cold.
"RECALL"
Press "RECALL" to see current track number. Press
"RECALL" again within five seconds to see time elapsed
in current track on the display. The track number also
appears when the disc is inserted.
"PREV" {Previous)
Press "PREY" to play track again. If held or pressed
more than once, the disc will return to previous track. If
"PREY" is pressed within eight seconds from start of
track, the disc will go to the beginning of the previous
track and begin to play. If "PREY" button is pressed after
eight seconds into the track, the disc will go to the begin-
ning of the current track and begin to play.
To Play Next Selection
Press "NEXT" or "SEEK A" when you want to
hear the next track now (before the present track is fin-
ished). If "NEXT" or "SEEK A" is held or pressed more
than once, the disc will advance farther.
To Replay Current Selection
Press "PREY" or "SEEK T" to play a track again.
If you press and hold these buttons or press more than
once, the disc will return to previous tracks.
"FWD" {Forward)
Press and hold "FWD" to advance quickly within a
track. Release it to resume playing. The radio will play
during this operation.
"REV" {Reverse)
Push "REV" and hold it to return quickly to a favor-
ite passage on the disc. Release it to resume playing.
AUDIO SYSTEMS 9A·11
"ROM" {Random)
Press this button and the player chooses a random
order of tracks to play. When the final random track has
been played, the disc will play the same random selection
again. Press "RDM" again for a different selection of
tracks.
To Stop Disc Player
Any of the following steps will stop the disc player:
disc stays in the player and will resume playing at
the point where it stopped.
• Press "AM/FM" to stop playing the disc and switch
to the radio. Press "CD/PLAY" to restart the disc at
the point where it stopped.
• Press "EJECT" to eject the disc or stop the disc and
switch to radio. "EJECT" will work with the igni-
tion or radio off.
ETR AM/FM STEREO/COMPACT DISC
PLAYER WITH GRAPHIC EQUALIZER (UP3)
Pontiac
Figure 8
Radio Assembly Operation
Volume Knob
Push the "VOLUME" knob to turn the radio on or
off. Rotate the knob to adjust sound.
"AM/FM"
Press "AM/FM" to receive either AM/FMl or
FM2. The lighted display shows the selection.
Tune Knob
Press the "TUNE" knob to release the knob. Tum
the knob to choose desired radio stations. Push the
"TUNE" knob back in to store it when not in use.
"RECALL"
Press "RECALL" to recall the station being played
or the clock display. Press "RECALL" also to display the
time when the ignition is off.
"SEEK"
Press "SEEK T" or "A" and the radio will tune to
the next lower or higher station and stay there.
AMAX Stereo Certification
With an AMAX-certified receiver, the radio can pro-
duce quality AM sound comparable to FM stereo. AMAX
reduces noise without reducing the high frequencies
needed for the best sound. In addition to improved sound
quality, AMAX includes more stations on the AM band.
You don't have to do anything to a Delco® GM radio
because AMAX is automatic.
Clock
To set the clock display on the radio assembly, the
ignition may be off. To set the clock:
:9A·12 AUDIOSYSTEMS
1. Press and hold "HR" (hour) until the correct hour
appears.
2. Press and hold "MIN" (minute) until the correct
minute appears.
There will be a two-second delay before the clock
goes into the time-set mode.
Push Buttons
To preset six AM stations and six FM I stations or six
FM2 stations:
I. Tune in desired station.
2. Press and h9ld one of the six push buttons until dis-
play shows "SET." Whenever pressing that button,
the preset station will return.
Repeat t.hese steps for each push button.
Speaker Adjustment
Balance Knob: Press "BAL" knob to release the
knob. Tuni the knob to move the sound between the right
and left speakers. Push "BAL'' knob back in to store it
when not adjusting.
Fade Knob: Press "FADE" knob to release the
knob. Turn the knob to move the sound between the front
and rear speakers. Push "FADE" knob back in to store it
when not adjusting.
Steering Wheel Controls
Vehicles equipped with this radio have steering
wheel controls for the audio system. With steering wheel
controls, use the buttons on the steering wheel to:
I. Turn the radio on or off.
2. Adjust the volume.
3. Choose AM, FM! or FM2.
4. Use the "SEEK" and "RECALL" functions.
5. Choose one of the preset stations.
Setting the Graphic Equalizer
Use the levers to set the bass, midrange and treble
until you get the sound you want. The 40, 100, 250 and
625 levers adjust the bass; 1.6K is midrange, and 4K and
12K control the treble. The 1.6K lever may be set in the
middle position and then the other levers may be moved
up or down until a satisfactory amount of bass and treble
is achieved.
Compact Disc Player
With the radio assembly on, insert the disc into the
slot, label side up (player pulls it in). "CD" will appear on
the display and track 1 will begin to play. If the disc comes
back out and "ERR" appears on display, check to see if:
• Disc is upside down.
• Disc is dirty, scratched or wet.
• Too much moisture is in the air.
• Temperature is too hot or too cold.
"RECALL"
Press "RECALL" to see current track number. Press
"RECALL" again within five seconds to see time elapsed
in current track on the display. The track number also
appears when the disc is inserted.
"PREV" (Previous)
Press "PREY" to play track again. If held or pressed
more than once, the disc will return to previous track. If
"PREY" is pressed within eight seconds from start of
track, the disc will go to the beginning of the previous
ti:ack and begin to play. If "PREY" button is pressed after
e1.ght seconds into the track, the disc will go to the begin-
ning of the current track and begin to play.
To Play Next Selection
Press "NEXT" or "SEEK A" when you want to
hear the next track now (before the present track is fin-
ished). If "NEXT" or" SEEK A" is held or pressed more
than once, the disc will advance farther.
To Replay Current Selection
Press "PREY" or "SEEK T" to play a track again.
If you press and hold these buttons or press more than
once, the disc will return to previous tracks.
"FWD" (Forward)
Press and hold "FWD" to advance quickly within a
track. Release it to resume playing. The radio will play
during this operation.
"REV" (Reverse)
. Push "REV" and hold it to return quickly to a favor-
ite passage on the disc. Release it to resume playing.
"RDM" (Random)
Press this button and the player chooses a random
order of tracks to play. When the final ranpom track has
been played, the disc will play the same random selection
again. Press "RDM" again for a different selection of
tracks.
To Stop Disc Player
Any of the following steps will stop the disc player:
• Turn the power off or turn the ignition key off. The
disc stays in the player and will resume playing at
the point where it stopped.
• Press "AM/FM" to stop playing the disc and switch
to the radio. Press "CD/PLAY" to restart the disc at
the point where it stopped.
• Press "EJECT" to eject the disc or stop the disc and
switch to radio. "EJECT" will work with the igni-
tion or radio off. Press "EJECT" to load a disc when
the radio is off.
SETIING RADIO ANTI-THEFT FEATURE
Delco®-Loc II and Theftlock is a security feature
which can be used or ignored. If ignored, the radio assem-
bly will play normally. If used, the radio assembly will be
useless if stolen because it won't turn on.
This is how to enter a secret code into the radio
assembly. If battery power is lost for any reason, the secret
code must be entered again before the radio assembly will
turn on.

Delco®-Loc II
Chevrolet
I. Write down any 6-digit number and keep in safe
place.
2. Turn ignition to "ACCESSORY" or "RUN" posi-
tion.
3. Turn the volume control knob to the left to tum radio
assembly off.
4. Press buttons "1" and "4" together and hold until
" --- " shows on display.
5. Do not wait more than 15 seconds between each
step.
6. Press "SET" and "000" appears on the display.
7. Press "SCAN" and hold until first digit of code
appears.
8. Press "SEEK .... or ..,.. .. to make second and third
digits appear.
9. Press the lower knob (tune knob) ("000" appears).
I 0. Press "SCAN" and hold until fourth digit of code
appears.
11. Press "SEEK .... or ..,..,, to make last two digits of
code appear.
12. Press the lower knob (tune knob) ("rEP" appears
for 5 seconds, then "000" appears).
13. For verification, repeat steps 7 through 11. Next,
press the lower knob (tune knob). "SEC" will then
be seen on display, meaning radio assembly is
secured. If the display shows "--- ", the verification
steps were not successful and the entire sequence
must be repeated from step 6.
Theftlock
Pontiac
The instructions below explain how to enter a secu-
rity code into the system. If the vehicle loses battery
power for any reason, the security code must be entered
again before the system will turn on.
I. Write down any number from 000 to 1999 and keep
it in a safe place.
2. Turn ignition switch to the "ACCESSORY" or
"RUN" position.
3. Turn audio system off.
4. Press and hold pushbuttons "1" and "4" together
until "---" shows on the display..
You are now ready to enter the security code, paus-
ing no more than 15 seconds between steps.
5. Press "MIN" and "000" will appear on the display.
6. Press "MIN" again and hold until the last two digits
of the code appear. Release button.
7. Press "HR" until the first one or two digits of the
code appear.
8. Press "AM/FM;" "rEP" will appear on the display.
9. Repeat steps 5 through 7.
AUDIO SYSTEMS 9A·13
I 0. Press "AM/FM," "SEC" will appear on the dis-
play. This means that the audio system is secured.
The indicator light will also flash when the ignition
is off. If the display shows " --- ", the verification steps
were not successful and the entire sequence must be done
over.
UNLOCKING SECURED RADIO ASSEMBLY
Theftlock
Pontiac
If the audio system is secured ("SEC" shows on the
display) and you wish to disable it, enter the security code
as follows, pausing no more than 15 seconds between
steps:
1. Turn ignition on. Make sure audio system is off. The
time will show on the display.
2. Press pushbuttons "1" and "4" together until
"SEC" shows on the display. ·
3. Press "MIN" and "000" will appear on the display.
4. Press "MIN" again and hold until the last two digits
of the code appear. Release the button.
5. Press "HR" until the first one or two digits appear.
6. Press "AM/FM." If"---" shows, you have shut off
the theft-deterrent feature. If "SEC" shows, the
audio system is still secured.
rn Important
• If the security code is lost or forgotten, contact the
dealer for assistance.
UNLOCKING SECURED RADIO ASSEMBLY
AFTER POWER LOSS
When battery power is reapplied to a secured radio
assembly, the radio assembly won't turn on and "LOC"
appears on the display. Enter the secret customer or fac-
tory backup code as follows (do not pause more than
15 seconds between steps):
Delco®-Loc II
Chevrolet
I. Turn ignition to "ACCESSORY" or "RUN" posi-
tion.
2. Press "SET" and "000" appears on display.
3. Press "SCAN" and hold until first digit of secret
code appears.
4. Press "SEEK or .,.,, to make second and third
-411111
digits of code appear.
5. Press the lower knob (tune knob) and "000" appears
on display.
6. Press "SCAN" and hold until fourth digit of secret
code appears.
7. Press "SEEK .... or ..,..,, to make fifth and sixth dig-
its of code appear.
8. Press the lower knob (tune knob). If the unlock
sequence was successful, the display will show the
"Time of Day (CLOCK)," indicating the radio is
9A-14 AUDIO SYSTEMS
operational and in the SECURED mode. If "LOC"
shows, the numbers did not match and the unit is still
locked. Repeat steps 2 through 8.
Theftlock
Pontiac
If power is disrupted to the audio system while in the
"SEC" mode, the unit will not work and "LOC" will
show on the display whenever the ignition is on. To
unlock the unit (with the ignition in "ACC" or "RUN"
position and radio off):
1. Press "MIN" and "000" will appear on the display.
2. Press "MIN" again and hold until last two digits 6f
the code appear. Release the button.
3. Press "HR" until the first one or two digits appear.
4. Press "AM/FM" and "SEC" will appear and the
unit will work. If "LOC" shows, the numbers did
not match and the unit is still locked.
DETERMINING FACTORY BACKUP
UNLOCKING CODE FOR SECURED RADIO
ASSEMBLY
If the security is activated and the radio assembly is
disconnected from battery power, the radio assembly will
display "LOC." The radio assembly will not turn on until
the correct unlocking code is entered. If the customer code
is lost or unavailable, use the following procedures to
determine the factory backup code. This procedure
requires a tone dialing telephone.
Delco®-Loc II
Chevrolet
I. Turn ignition to "ACCESSORY" or "RUN" posi-
tion.
2. Press and hold "COMP" and "ROM" (push but-
tons 2 and 3). After three seconds, digits I through 3
of radio identification number will be displayed.
Write them down.
3. Press lower knob (tune knob). Digits 4 through 6 of
radio identification number will be displayed. Write
them down.
4. Using tone dialing telephone, call 1-800-537-5140
(U.S. and Canada) or (317) 451-8965.
5. When computer advises, enter dealer code or radio
shop account number using telephone keypad, then
press "*".
6. When advised, enter six-digit radio identification
number obtained in steps 2 and 3, then press "*".
Computer will respond with unlocking code. Write
it down.
7. To unlock secured radio, refer to "Unlocking
Secured Radio Assembly after Power Loss" in this
section.
Theftlock
Pontiac
I. Turn ignition to "ACCESSORY" or "RUN" posi-
tion and turn radio off.
2. If the unit is in the locked condition ("LOC' is dis-
played), skip this step. Otherwise, depress preset
buttons I ("PREY") and 4 for five seconds. The dis-
play will show either " --- " ( unsecured state) or
"SEC" (secured state).
3. Depress preset buttons 2 ("NEXT") and 3 for five
seconds. Display will show first three digits of fac-
tory code. Write them down.
4. Depress "AM/FM" button. Display wiJI show
second three digits of factory code. Write them
down.
5. Depress "AM/FM" button. Unit will display either
"LOC," "SEC" or"---" dependiryg on state unit is
in. Unit will revert to initial display prior to code
retrieval sequence after 15 seconds or any operator
interaction.
6. Using tone dialing telephone, call 1-800-537-5140
(U.S. and Canada) or (317) 451-8965.
7. When computer advises, enter dealer code or radio
shop account number using telephone keypad, then
press "*".
8. When advised, enter six-digit radio identification
number obtained in steps 2 and 3, then press "*".
Computer will respond with unlocking code. Write
it down.
9. To unlock secured radio, refer to "Unlocking
Secured Radio Assembly after Power Loss" in this
section.
DIAGNOSIS
AUDIO SYSTEM DIAGNOSIS
For information on audio system diagnosis, refer to
SECTION 8A.
RADIO FIXED ANTENNA ASSEMBLY
DIAGNOSIS
Unplug antenna lead-in at back of radio assembly
and plug a test antenna into the radio assembly. Make sure
test antenna base is grounded to the vehicle chassis and
keep hands off of antenna. Check radio reception in an
area away from electrical interferences. These include taJI
buildings, metal structures, power lines, fluorescent light-
ing and power tools. Tune to high and low ends of the dial
on both AM and FM, checking weak and strong station
reception. If reception is OK, problem exists with antenna
assembly and/or its lead-in cable. If reception is still poor,
refer to SECTION 8A.
ON-VEHICLE SERVICE
TAPE PLAYER AND CASSETIE CARE
Tape Head and Capstan Cleaning
Figure 9
Two parts should be cleaned on the tape player, the
head and the capstan. Since they can be reachedthrough
the tape door, leave the tape player in the vehicle. This
service should be performed every l 00 hours of cassette
operation.
To clean the head and capstan, use a cotton swab
dipped in rubbing alcohol.
 AUDIO SYSTEMS 9A·15

A cassette cleaning kit may also be used to clean the Diagnostic Charts" in SECTION SA for determining
head and capstan. Follow instructions on the kit to clean locations.
the tape player.
Do not contact the tape head with magnetized tools. RADIO FIXED ANTENNA ASS EMBLY
If the head becomes magnetized, it will degrade every Figure 10
cassette played in the player.
Tool Required:
No service is performed on the cassettes. The cas-
sette manufacturer handles warranties of cassettes. The J 38536-A Antenna Bezel Socket
test cassette used by the dealer should be stored in its
container to keep the tape clean. Store cassette away from !++! Remove or Disconnect
extreme heat and direct sunlight. I. Using J 38536-A loosen nut (2).
COMPACT DISC CARE 2. Antenna base (3) from spare tire bracket.
3. Nut (2) and bezel (1).
Handle discs carefully. Store in protective case away
from sun, heat and dust. If surface is soiled, dampen a 4. Top of antenna base (3) from rear quarter panel
clean, soft cloth in a solution of mild neutral detergent and 5. Cable (4) from antenna base (3).
wipe clean. Mini discs called "singles" (about 3 inches in
diameter) will not eject and should not be used. !++! Install or Connect
CAUTION; If substituting an antenna or
RADIO ASSEMBLY cable, be sure to use a barbless-type
connector. Incorrect connectors may
Refer to SECTION 8C for removal and installation cause poor reception or damage to
procedures. connectors.
NOTICE: See "Notice" on page 9A-l of this
SPEAKER ASSEMBLIES
section.
For removal and installation of radio front side
1. Cable (4) into antenna base (3).
door speakers, refer to SECTION 10-6. For removal and
installation of rear speaker assemblies (including the Bose 2. Top of antenna base (3) into hole in rear quarter
amplifier), refer to SECTION 10-7. panel.
3. Bezel (1) to antenna base (3) and secure with nut (2)
[TI Important (finger tighten only).
• All Delco® sound systems have ungrounded speak- 4. Bottom of antenna base (3) into spare tire bracket.
ers. Installing add-on tape players, CBs or other units
which use the vehicle speakers may damage your !~! Tighten
Delco® sound system, and is not recommended. • Nut (2) to 3 N•m (34 lb. in.) using J 38536-A.
RADIO SUPPRESSION EQUIPMENT
When installing a new radio assembly, or when
noise is a problem, ensure that radio suppression equip-
ment is present and properly installed. Refer to "Noise

A PANEL, REAR QUARTER

B BRACKET, SPARE TIRE
USE NON-ABRASIVE
1 BEZEL, FIXED MAST ANTENNA
CLEANER. FOLLOW 2 NUT, FIXED MAST ANTENNA
DIRECTIONS IN 3 BASE, ANTENNA
PACKAGE. 4 CABLE, INSTRUMENT PANEL HARNESS
PC0001-9A-F-RP
G20003-9A
Figure 10 - Antenna Mounting
Figure 9 - Cleaning Cassette Player
9A·16 AUDIO SYSTEMS

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Radio Antenna Nut ................................................... 3 N•m (34 lb. in.)

SPECIAL TOOLS

1.

J 38536-A

1. ANTENNA BEZEL SOCKET

PC0002-9A-F-RP
 CRUISE CONTROL 98·1

SECTION 98

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

CONTENTS
General Description ......•................. 9B-l Engagement Switch ..................... 9B.:14
Cruise Control Module Assembly . . . . . . . . . . . 9B-l Cruise Control Module Assembly .......... 9B-14
Cruise Control Switch Assemblies .......... 9B-1 Cruise Control Cable Assembly ........... 9B-16
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-2 . Cable Assembly Replacement (Standard) .. 9B-16
Vehicle Speed Sensor (VSS) Assembly ..... 9B-2 Cable Assembly Replacement (Optional) . . 9B-17
Functional Control Switches . . . . . . . . . . . . . . . 9B-2 Cable Assembly Adjustment (Standard) ... 9B-18
Off-On-Resume/Accelerate Switch ...... : . 9B-2 Cable Assembly.Adjustment (Optional) ... 98-18
Set/Coast Button Switch ................ 9B-2 Specifications ............................ 913-18
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-4 Fastener Tightening Specification . . . . . . . . . . 9B-18
On-Vehicle Service .................. , . . . . 9B-13 Special Tools ............................ 9B.:18
Cruise Control Switch Assemblies . . . . . . . . . 9B-13

GENERAL DESCRIPTION pedal is depressed, the cruise control system is electrically

Cruise control is a speed control system that main-
tains a desired vehicle speed under normal driving condi-
tions. However, steep grades up or down may cause
variations in the selected speeds. The electronic cruise
control system has the capability to cruise, coast, resume
speed, accelerate, and "tap-up" and "tap-down."
The main parts of the cruise control system are the
functional control switches, cruise control module assem-
bly, vehicle speed sensor assembly and cruise control
release switch, stoplamp and torque converter clutch
(TCC) switch, and clutch (5.7L LTl engine) or clutch
anticipate (3.4L L32 engine) switch assemblies. . serviceable.
The cruise control system uses a cruise control mod-
ule assembly to obtain the desired vehicle cruise opera-
tion. Two important components in the module assembly
help to do this. One is an electronic controller and the
second is an electric stepper motor. The controller moni-
tors vehicle speed and operates the electric stepper motor.
The motor moves a ribbon and throttle linkage, in
response to the controller, to maintain the desired cruise
speed. The cruise control module assembly contains a low
speed limit which will prevent system engagement below
a minimum speed of 40 km/h (25 mph). The operat,ic;m of
the controller is controlled by functional control switches
located on the turn signal and headlamp dimmer switch
and cruise control actuator and windshield wiper and
windshield washer lever assembly.
Cruise control release switch, stoplamp and TCC
switch, and clutch or dutch anticipate switch assemblies
are provided to disengage the cruise system. The switch
assemblies are mounted on the br.ake and accelerator and
clutch pedal bracket. When the brake pedal or clutch
disengaged and the throttle is returned to the idle position.
If vehicle is equipped with traction control (accel-
eration s'lip regulation), in a low tract situation the crui~e
control will disengage.
CRUISE CONTROL MODULE ASSEMBLY
The cruise control module assembly is mounted on
the left engine compartment irtner side rail assembly. The
module assembly has an electronic controller and an
electric stepper motor to vary the throttle with each differ-
ent cruise' control mode. The module assembly is not
CRUISE CONTROL SWITCH ASSEMBLIES
The cruise control release switch, stoplamp and
TCC switch, and clutch or clutch anticipate switch assem-
blies are used to disengage the cruise control system. A
release switch assembly, a stoplamp and TCC switch
assembly, and a clutch or clutch anticipate switch assem-
bly mqunted on the brake pedal bracket assembly disen-
gage the system electrically when the brake pedal or
clutch pedal is depresseq. This is done by activating the
brake cut-out inputto the cruise con.trol modu.le assembly.
The speed of the vehjcle at brake·actuation will be stored
in the memory of the system. The stoplamp and TC.C
switch assembly has a three-wire stoplamp connector and
a two-wire TCC connector on automatic transmission
only. The cruise control release switch assembly has a
two-wire cruise control disable connector. The clutch
switch assembly (5.7L LTl engine) has a two-wire cruise
control disable connector and the clutch anticipate switch
assembly (3.4L L32 engine) has a four-wire cruise control
disable connector.
98·2 CRUISE CONTROL
SPEED SENSOR
Vehicle Speed Sensor (VSS) Assembly
The vehicle speed sensor (VSS) assembly is
mounted to the automatic transmission assembly and pro-
d~ces. an al~ernating ~urrent (ac) signal. The frequency of
this s1gnal 1s proportional to the speed at which the auto-
matic transmission assembly output shaft rotates, which
in turn, is proportional to the speed of the vehicle.
. The ac signal p~oduced by the VSS assembly is sup-
phed to the powe11ram control module (PCM), cruise con-
trol module assembly and instrument cluster assembly.
The signal to the PCM, cruise control module
assembly and speedometer assembly is at a rate of 4000
pulses per mile. The PCM, cruise control module
assembly and speedometer assembly internally convert
the number of pulses per mile per second to determine
vehicle speed.
For removal procedure, refer to SECTION 7A or to
SECTION 8A for diagnostic information.
FUNCTIONAL CONTROL SWITCHES
Off-On-Resume/Accelerate Switch
Figure 1
rn Important
• Vehicle is equipped with a "Set To Get Cruise" fea-
ture requiring operator to set an initial speed by
using "SET/COAST" button before "RESUME/
ACCEL" slider switch will activate.
The "OFF-ON-R/A" switch (2) has three positions.
This switch turns the cruise control system "ON" and
"OFF" and also returns cruise control operation to the
last speed setting when momentarily moved toward the
"RIA" (RESUME/ACCELERATE) position after brak-
ing. Do not hold the "OFF-ON-R/A" switch (2) in the
"RIA" position. Release it immediately. If the "OFF-ON-
R/A" switch (2) is held in the "R/A" position for more
than one second, the system goes into the acceleration
mode. To accelerate the vehicle, move the "OFF-ON-
R/A" switch (2) to the"R/A" position and hold it there
until the vehicle reaches the desired speed. When the
"OFF-ON-R/A" switch (2) is released, the system will
maintain the new cruise speed. In order to use the accel,
eration mode, the "OFF-ON-R/A" switch (2) must be in
the "ON" position and the vehicle must be above the low
speed limit of 40 km/h (25 mph).
The "OFF-ON-R/A" switch (2) can also be used to
"tap-up" vehicle speed. In order to do this the cruise con-
trol system must be engaged and operating. "Tap-
ping-up" is done by quickly pressing the "OFF-ON-R/A"
switch (2) toward the "R/A" position and quickly releas-
ing it, or "tapping" the "OFF-ON-R/A" switch (2). Do
not hold the "OFF-ON-R/A" switch (2) in the "R/A"
position, or the system will go into the acceleration mode.
"Tap-up" is a function in which cruise speed can be
increased by 1.6 km/h (I mph) increments (one tap =
1.6 km/h ( 1 mph) increase).
Set/Coast Button Switch
Figure 1
The cruise control "SET/COAST" button switch
(3) (located in the end of the turn signal and headlamp
dimmer switch and cruise control actuator and windshield
wiper and windshield washer lever assembly) has two
positions - "NORMAL" and "DEPRESSED."
• The Set Position- With the "SET/COAST" button
switch depressed and then released (vehicle speed
must exceed the low speed limit point, and the
"OFF-ON-R/A" switch (2) must be in the "ON"
position), the cruise speed will be set at the speed the
vehicle was going when the "SET/COAST" button
switch (3) was released. Vehicle cruise speed will be
within ± 1.6 km/h ( 1 mph) of the actual speed at
engaged speed. The system will cruise until either
the "OFF-ON-R/A" switch (2) is moved to "OFF,"
the ignition switch is turned "OFF," and/or the
"SET/COAST" button switch (3) is pushed in fully
and held. Pushing the brake pedal assembly releases
the "SET/COAST" button switch (3) but not the
resume capability.
• The Coast Position - With the "SET/COAST"
button switch (3) fully depressed, the driver can
raise or lower vehicle speed. To increase speed, the
driver can accelerate to a new speed, fully depress
the "SET/COAST" button switch (3) and release
the button. The cruise control module assembly
"forgets" the previously set speed. An increased
control speed can be more easily set with the "OFF-
ON-R/A" switch (2) as previously described. To
decrease cruise ,speed, the "SET/COAST" button
switch (3) is held in, disengaging the cruise system,
which allows the throttle to return to the idle posi-
tion. When the vehicle has slowed to the desired
cruise speed, releasing the "SET/COAST" button
switch (3) will re-engage the system at the new
selected speed.
• The "Tap Down" Position - To "tap down" the
cruise must be engaged and operating. "Tapping-
down" is done by quickly pressing and releasing the
"SET/COAST" button switch (3), or "tapping" the
"SET/COAST" button switch (3). Do not hold the
"SET/COAST" button switch (3) in the depressed
position or the system will go into the coast mode.
"Tap-down" is a function in which cruise speed can
be decreased by 1.6 km/h ( 1 mph) increments (one
tap= 1.6 km/h (1 mph) decrease). The accelerator
3
1 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
2 SWITCH, OFF-ON-RESUME/ACCELERATE
3 SWITCH, SET/COAST BUTION
PC0001·9B-F·RP
Figure 1 - Cruise Control Actuator Lever Assembly (Typical)

pedal assembly may be depressed at any time to
override the cruise system. Release of the accelera-
tor pedal assembly will return the vehicle to the pre-
viously set cruise speed.
CAUTION: To keep the vehicle under
control, and to prevent possible per-
sonal injury and vehicle damage, the
cruise control should not be used on
slippery or winding roads or in traffic of
CRUISE CONTROL 98~3
heavy or varying volume. When travel·
ing down a steeply graded hill, the
cruise control should be disengaged
by depressing the brake pedal assem-
bly lightly. The automatic transmission
assembly can then be shifted into a
lower gear range to help control vehicle
speed.
98 - 4 CRUISE CONTROL

ELECTRICAL DIAGNOSIS (K34)

.35 PNK
(CHEVY) 013

1-; ---
39
(PONT) AS
r TO O"fHER
1 INSTRUMENT
CLUSTER
I INDICATORS ·~ ~r - - - - °7EEPo~R- 1 - - - °7E;;"o;R- 1
:<D:hQ~
y :~ r INDICATOR -. S206
FUSE
BLOcd

'1, ~t~E;
DISTRIBUTION

PAG~G~A;10·3
I
••
A/C -
CRUISE

FUSE 12
DISTRIBUTION
PAGE SA-10-3
I
I
I
I :J.: 10 AMP (NOT USED)

+
I 20AMP
_______ J
L------J L------
.8PNK.•3•9. . . . . . . . . . . . . . . . . . . . . .. .
__ J

·--,
(PONT) A16l
(CHEVY) 016 139
.35 OK BLU 1537 .8PNK .8 PNK
SEE FUSE
A9 C200D BLOCK DETAILS
9C200A 139 139 S165
PAGE 8A·11·5
I
.35 DK BLU 1537 .35 DK BLU

S2781·--·,·s·37. . . . . ::t..
M C215
I
•
35
DK BLu
1537
'~======~~~~======~/
j ! Iv j
w1TH NW9 ! w1THouT NW9 r-- ----------,
LEVER
~
r
BS
A-;fT~
Q
1
.8 PNK
.35 OK BLU
139 (WITHOUT NW9)
1537 (WITH NW9)
·~ITT
I SWITCH
I
I
SEE FUSE
BLOCK DETAILS

I ACTIVE I IMANUAL I I AUTOMATIC I I OFF -

-------- ------

I
PAGE SA-11-15

I I '
RIA OFF · - .. - RIA
I I /,......=:====!......t0 ~-=======~ I ~ ~ I
L __ J I I
ELECTRONIC
BRAKE/TRACTION
CONTROL MODULE
(EBTCM)

I
CLUTCH ANTICIPATE'
V6 VIN S
.35 PNK

I
B Ic;.2~

B
r-\ 1
I
139

V8 VIN p
CRUISE
.35 PNK

I
B C250

139
I
L-- ----=1--- SETCOAST I
J

CRUISE RELEASE SWITCH RELEASE'

(4 CAVITY DUAL SWITCH) I I CLUTCH -
(OPEN WITH
CLUTCH PEDAL I •
L
-1'J SWITCH
(2 CAVITY)
------- K

y
DEPRESSED> (OPEN WITH
PAGE 8A-20-7 - CLUTCH PEDAL
A DEPRESSED)

.35 BRN/W::l379 B

CRUISE RELEASE/[] [ ] CRUISE RELEASE/

BRAKE SWITCH BRAKE SWITCH
(OPEN WITH (OPEN WITH
BRAKE DEPRESSEDl BRAKE DEPRESSEDl

•- - .35 OK BLU 84 .8 PNK 139

Jg~ ______
·tg~
.35 GRY 397 .35 GRY BLK 37
.35 BR:'1:6 35 BR:'1:6

_,/
'
,..f.------------
BRAKE RESUME,
INPUT ACCEL
INPUT

[I] IMPORTANT:
• THE "SET TO GET CRUISE" FEATURE REQUIRES THE OPERATOR TO SET AN INITIAL SPEED BY USING THE "SET/COAST"
BUTION BEFORE THE "RESUMEiACCEL" SLIDER SWITCH WOULD BE ACTIVE.
• THE "BRAKE BEFORE CRUISE" FEATURE REQUIRES THE CRUISE MODULE TO SEE BRAKE INPUT AT TERMINAL "D" TO
CHANGE STATES ONCE EACH IGNITION CYCLE BEFORE ALLOWING CRUISE TO OPERATE. (LATER PRODUCTION VEHICLES
REQUIRE BRAKE INPUT AT EITHER TERMINAL "D" or "G"l.
 CRUISE CONTROL 98 • 5

rS;;-P~E; -
LT1 PCM CONNECTOR IDENTIFICATIQI\I
IDISTRIBUTION A - RED 32 WAY
IPAGE SA-10-1 B
C
-
·
BLACK (BLK)
CLEAR (CLR)
32
32
WAY
WAY
0 - BLUE (BLU) 32 WAY

l
j
L32 P~M CO_IIINECTOR IOEN_TIFICA_TION
ALL CONNECTOR BOOlfS ARE GRA v
WITH COLORED TPA,
A CLEAR (CLR) H tNA Y
B BLACK (BLK) 32 WAY
C BLUE (BLU) 32 WAY
BRAKEr""'.....................~;;...................;;...:,,.:,;~..........,.
SWITCH BRAKE LIGHT TCCISHIFT
ASSEMBLY CRUISE RELEASE INTERRUPT
SWITCH SWI~ I'" - - - - "1 POWERTRAIN
CONTROL
(NORMALLY
OPEN)
(NORMALLY
CLOSED)
I 4000 PULSES I MODULE
I PER MILE, I (PCM)
SPEED "'
I OUTPUT I ,.
L----..1 ~
c
~
A C_!
28 ll (BLK) (V6 VIN S)
8 ll (BLK) (VS VIN P)
TO AUTO TRANS
PAGE SA-20-6 (V6 VIN S)
.8 YEL 820
SA-21-6 (VS VIN P)
NOT USED WITH
.8 LTBLU 20
MANUAL TRANS
.35 DK GRNIWHT 817

TO TURN/HAZARD !'_1_1_Q_
SWITCH ASSEMBLY
PAGES SA-110-0, 1
.S YEL TO CENTER
5243 • - - -. .
· 820 ....
b~ HIGH MOUNTED
STOP LIGHT (CHM SL)
PAGE SA-110-1

rn
•
IMPORTANT:
BRAKE SIGNAL INPUT MUST BE
PULLED LOW THRU CENTER HIGH
MOUNTED STOPLAMP BULB OR
CRUISE CONTROL WILL NOT WORK •

.8 YEL 820

.35 DK GRN,WHT 817

TO ELECTRONIC BRAKE CONTROL

MODULE (EBCM) OR ELECTRONIC

BRAKE VEHICLE SPEED

INPUT SENSOR INPUT STEPPERQ
MOTOR©

12V 5V

~
I
I MECHANICAL
I

•
I LINK (CABLE)
.8BLK 1650

SEE GROUND
DISTRIBUTION
PAGE SA-14-2
TO THROTTLE BODY
AV~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
98 - 6 .CRUISE CONTROL

ELECTRICAL DIAGNOSIS (K34)

12065425
10-WAY F METRI-PACK 150 SERIES
BLK

CRUISE CONTROL MODULE

**CAVITIES NOT LISTED ARE NOT USED
.
CAVITY WIRE COLOR CKT DESCRIPTION PAGE

A GRY 397 CRUISE CONTROL SWITCH - ON 98-4

B DKBLU 84 CRUISE CONTROL SWITCH - SET/COAST 98-4

c GRY/BLK 87 CRUISE CONTROL SWITCH - RESUME/ACCEL 98-4

D BRN 86 CRUISE RELEASE/BRAKE SWITCH OUTPUT 98-4

E BLK 1650 GROUND SA-14·0, 2

F PNK 139 POWER FEED FROM A/C-CRUISE FUSE #12 98-4

G YEL 820 BRAKE DEPRESSED INPUT 98-5

K DKGRN/WHT 817 VEHICLE SPEED SIGNAL 98-5

'

GGGGGGGGGGGGGGGG
8088080888888®88•
12129025
32-WAY F MICRO-PACK 100 SERIES
NAT

POWERTRAIN CONTROL MODULE

(V6 VIN S) AND (VS VIN P)

V6 VIN S VS VIN P
CONNECTOR ASSEMBLY BREAKDOWN CONNECTOR ASSEMBLY BREAKDOWN
TPA · 12129021 (BLK) TPA - 12129021 (BLK)
SEAL • 12146093 SEAL · 12146093
STRAIN RELIEF · 12129030 STRAIN RELIEF · 12129028
CONNECTOR · 12129025 CONNECTOR · 12129025
 CRUISE CONTROL 98 - 7

C215 fr O J FORWARD LAMP

--~P INIMIL IKI lolH IGIF le 1°PJ
1
~~~~~SJ ~2~~~~~ING
06294509
11-WAY F PACK-CON I
BLK
SECTION
COMPONENT LOCATION SA-201-PG FIG. CONN
Brake Switch Assembly Mounted in lower hole of brake pedal bracket (2 conn
with Automatic), (1 conn with Manual)
same switch for both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
Clutch Anticipate/
Cruise Release Switch
(all, V6 Ma.qual) . ,. . . . . . . . Mounted in clutch pedal bracket (4 cavity conn) . . . . . . 0 . . . . 1 . . . 202-20
Cruise Control Module . . . . Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse .................................... 19 ... 36 . . 202-11
Cruise Release/Brake Switch
(all with K34) . . . . . . . . . . Mounted in upper hole of brake pedal bracket
(2 cavity conn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 1
Cruise Release/Clutch Switch
(VS Manual with K34) Mounted in clutch pedal bracket (2 cavity conn) 0 1
Electr.onic Brake/Traction
Control Module (EBTCM) Under 1/P, next to LH hinge pillar,just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14 .. 202-13
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 .. 202-23
Instrument Cluster ...... . LH side of I/P ................................................... . 202-23
Multi-Function Lever ... . Left Arm on Steering Column . . . . . . . . . . . . . . . . . . . . . . . 27 53
Powertrain Control Module
. (PCM) (V6 VIN S) ..... . In Engine Compartment, rearw.ard of RH Shoc.k Tower 19 35 202-25
Powertrain Control Module
(PCM) (V8 VIN P) ..... . In Engine Compartment, rearward of RH Shock Tower 19 35 202-26
Underhood Electrical Center LH side of Engine Compartment, forward
of wheelhouse ................................... . 19 36 202-28
C200A (17 cavities) Part of Forward Lamp Harn, between LH kick panel
and Steering Column ............................ . 25 49 202-2
C200D (48 cavities) Part of 1/P Harn, between LH kick panel and
Steering Column ................................ . 25 49 202-2
C215 (11 cavities) ....... . Near base of Steering Column ..................... . 35 64 202-4
C220 (10 cavities) ....... . Under RH side ofl/P, behind kick panel ............. . 20 37 202-6
C250 (2 cavities) ........ . Forward Lamp Harn to Clutch Jumper Harn or Switch,
near brake/clutch pedal bracket .................. . 0, 1 .. 1, 2
Gl09 Bolted to left front frame rail (2 rings, 1 wire and
braided strap) ................................... . 11 21
PlOO Left side in dash panel, Engine to Passenger
Compartment ................................... . 19 36
PllO Right side in dash panel, Engine to Passenger
Compartment ................................... . 19 35
Sl65 Forward Lamp Harn, approx 7 cm from Electrical
Center breakout
S206 1/P Harn, approx 18 cm from Convenience Center
breakout
S242 1/P Harn, approx 26 cm from Instrument Cluster Conn
S243 1/P Harn, approx 14 cm from Fuel Pump Relay breakout 7 13
S271 Forward Latnp Harn, approx 19 cm from breakout
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 14
S278 Forward Lamp Harn, approx 9 cm from EBCM breakout

For a Service Part Cross Reference List and Information, refer to SECTION SA-200.
 98-8 CRUISE CONTROL

ELECTRICAL DIAGNOSIS (K34)

TROUBLESHOOTING HINTS
C~erfor!ll before beginning
t>1agnos1s)
1. Check that Cruise Control Module Linkage is
System m
•
Important:
Cruise will not control speed down large grades.
connected and moving freely. • Cruise Performance may degrade with heavy
2. Check Cruise Cable Adjustment. loads, such as trailering, depending on Powertrain
3.
4.
5.
•
Check for poor connection at G 109.
Check connection at Cruise Control Module.
Check Brake Switch Adjustments.
Make sure ABS/TCS DTC(s) are diagnosed first.
An open CHMSL Circuit or "LOW TRAC"
m
•
capabilities.

Indicator Circuit will set a DTC and also disable
the Cruise Control Module. Check for burnt
CHMSL Bulbs or "LOW TRAC" Indicator Lamp.
• Check for a broken (or partially broken) wire
inside of the insulation which could cause system
malfunction but prove "GOOD" in a
continuity/voltage check with a system
disconnected. These circuits may be intermittent
or res is ti ve when loaded, and if possible, should be
checked by monitoring for a voltage drop with the
system operational (under load).
• Check for proper installation of aftermarket
electronic equipment which may affect the
integrity of other systems (see "Troubleshooting
Procedures," page SA-4-0).
• Refer to System Diagnosis.
Important:
The "Set To Get Cruise" feature requires the
Operator to set an initial speed by using the
"Set/Coast" button before the "Resume/ Acee!"
Slider Switch would be active.
• The "Brake Before Cruise" feature requires the
Cruise Module to see brake input at terminal "D"
to change states once each Ignition Cycle before
allowing cruise to operate. (later production
vehicles require brake input at either terminal "D"
or"G").
SYSTEM DIAGNOSIS
• Perform the System Check and refer to the
Symptom Table for the appropriate diagnostic
procedure(s).
• If speedometer is inoperative, refer to "Vehicle
Speed Sensor," page SA-33-2.

SYSTEM CHECK
ACTION NORMAL RESULTS

[ 1J
• Cruise
Drive vehicle above 25 mph. Vehicle maintains set speed (at ti me of button
• DepressSwitch to "ON." release) .
• Remove Set Switch once and release .
• foot from accelerator pedal.
[2]
• decreases
Depress and hold Set Switch until vehicle speed
by 4 to 5 mph.
Vehicle decelerates and maintains a new I ower set
speed, if speed is above 25 mph.
• Release Set Switch .
[3]
• increases
Depress and hold RIA Switch until vehicle speed
by 4 to 5 mph.
Vehicle accelerates and maintains a new higher set
speed.
• Release RIA Switch .
[4]
• Depress brake pedal slightly . Cruise Control disengages. Memory unchanged.
[SJ
• and
Depress RIA Switch once (less than 3/4 second)
release.
Vehicle accelerates to and maintains previous set
speed.

[6]
• Depress RIA Switch once and release (less than 1/2 Vehicle speed increases by 1 mph and maintains new
of a second). set speed.
(CONTINUED ON NEXT PAGE)
 CRUISE CONTROL 98 .. 9

(CONTINUED FROM PREVIOUS PAGE) SYSTEM CHECK

ACTION NORMAL RESULTS

[7]
• Depress Set Switch once and release (less than 1/2 Vehicle speed decreases by 1 mph and maint~ins new
of a second). set speed.
[8]
• Depress Set and RIA Switches simultaneously. Vehicle put in Non-Cruise mode with memory
unchanged.
[9]
• Depress RIA Switch once (less than 3/4 second) Vehicle accelerates to and maintains previous set
and release. speed.
[10]
• Cruise Switch to "OFF." Cruise Control disengages. Memory is lost .

ADDITIONAL SYSTEM CHECK • Fully depress and holcl brake pedal.

The following Procedure may be used as a System
Check to verify operation of the Cruise Control System
after repairs.
• Set Park Brake.
• Start Engine.
• Move Cruise Switch to "OFF."
• Move Cruise Switch to "ON" and then wait at
least 3 seconds before doing next step.
• Push Cruise Set Switch in and hold.
• Hold Cruise Slider Switch in "RI A" position.
• After 10 seconds, release brake pedal while
still holding RI A and Set Switches.
• Engine RPM should increase momentarily
then return to normal.

SYMPTOM TABLE
SYMPTOM PROCEDURE PAGE NUMB!;R

Cruise Control wi II not engage. Speedometer Chart #1 98-10

operates normally.
Cruise Control will not resume, accelerate or tap-up. Chart #2 98-12
Cruise Control will not engage. Speedometer does See"Vehicle Speed Sensor," page BA-33-2.
not operate.
Cruise Control "Surges" around a set speed. With DVM measure frequency at Cruise Control
Speedometer operates normally. Module Conn Term "K". If fluctuating replace Vehicle
Speed Sensor or Shaft as necessary. (Improper
tolerance with Shaft causing a wobble.)
98-10 CRUISE CONTROL

ELECTRICAL DIAGNOSIS (K34)

CHART #1
CRUISE CONTROL WILL NOT ENGAGE
(ASSUMES SPEEDOMETER OPERATES NORMAU.Y)
• TURN IGNITION SWITCH TO "OFF."
• DISCONNECT CRUISE CONTROL MODULE CONNECTOR.
• TURN IGNITION SWITCH TO "RUN."
• CONNECT TEST LIGHT FROM CONN TERM "F" TO GROUND.
IS TEST LIGHT "ON"?

• CONNECT TEST LIGHT FROM CRUISE CONTROL

MODULE CONN TERM "F" TO TERM "E".
IS TEST LIGHT "ON"?

• CRUISE SLIDER SWITCH "ON" AND
IGNITION SWITCH STILL IN "RUN."
• CONNECT TEST LIGHT FROM CRUISE
CONTROL MODULE CONN TERMINALS "B"
AND "C" TO GROUND.
IS TEST LIGHT "ON" AT EITHER TERMINAL?
• CHECK FOR POOR CONNECTION AT CRUISE
CONTROL MODULE.
IF OK, REPAIR OPEN IN GROUND CKT 1650
TO CRUISE CONTROL MODULE.

• CONNECT TEST LIGHT FROM • CHECK CKT 84 (TERM "B") OR CKT 87 (TERM "C") FOR SHORT TO B +.
CONN TERM "A" TO GROUND. IF OK, REPLACE MUL Tl-FUNCTION LEVER.
IS TEST LIGHT "ON"?

• CONNECT TEST LIGHT FROM • BACKPROBE TERM "M" OF C215 WITH TEST LIGHT TO GROUND.
CONN TERM "D" TO GROUND. IS TEST LIGHT "ON"?
IS TEST LIGHT "ON"?

• CHECK FOR POOR CONNECTION AT • CHECK FOR POOR

MUL Tl-FUNCTION LEVER. CONNECTION AT TERM "M'.'
• CHECK FOR OPEN IN CKT 397 BETWEEN OFC215.
MUL Tl-FUNCTION LEVER AND CRUISE IF OK, REPAIR OPEN IN CKT
CONTROL MODULE, OR CKT 139 FROM C21 S 139 BETWEEN 5165 AND
TERM "M" TO MULTI-FUNCTION LEVER. C215 TERM .. M ...
IF OK, REPLACE MUL Tl-FUNCTION LEVER.

• CONNECT TEST LIGHT FROM • BACKPROBE C250 TERM "B" WITH A TEST LIGHT TO GROUND.
CONN TERM "G" TO GROUND. IS TEST LIGHT "ON"?
• DEPRESS BRAKE PEDAL.
IS TEST LIGHT "ON"?

(AUTOMATIC) (MANUAL) REPAIR OPEN

• CHECK FOR OPEN IN • CHECK FOR POOR CONNECTIONS AT IN CKT 139
CKT 86 OR POOR VARIOUS COMPONENTS IN CRUISE (WITHOUT
CONNECTION AT C250. JUMPER HARNESS. NW9)0R
(CONTINUED ON NEXT PAGE) IF OK, REPLACE CRUISE • BACKPROBE SWITCH CONNECTORS OPEN INCKT
RELEASE/BRAKE TO LOCATE BAD COMPONENT OR 1537(WITH
SWITCH. OPEN IN CKT. REPLACE OR REPAIR. NW9).
 CRUISE CONTROL 98-11

(CONTINUED FROM PREVIOUS PAGE)

• CONNECT A TEST LIGHT • BACKPROBE BRAKE SWITCH ASSEMBLY CONN C1

FROM CONNECTOR TERM "B" WITH A TEST LIGHT TO GROUND.
TERM "B" TO GROUND. IS TEST LIGHT "ON"?
• PRESS AND HOLD SET
SWITCH.
IS TEST LIGHT "ON"?

• CH ECK FOR POOR

CONNECTION AT BRAKE BRAKE SWITCH ASSEMBLY.
SWITCH ASSEMBLY.
• CHECK FOR OPEN IN CKT 820.
IF OK, REPLACE BRAKE SWITCH
ASSEMBLY.

• CONNECT 1/P TESTER(J33431) TO • BACKPROBE TERM "K" OF C215 WITH A TEST LIGHT TO GROUND.
VEHICLE SPEED SENSOR CONN. • PRESS AND HOLD SET SWITCH.
• SET TESTER TO 60 Hz. IS TEST LIGHT "ON"?
• WITH DVM, MEASURE
FREQUENCY OF SIGNAL AT
CRUISE CONTROL MODULE
CONN TERM "K".

• CHECK FOR POOR CONNECTION • CHECK FOR POOR CONNECTION AT C215

AT C215 TERM "K". TERM"K".
IF OK, REPAIR OPEN IN CKT 84 • CHECK FOR OPEN IN CKT 84 INSIDE
TO CRUISE CONTROL MODULE. STEERING COLUMN.
IF OK, REPLACE MUL Tl-FUNCTION LEVER.

• CHECK FOR POOR CONNECTION IS SPEEDOMETER APPROX 54 mph?

AT CRUISE CONTROL MODULE.
• CHECK FOR PROPER OPERATION
OF MECHANICAL LINK CABLE.
IF OK, REPLACE CRUISE
CONTROL MODULE. MAKE ---------------------,
SURE CABLE STRAP IS NOT • CHECK FOR POOR CONNECTION AT CHECK FOR PROPER HOOKUP OF :
TWISTED ON REINSTALLATION. C200TERM "A1". 1/P TESTER. 1

• PERFORM ADDITIONAL SYSTEM IF OK, REPAIR OPEN IN CKT 817 IF OK, REFER TO "VEHICLE SPEED :
CHECK ON PAGE 98-9 TO VERIFY BETWEEN 5242 AND CRUISE SENSOR," PAGE 8A-33-0 FOR :
REPAIRS. CONTROL MODULE CONN TERM "K".
I 1 ADDITIONAL DIAGNOSIS.
L-~~~~~~~~~~~~~~L-----------------------J
 98-12 CRUISE CONTROL
ELECTRICAL DIAGNOSIS (K34)
CHART #2
CRUISE CONTROL WILL NOT RESUME, ACCELERATE OR TAP-UP
• TURN IGNITION SWITCH TO "RUN."
• CRUISE CONTROL SWITCH TO "ON."
• BACKPROBE C215 (AT BASE OF STEERING COLUMN)
WITH A TEST LIGHT FROM TERM "J" TO GROUND.
• PRESS AND HOLD RESUME/ACCEL SWITCH.
IS TEST LIGHT "ON"?
• CHECK FOR OPEN IN CKT 87 BETWEEN C215
AND CRUISE CONTROL MODULE.
• ALSO CHECK FOR POOR CONNECTION AT
CRUISE CONTROL MODULE TERM "(".
IF OK, REPLACE CRUISE CONTROL MODULE.
CIRCUIT OPERATION
The Electro-Motor Cruise Control is a speed
control system which maintains a desired vehicle
speed under normal driving conditions. The system
has the capability to CRUISE, COAST, RESUME
SPEED, ACCELERATE, TAP-UP, TAP-DOWN AND
CANCEL (Depress "SET" and "RIA" simultaneously).
An Electronic Controller and Electric Motor are
contained in the Cruise Control Module. The
Controller monitors vehicle speed and operates the
Electric Motor. In response to the Controller, the
motor moves a connecting strap that is attached to the
Cruise Control Cable. The Cable moves the Throttle
Linkage to vary throttle position in order to maintain
the desired cruise speed. The Cruise Control Module
contains a low speed limit which will prevent system
engagement below a minimum speed, about 25 mph.
The module is controlled by mode control switches
located on the Multi-Function Lever. The "Set To Get
Cruise" feature requires the operator to set an initial
speed by using the "Set/Coast" button before the
"RESUME/ACCEL" Slider Switch would be active.
With the Ignition Switch in "RUN," battery
voltage is applied to terminal "F" of the Cruise Control
Module. When the Slider Switch is moved to the "ON"
position, battery voltage is applied to terminal "A" of
the Cruise Control Module. The Cruise Control
Module needs to see Ignition Voltage at terminal "D"
to change states once each ignition cycle before
allowing Cruise to operate. (Later production vehicles
require Brake Input at either terminal "D" or "G").
• CHECK FOR OPEN OR SHORT TO GROUND
IN CKT 87 IN STEERING COLUMN, OR
POOR CONNECTION AT C215 TERM" J".
IF OK, REPLACE MUL Tl-FUNCTION LEVER.
On vehicles with Traction Control (NW9) the
voltage path is through the "LOW TRAC" Indicator,
the normally closed Clutch Start Switch (Manual
Transmission only) and Brake Switch. On vehicles
without Traction Control (NW9) the voltage path is
through the NC CRUISE Fuse 12, the normally closed
Clutch Start Switch (Manual Transmission only) and
Brake Switch. If either switch is opened the voltage to
the Cruise Control Module terminal "D" is
interrupted. With Traction Control (NW9) if a low
traction condition occurs the Electronic
Brake/Traction Control Module (EBTCM) will ground
CKT 1537 causing a grounc;l potential at terminal "D"
of the Cruise Control Module disabling the Cruise
Control. Terminal "G" must see a ground path
through the CHMSL bulb for cruise to operate
properly. If the brake pedal is depressed, battery
voltage is present at module terminal "G". When the
Slider Switch is moved to the "R/A" position, battery
voltage is applied to terminal "C" of the module. With
the Set Switch depressed, battery voltage is present at
Cruise Module terminal "B". Cruise Module
Connector terminal "K" is the speed signal terminal.
In operation, voltage will oscillate between a high of 4
to 5 volts and a low of near ground. Cruise Module
terminals "H" and "J" are not used. Ground is at
module terminal "E".
 CRUISE CONTROL 98·13

ON-VEHICLE SERVICE
CRUISE CONTROL SWITCH ASSEMBLIES
Figure 2
Adjustment
The release switch assembly (6) must be adjusted at
the same time the stoplamp and torque converter clutch
(TCC) switch is adjustei:l. The clutch switch assembly (5)
or clutch anticipate switch assembly (4) cannot be
adjusted until after clutch pedal assembly (20) is installed.
NOTICE: Proper stoplamp switch assembly adjust-
ment is essential. Improper stoplamp switch assem-
bly adjustment will cause brake drag and excessive
brake lining wear.
12) Adjust
1. To adjust, depress brake pedal assembly or clutch
pedal assembly and insert release switch assembly
(6), stoplamp and TCC switch assembly (7), and
clutch switch assembly (5) or clutch anticipate
switch assembly (4) into pedal assembly with
bracket (20 or 21) until retainer on release switch
assembly (6), stoplamp and TCC switch assembly
(7), or clutch switch assembly (5) or clutch antici-
pate assembly ( 4) is fully seated.
NOTICE: Make sure to apply the proper amount of
force to the brake pedal assembly during adjustment.
Too much force could damage the vacuum booster
assembly. Too little could cause dragging brakes.
2. Slowly pull brake or clutch pedal assembly rearward
with a force of 222 N (50 pounds) until "click"
sounds can no longer be heard. At this point, release
switch assembly (6), stoplamp and TCC switch
assembly (7), and clutch switch assembly (5) or
clutch anticipate assembly (4) will have moved
retainers to their original position.

20

21

A MANUAL TRANSMISSION
B AUTOMATIC TRANSMISSION
C CONNECTOR, ELECTRICAL
D CONNECTOR, ELECTRICAL
E CONNECTOR, ELECTRICAL
F CONNECTOR, ELECTRICAL
G CONNECTOR, ELECTRICAL
H. WITH 3.4L L32 ENGINE
J WITH 5.7L LT1 ENGINE
4 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
ANTICIPATE
5 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
6 SWITCH ASSEMBLY, CRUISE CONTROL RELEASE
7 SWITCH ASSEMBLY, STOPLAMP AND TORQUE
CONVERTER CLUTCH
19 SWITCH ASSEMBLY, CLUTCH START
20 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
21 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR (WITH
BRACKET) B
PC0002·9B·F·RP

Figure 2 - Cruise Control Switch Assemblies

 98-14 CRUISE CONTROL

!tm I Measure
• The release switch assembly and stoplamp and TCC
switch assembly contacts should be open at 25.4 mm
( 1 inch) or less of pedal assembly travel, and occur at
the same time or before th.e onset of braking. The
brake pedal assembly travel can be up to 25.4 mm
( 1 inch) before the cruise control system disengages .

.Replacement

!+-+I Remove or Disconnect A

1. Left-hand instrument panel sound insulator
assembly. A COVER, ACCESS
2. Electrical connectors. B CONNECTOR, ELECTRICAL
C TANG
3. Release switch assembly (6), stoplamp and TCC 1 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
switch assembly (7), and clutch switch assembly (5) DIMMER SWITCH AN.D CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
or clutch anticipate switch assembly (4), if 8 COLUMN ASSEMBLY, STEERING
equipped, from pedal assembly with bracket
(20 or 21). PC0003-9B-F-RP
Figure 3 - Engagement Switch
1-++I Install or Connect
1. Release switch assembly (6), stoplamp and TCC
switch assembly (7), and clutch switch assembly (5) !++I Install or Connect
or clutch anticipate switch ~ssembly (4), if l. Lever assembly (1).
equipped, to pedal assembly with bracket (20 or 21). • Align tang on lever assembly (1) to notch on
2. Electrical connectors. column assembly (8) and push in until fully
3. Left-hand instrument panel sound insulator seated.
assembly. 2. · Electrical connector.
3.. Steering column access cover.
[el Adjust 4. Battery negative cable assembly
• Release switch assembly (6), stoplamp and
TCC switch assembly (7), and clutch switch.
CRUISE CONTROL MODULE ASSEMBLY
assembly (5) or clutch anticipate switch assem~ Figure 4
bly (4) as outlined above.
The cruise control module assembly (11) is mounted
on the left engine compartment inner side rail assembly
ENGAGEMENT SWITCH using two cruise control module bracket bolts/screws
(16).
Figure 3
The engagement switch cannot be serviced. The
j+-+I Remove or Disconnect
complete turn signal and headlamp dimmer switch and 1. Accelerator control cable splash shield bolts/screws.
cruise control actuator and windshield wiper and wind- 2. Accelerator control cable splash shield;
shield washer lever assembly must be replaced as an 3. Left-hand front bumper fascia lower deflector. Refer
assembly. to SECTION 10-4.
4. Cruise control cover (13) to access connectors.
!+-+I Remove or Disconnect
5. Electrical connector from cruise control module
CAUTION: Refer to "Caution" under assembly (11 ).
"Disconnecting the Battery Negative 6. Cruise control cable assembly from cruise control
Cable Assembly" in SECTION OA. module assembly. · Refer to "Cable Assembly
1. Battery negative cable assembly. Replacement" in this section.
2. Steering column access cover. 7. Bolts/screws (16).
8. Cruise control module assembly (11) with bracket
3. Electrical connector.
assembly (12) from left engine compartment inner
• Make sure windshield wiper switch is in the side rail assembly.
"OFF" position. 9. Bolts/screws (10) attaching cruise control module
4. Lever assembly ( 1) by pulling it straight out. assembly ( 11) to bracket assembly ( 12).
 CRUISE CONTROL 98·15

12

A CONNECTOR, ELECTRICAL 14 CABLE ASSEMBLY, CRUISE CONTROL

10 BOLT/SCREW, CRUISE CONTROL, 6 N•m (53 LB. IN.) 15 HARNESS ASSEMBLY, FORWARD LAMP WIRING
11 MODULE ASSEMBLY, CRUISE CONTROL 16 BOLT/SCREW, CRUISE CONTROL MODULE BRACKET,
12 BRACKET ASSEMBLY, CRUISE CONTROL MODULE 10 N•m (89 LB. IN.)
13 COVER, CRUISE CONTROL 17 RAIL ASSEMBLY, ENGINE COMPARTMENT INNER SIDE

PC0004-9B·F-RP
Figure 4 - Cruise Control Module Assembly

10. Cruise control module assembly ( 11) from bracket 3. Cruise control module assembly (11) with bracket
assembly ( 12). assembly (12) to left engine compartmentinner sid.e
rail assembly.
(++I Install or Connect 4. Bolts/screws (16).
NOTICE: See "Notice" on page 9B-l of this
section.
I. Cruise control module assembly ( 1.1) to bracket
l~I Tighten
• Bolts/screws (16) to 10 N•m (89 lb. in.).
assembly (12).
2. Bolts/screws (10) attaching cruise control module 5. Cable assembly to module assembly. Refer to
assembly (11) to bracket assembly (12). "Cable Assembly Replacement" in this section.
6. Electrical connector to cruise control module assem-
f~I Tighten
bly (11 ).

• Bolts/screws (10) to 6 N•m (53 lb. in.). 7. Cruise control cover (13) over connectors.
8. Left-hand front bumper fascia lower deflector. Refer
to SECTION 10-4.
9. Accelerator control cable splash shield.
10. Accelerator control cable splash shield bolts/screws.

f~I Tighten
• Accelerator control cable splash shield bolts/
A RIBBON· screws to 1.9 N•m (17 lb. in.).
B BEAD
11
14
MODULE ASSEMBLY, CRUISE CONTROL
CABLE ASSEMBLY, CRUISE CONTROL
PC000&-9B·f.RP
12) Adjust
• Cable assembly, if necessary. Refer to "Cable
Figure 5 - Cable Bead to Cruise Control Module Assembly
Assembly Adjustment" in this section.
98·16 CRUISE CONTROL

A RIBBON
B RIBBON MUST NOT BE TWISTED
C MARKINGS IN YELLOW FOR LT1 ENGINE, PINK FOR L32 ENGINE
D BEAD
11 MODULE ASSEMBLY, CRUISE CONTROL
14 CABLE ASSEMBLY, CRUISE CONTROL
PC0006-9B·f·RP

Figure 6 - Pulling Cruise Control Cable Assembly

CRUISE CONTROL CABLE ASSEMBLY

Figures 5 through 7
The cable assembly (14) is connected between the
cruise control module assembly ( 11) and the throttle body
lever, or accelerator control/cruise control servo cable
adjuster, if equipped. ·

Cable Assembly Replacement (Standard)

!+,.I Remove or Disconnect

I. Cable assembly (14) and conduit from engine
bracket.
2. Cable end fitting from throttle body lev~r stud.
3. Cruise control retainer (18) at cruise control module
assembly.
4. Cable assembly (14) from cruise control module
assembly (11).
A CONDUIT
A. Compress conduit tangs and pull out of cruise B TANG
control module housing. ( 11 ). C HOUSING
D END FITTING
B. Disconnect cable bead from cruise motor band 11 MODULE ASSEMBLY, CRUISE CONTROL
end fitting on cruise control module assembly 14 CABLE ASSEMBLY, CRUISE CONTROL
(11). 18 RETAINER, CRUISE CONTROL
PC0007·9B·F·RP
C. Note routing and remove cable assembly (14)
from vehicle. Figure 7 - Installing Cruise Control Cable Assembly to Cruise
Control Module Assembly .
j.. +J 1nstall or Connect
I. Cable assembly (14) to cruise control module
assembly (11).
m Important
• Ribbon must not be twisted.
A. Attach cable bead to cruise motor ribbon end - Slide cable conduit fitting over ribbon
fitting on cruise control module assembly (11). and snap into module housing assuring
B. Pull engine end of cable assembly (14) until it that both tangs are engaged.
is taut. 2. Cruise control retainer (18) at cruise control module
C. Turn engine end of cable assembly until ribbon assembly (11).
is flat. 3. Cable assembly (14) to vehicle.
 CRUISE CONTROL 98·17

• Use routing noted during removal.
4. Cable end fitting to throttle body lever stud.
5. Cable assembly (14) and conduit to engine bracket.
llJ Adjust
• Cable assembly. Refer to "Cable Assembly
Adjustment (Standard)" in this section.
A. Compress conduit tangs and pull out of cruise
control module housing.
B. Disconnect cable bead from cruise motor band
end fitting on cruise control module assembly
(11).
C. Note routing and remove cable assembly (14)
from vehicle.

Cable Assembly Replacement (Optional)

!++! Install or Connect
1. Cable assembly (14) to cruise control module
Figures 5 through 8 assembly (11 ).

m Important
• If vehicle is equipped with accelerator control/cruise
control servo cable adjuster (throttle relaxer), follow
these procedures to replace cable assembly.
j+ ..! Remove or Disconnect
1. Cover (19).
2. Cable assembly (14) and conduit from engine
bracket.
3. Cable end fitting from accelerator control/cruise
control servo cable adjuster (20).
4. Cruise control retainer ( 18) at cruise control module
assembly.
5. Cable assembly (14) from cruise control module
assembly (il).
A. Attach cable bead to cruise motor ribbon end
fitting on cruise control module assembly ( 11 ).
B. Pull engine end of cable assembly (14) until it
is taught.
C. Turn engine end of cable assembly until ribbon
is flat.
rn Important
• Ribbon must not be twisted.
- Slide cable conduit fitting over ribbon
and snap into module housing assuring
that both tangs are engaged.
2. Cruise control retainer ( 18) at cruise control module
assembly (11).
3. Cable assembly (14) to vehicle.
• Use routing noted during removal.

20

A CABLE END FITIING

B CABLE LOCKING TAB
14 CABLE ASSEMBLY, CRUISE CONTROL 19
19 COVER, ACCELERATOR CONTROLJCRUISE CONTROL
SERVO CABLE ADJUSTER
20 ADJUSTER ASSEMBLY, ACCELERATOR CONTROLJ
CRUISE CONTROL SERVO CABLE
21 CABLE ASSEMBLY, ACCELERATOR
PEDALJCRUISE CONTROL RC0001-9B-F-RP

Figure 8 - Cable Assembly Replacement (Optional)

 98-18 CRUISE CONTROL
4. Cable end fitting from accelerator control/cruise
control servo cable adjuster (20).
5. Cable assembly (14) and conduit to engine bracket.
6. Cover ( 19).
12} Adjust
• Cable assembly. Refer to "Cable Assembly Adjust-
ment (Optional)" in this section.
If replacing accelerator pedal/cruise control cable
~ssembly, refer to SECTION 5E2 for replacement and ad-
JUstment procedures.
Cable Assembly Adjustment (Standard)
• With throttle closed, lock cable conduit by pressing
down on lock button.
LT1 Engine
A. Pull cruise cable adjust slider rearward out of
adjuster to remove cable slack without moving
throttle lever from its idle stop. Push down
cruise cable adjust lock button until it snaps
and locks into place.
B. A gap O - 2 mm (0.07 inch) between terminal
end of cable to the plastic connector that snaps
on to throttle body lower is allowed when
checking for this condition. Pull on terminal
end making sure connector to throttle body is
hard against its fitting. If more than 2 mm (0.07
inch) exist, readjust cable.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Accelerator Control Cable Splash Shield Bolt/Screw ...................... 1.9 N•m (17 lb. in.)
Cruise Control Bolt/Screw ............................................. 6 N•m (53 lb. in.)
Cruise Control Module Bracket Bolt/Screw ............................... 10 N•m (89 lb. in.)
SPECIAL TOOLS
1. FLUKE 87 KIT
L32 Engine
A. Pull cruise cable adjust slider rearward until
cruise cam lever contacts throttle body lever
without opening the throttle. Push down cruise
cable adjust lock button until it snaps and locks
into place.
B. A gap of O- 2 mm (0.07 inch) between cruise
cam lever and throttle body lever is allowed
after lock button is depressed.
Cable Assembly Adjustment (Optional)
To manually adjust the cable assembly (14):
A. Place finger on throttle making sure throttle
arm is hard against stop.
B. Pull cable assembly (14) to remove slack from
cable.
m Important
• Do. not disturb cable after removing
slack.
C. Press locking tab down to retain cable.
m Important
• Cable should never be adjusted so tight
that tension from cable will not allow
throttle to close solidly. If cable is
adjusted too tight, the cable will prevent
engine from returning to idle and will
cause unstable idle quality.
J 39200
PC0008-9B-F-RP
 THEFT DETERRENT SYSTEMS 90-1

SECTION 90

THEFT DETERRENT SYSTEMS

CAUTION: This vehicle is equipped with the Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.

CONTENTS
General Descriution . . . . . . . . . . . . . . . . . . . . . . . . 9D- l Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
PASS-Key 11® System .................... 9D-1 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 90-17
System Operation . . . . . . . . . . . . . . . . . . . . . . . . 9D- l Ignition Key Assembly . . . . . . . . . . . . . . . . . . 90-17
System Components . . . . . . . . . . . . . . . . . . . . . 9D-1 Copying Ignition Key Assemblies . . . . . . . . 90-17
Ignition Key Assembly . . . . . . . . . . . . . . . . . 9D-1 Replacing Lost Ignition Key Assemblies . . 90-17
Steering Column Lock and Ignition Steering Column Lock and Ignition Cylinder
Cylinder Assembly .................. 9D-2 Assembly . . . . . . . . . . . . . . Refer to Section 3F5B
Theft Deterrent Module Assembly ........ 9D-2 Theft Deterrent Module Assembly . . . . . . . . . 90-17
Ignition Input ......................... 9D-2 Theft Deterrent Relay Assembly . . . . . . . . . . . 90-18
Key Resistor Inputs .................... 90-2 Engine Control Module
Starter Enable Output ................... 9D-2 (ECM) . . . . . . . . . . . . . . . . . . Refer to Section 6E
Fuel Enable Output .................... 90-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
Security Indicator Lamp Output .......... 9D-3 Fastener Tightening Specifications . . . . . . . . . 90-18
Theft Deterrent Relay Assembly .......... 9D-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
Engine Control Module (ECM) ........... 9D-3

GENERAL DESCRIPTION
PASS-Key II® SYSTEM
The personal automotive security system (PASS-
Key II®) is standard equipment on this vehicle. The sys-
tem is designed to prevent vehicle theft by disabling the
engine unless an ignition key assembly with a specific
electrical resistance is used in the ignition cylinder assem-
bly. The components of the system are the ignition key
assembly, the ignition cylinder assembly, the theft deter-
rent module assembly, the theft deterrent relay assembly,
and the engine control module (ECM).
SYSTEM OPERATION
The PASS-Key 11® system is designed to prevent
the engine from starting if the proper resistance is not
sensed from the ignition key assembly. Of the 15 key
codes (resistance values) available, only one will work
with each theft deterrent module assembly.
The PASS-Key n® system prevents the engine from
starting by controlling the theft deterrent relay assembly
and the ECM fuel enable input. If the ECM does not sense
the proper pulse width modulate (PWM) signal on the fuel
enable input, it will not provide fuel to the engine.
If the wrong resistance value is sensed when the
ignition switch is in the "RUN" position, the theft deter-
rent module assembly will not ground the starter enable
circuit and will not output the fuel enable PWM signal for
approximately three minutes. This prevents the engine
from starting and discourages the thief from trying key
codes (resistance values) at random.
If the correct resistance value is sensed when the
ignition switch is in the "RUN" position, the theft deter-
rent module assembly will ground the starter enable cir-
cuit and output the fuel enable PWM signal. This will
allow the engine to start normally.
SYSTEM COMPONENTS
Figure 1
Ignition Key Assembly
The ignition ke$ assembly for vehicles equipped
with the PASS-Key II system is an assembly of a typical
square ignition key blank and resistor assembly. The igni-
tion key blank and resistor assembly are not serviceable
separately. There are 15 different ignition key assemblies,
 90-2 THEFT DETERRENT SYSTEMS
each with a different resistance value. The ignition key
assem~y also has mechanical cuts similar to non-PASS-
Key II R ignition key assemblies.
[I] Important
• Wh~n .s~rvicing the PASS-Key n® system, obtain
all 1gmllon key assemblies, if possible, and verify
proper values with tool J 35~28-A, VATS/PASS
Interrogator. Refer to "Copying Ignition Key
Assemblies" in this section.
Steering Column Lock and Ignition Cylinder
Assembly
Figure2
. The ignition cylinder assembly in vehicles equipped
with the PASS-Key n® system contains a set of electrical
c_ontacts used to measure the resistor assembly in the igni-
tion key assembly._ When servicing the ignition cylinder
assem~ly, be certam to maintain proper wire routing. A
two pm connector at the base of the steering column
assembly c_onnects the conta_cts to the vehicle wiring. The
~onnec~or 1s also used for diagnostic purposes. The igni-
t~on cyl~nder assembl~ also performs all functions of igni-
tion cylmder assemblies on non-PASS-Key n® vehicles.
When replacing anignition cylinder assembly, it will be
necessary to make new ignition key assemblies which
match the PASS-Key II® key code of the theft deterrent
module assembly and the mechanical cut of the new igni-
tion cylinder assembly.
[I] Important
• The wire routing for the contacts inside the steering
column assembly is critical.
Theft Deterrent Module Assembly
The theft deterrent module assembly contains the
logic of the PASS-Key n® system. The theft deterrent
1 MODULE ASSEMBLY, THEFT DETERRENT
2 KEY ASSEMBLY, THEFT DETERRENT IGNITION
3 CYLINDER ASSEMBLY, STEERING COLUMN LOCK ANO
IGNITION
4 RELAYASSEMBLY, THEFT DETERRENT
5 MODULE, ENGINE CONTROL
Figure 1 - PASS-Key 11® System Components (Typical)
module assembly has inputs from the ignition circuit and
the resistor assembly. The theft deterrent module assem-
. bly has outputs to the starter enable circuit, the fuel enable
circuit, and the security lamp circuit.
Ignition Input
The ignition input is used to tum the theft deterrent
module assembly on, When the theft deterrent module as-
sembly is turned on, it will r~ad the resistor assembly and
control the outputs accordingly. When the theft deterrent
module assembly is turned off the resistor assembly is not
read, and the theft deterrent relay assembly and fuel
enable output will not allow the engine to start. When the
ignition switch is in the "OFF" position, the battery input
to the theft deterrent module assembly will draw about 1
milli-amp.
Key. Resistor Inputs
The key resistor inputs are used to determine if the
correct ignition key assembly is being used to start the
vehicle. The key resistor inputs are read only when the
theft deterrent module assembly is first turned on. If the
key code (resistance value) of the ignition key assembly
matches the value stored in the theft deterrent module
assembly, the theft deterrent relay assembly and fuel
enable output will allow the vehicle to start. If the resis-
tance value of the ignition key assembly does not match
the value stored in the theft deterrent module assembly,
the relay assembly and fuel enable output will not allow
the vehicle to start.
Starter Enable Output
The starter enable circuit controls the theft deterrent
relay assembly. When the theft deterrent module assem-
bly sees the proper resistance at the ignition key assembly,
it grounds the starter enable circuit which allows the
engine to be cranked. If the theft deterrent module assem-
bly does not see the proper resistance at the ignition key
assembly, it will not ground the starter enable circuit.
PC0001·9D·F-RP
 THEFT DETERRENT SYSTEMS 90·3

A PROPER WIRE ROUTING FROM STEERING COLUMN

LOCK AND IGNITION CYLINDER ASSEMBLY
(DO NOT TWIST WIRES)
B CUT OFF WIRE RETAINER LEG
ON ORIGINAL CONNECTION WHEN REPLACING
STEERING COLUMN LOCK AND IGNITION
CYLINDER ASS EMBLY
2 KEY ASSEMBLY, THEFT DETERRENT IGNITION
3 CYLINDER ASS EMBLY, STEERING COLUMN LOCK
AND IGNITION
PC6003-9D-D·RP

Figure 2 - Ignition Cylinder Assembly Wire Routing

Fuel Enable Output Theft Deterrent Relay Assembly

The fuel enable circuit is an output from the theft
deterrent module assembly and an input to the ECM.
When the theft deterrent module assembly sees the proper
resistance at the ignition key assembly, it will output a
pulse width modulated (PWM) signal to the ECM. If the
theft deterrent module assembly does not see the proper
resistance at the ignition key assembly, it will not output
the PWM signal to the ECM.
Security Indicator Lamp Output
The "SECURITY" lamp circuit is an indicator lamp
output. The lamp output will be grounded during a five
second "bulb test" at key on, at any time that the theft
deterrent module assembly is preventing the engine from
starting, or if the theft deterrent module assembly is not
properly programmed.
The relay assembly is used to stop the engine from
cranking if the correct resistance is not sensed at the igni-
tion key assembly. It prevents the engine from cranking
by opening the circuit to the starter solenoid switch.
Engine Control Module (ECM)
The ECM reads the fuel enable circuit to determine
if fuel injection should be allowed. If the fuel enable
PWM signal is not present, the ECM will not allow fuel
injection. If the PWM signal is present, the ECM will
allow fuel injection and normal engine operation.
The ECM has some diagnostic features associated
with the fuel enable input, including diagnostic trouble
codes. For details, refer to SECTION 6E.
90-4 THEFT DETERRENT SYSTEMS

ELECTRICAL DIAGNOSIS: PASS-Key®II

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)

_--,
r- - - _
HOT AT ALL TIMES

IGNITION

I
•• 7ACCY

L-------
LO;;.......
OFF
_ _.,.. .;U~B
RUN TEST
START I~-
1

1
SWITCH

sv~fsg_J
CST C200B
C200D
5 YEL 5

5 YEL 5223

~------·----.......................
I/Pr"" ---,
-,
FUSE
BLOCK
I
CRANK
I
I

__ ....
FUSE 17 5 YEL S
I 3AMP f

TO DIAGNOSTIC
ENERGY RESERVE
I
MANUAL I IAUTOMATIC

MODULE
PAGE SA-47-0
B 'X TRANSMISSION
/X
r- - - - - - ,
5 YEL S
C LUTCH[]
START
SWITCH
POSITION I
SWITCH
I
(CLOSED WITH
CLUTCH PEDAL _
I p I I
DEPRESSED) I 'R
e., N @ D / •
2'1

, ,J~
I ,._ ....... 1.
-----J L
.3SY:169

c2l
Zi---------------------:!21=M~
c1

A2L
5 PPL 6 · A
CllO P110 6
. Aly
3 PPL (V6 VIN 5)
5 PPL (VS VIN P)

r ;- -
·----------------111!1.~(
1 STAIITER
.8 YEL/BLK

625
.)

I I ~L!.~Q!Q
I I
L J

CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint

(SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and
the SIR Component and Wiring Location view in Section 9J before
performing service on or around SIR components or wiring. Failure to
SEE PAGE 8A-3-0
FOR PROPER
follow CAUTIONS could result in possible air bag deployment, personal
HANDLING
PROCEDURES
injury, or otherwise unneeded SIR system repairs.
 THEFT DETERRENT SYSTEMS 90-5

1
LT1 PCM CONNECTOR IDENTIFICATION
A - RED 32WAV

--,1:"_ FUSE
B
C
D
-
-
-
BLACK (BLK)
CLEAR (CLR)
BLUE (BLU)
32WAV
32WAV
32WAY
I BLOCK
I L32 PCM CONNECTOR IDENTIFICATION
I ALL CONNECTOR BODIES ARE GRAV
WITH COLORED TPAs.
_ _ ...J
A - CLEAR (CLR) 32WAV
.SORN 340 B - BLACK (BLK) 32WAV
.5 PNK 439

·---,
C - BLUE (BLU) 32WAV
llilli.........

h
SEE FUSE .SORN S209
BLOCK DETAILS
PAGE SA-11-5
,....-- - - • 520~
340
r - - - - , POWERTRAIN
SV CONTROL
I I MODULE (PCM)

INST!!.\!.~~.!
I
CLUSTER
C14
A13
r 1----(CHEVY)
(PONT)
"1
I
l
SEE FUSE
I
I
FUEL
ENABLE
I
I ~
•
BLOCK DETAILS L - ~G~L..J

.8 PNK 439
•
~
I
I
I
®
1 ---- "SECURITY"
INDICATOR
I
I
I
PAGESA-11-7 23
25
C (V6 VIN S)
~ (VS VIN P)

.35 DK BLU 229

~ ----~ P1_1_Q

.8 VEL/BLK
c~~I-. l~~~~,
.35 GRV 728 .8 ORN 340
E1C230
.35 DK BLU 229
. 625 A2 AS A1 Al
P""""""""""-,t~"""""""""""""""""""""'"":"""""""""""""""""""""""""""~"""""""""""""""""""""""""'"":"""""""""""""""""""""""""""""""""""""""""""""""""""~~....................-,THEFT
DETERRENT
MODULE
I
I
I
I
I
I
I IGNITION INDICATOR CONTROL BATTERY
I PWM
I FUEL ENABLE - - -1""1...J"'l._
SOLID STATE
L- START
DETECTOR SIGNAL
ENABLE SVREF
AND TIMER

SIGNAL GROUND

.35 WHT/BLK
BS y ---------------
ton
87

.35 PPL1WH~074
y 8
.35 BLK/W : T f 51

A B i.i>.•
I
IGNITIONKEV -, S215·- - -- ,
.35 WHT l,QQ(_~ .35 WHT - • ,

.s BLK/Wf,:T ,.;~:,o
.SBLK,W
P110
1-
l
[I] IMPORTANT: S_1Ql! (VS VIN P). -
SEEGROUND
DISTRIBUTION

• ANY NEW THEFT DETERRENT

MODULE WILL
~ (V 6 V l N S ) k
.8BLK,WHT 451 T PAGESSA-14-1,2,3

~
AUTOMATICALLY PROGRAM
TO THE RESISTANCE OF THE
KEY(ORINTERROGATOR
SETTING) BEING USED AT THE
FIRST IGNITION "ON" CYCLE.
RESISTOR
RESISTOR
PELLET
_c_ G103
---1
THIS CAN ONLY BE DONE
ONCE FOR THE LIFE OF THE
MODULE.
SENSING
CONTACTS

0
(VS VIN P)
G104 (V6 VIN S)
4$t~
SEE PAGE SA-3-0
FOR MEASURING
IGNITION AND HANDLING
~~ PROCEDURES
 90-6 THEFT DETERRENT SYSTEMS

ELECTRICAL DIAGNOSIS: PASS-Key®II

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)

12110259
16-WAY F MICRO-PACK 100 SERIES
GRN

THEFT DETERRENT MODULE

**CAVITIES NOT LISTED ARE NOT USED

CAVITY WIRE COLOR CKT DESCRIPTION PAGE

A1 ORN 340 POWER FEED FROM PCM BAT FUSE #4 SA-11-7

A2 PNK 439 POWER FEED FROM PCM IGN FUSE #5 SA-11-5

A3 DKBLU 229 FUEL ENABLE SIGNAL 90-5

A4 YEL/BLK 625 THEFT DETERRENT RELAY CONTROL 90-4,5

AS GRY 728 "SECURITY" INDICATOR LAMP CONTROL 90-5

BS BLK/WHT 451 GROUND SA-14-1, 2, 3

87 PPL/WHT 1074 IGNITION KEY RESISTOR RETURN 90-5

BS WHT/BLK 1073 IGNITION KEY RESISTOR FEED 90-5

SECTION
COMPONENT LOCATION SA-201-PG FIG. CONN
Clutch Start Switch Mounted to clutch pedal bracket, behind
Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 202-22
Ignition Key Lock Cylinder Top RH side of Steering Column . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 51
Ignition Switch ......... . Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . 51 .. 202-22
Instrument Cluster ...... . LH side ofl/P ................................................... . 202-22
Powertrain Control Module
(PCM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower 19 35 .. 202-18
Powertrain Control Module
(PCM) (VS VIN P) ..... . In Engine Compartment, rearward of RH Shock Tower 19 35 202-19
Starter Solenoid ........ . Bottom of RH side of Engine, above Starter Motor ..... 25 42
Theft Deterrent Module .. . In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15 202-14
Theft Deterrent Relay ... . Mounted to right side of SIR Bracket, behind 1/P ...... 45 66 . . 202-20
Transmission Position
Switch ................ . Under console, on base of shift control lever .......... 37 54 . . 202-24
C200B (18 cavities) ..... . Part of Forward Lamp Harn, between LH kick panel
and Steering Column ............................. 47 72 . . 202-2
 THEFT DETERRENT SYSTEMS 90-7

SECTION
COMPONENT LOCATION SA-201-PG FIG. CONN
C200D (48 cavities) Part ofI/P Harn, between LH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 72 202-2
C210 (4 cavities) ........ . Under RH side ofl/P, behind RH kick panel . . . . . . . . . . 46 67 202-16
C230 (IO cavities) ....... . Under RH side of I/P, behind kick panel . . . . . . . . . . . . . 46 67 202-7
Gl03 (LTl) ............. . RH side of Engine Block, just above Starter
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 42
Gl04 (L32) 2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, l stud in Intake Manifold . . 29 46
PllO .................. . Right side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 35
Sl09 (LTl) Engine Harn, approx 4 cm from main branch and
ECM breakout
SllO (L32) Engine Harn, approx 7 cm from main branch and
ECM breakout
S205 I/P Harn, approx 31 cm from Convenience Center
breakout
S209 I/P Harn; approx 24 cm from Convenience Center breakout
S215 1/P Harn, approx 30 cm before DLC breakout
S223 I/P Harn, approx 4 cm before DLC breakout

For a Service Part Cross Reference List and Information, refer to SECTION SA-200.

TROUBLESHOOTING HINTS
(Perform before beginning
Diagnosis)
1. Check the Ignition Key for a cracked resistor pellet
or a pellet that is dirty or coated. Also check that
the Ignition Key is free from excess plastic around
the resistor pellet contacts.
2. Check owner's Ignition Key using the J 35628-A
Interrogator or equivalent. If the Key Code
window shows "E", replace the owner's key. (See
"Key Replacement," page 90-15.) ,
3. Check the key pellet sensing contacts in the
Ignition Lock Cylinder by looking into the key
opening. If the contacts are damaged or not silver
in color, replace the Lock Cylinder.
4. Check for an open "PCM IGN Fuse 5" or "PCM
BATT Fuse 4". Also check the I/P Fuse Block
contacts for each fuse.
5. If the Theft Deterrent Relay must be replaced, also
check CKT 6 to the Starter Solenoid for a possible
short. A short may have caused the relay to fail.
6. To check the contacts to the key and the wires in
System the Steering Column, disconnect the connector
near the base of the column. Use the J 39200 DVM
set on "MIN MAX" to measure the resistance back
to the key at this connector while you turn and
adjust the Steering Wheel. If there is any change
or intermittent reading, replace the Lock Cylinder
and the Steering Column wires that come with it.
See SECTION 3F5.
7. Check for a broken (or partially broken) wire
inside of the insulation which could cause system
malfunction but prove "GOOD" in a
continuity/voltage check with a system
disconnected. These circuits may be intermittent
or resistive when loaded, and if possible, should be
checked by monitoring for a voltage drop with the
system operational (under load).
9D-8 THEFT DETERRENT SYSTEMS
ELECTRICAL DIAGNOSIS: PASS-Key®II
(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
8. Check for proper installation of aftermarket
electronic equipment which may affect the
integrity of other systems (see "Troubleshooting
Procedures," page 8A-4-0).
9. Refer to "Intermittents" on this page.
• Refer to System Diagnosis.
SYSTEM DIAGNOSIS
• Perform the System Check and refer to the
Symptom Table for the appropriate diagnostic
procedures.
INTERMITTENTS
rn
•
Important:
Additional information for detecting Electrical
Intermittents can be found on page 8A-4-8.
The most likely causes of intermittent no start no
crank complaints due to the PASS-Key®II SYSTEM
are either an incorrect resistance measurement of the
Ignition Key or an intermittent relay.
Incorrect resistance measurements checks:
• If one key works and not the other, clean or
replace the faulty key.
• If condition is present with all keys,
indications are that the lock cylinder is
dirty/defective or there is a fault in the key
resistance circuit wiring, connections or
contacts.
• A method for checking the key resistance
circuit with an ohmmeter is as follows:
1. Use the J 39200 DVM to measure
resistance across key contacts while
removed from vehicle.
2. Disconnect the Theft Deterrent Module,
insert key in Ignition. With the J 39200
set to "MIN MAX", measure resistance
across terminals "B8" and "B7'' of the
Theft Deterrent Module Harness
Connector. Listen for an audible tone from
the DVM. This would indicate a
fluctuating resistance, while manipulating
the harness and rotating the Steering
Wheel from side to side. If the resistance
fluctuates, check the wiring and wiring
connections to the lock cylinder for an
intermittent (Ex: poor connection
or broken wire inside the insulation). If
the resistance is not within 5 ohms of the
resistance measured on the key when it
was removed from the vehicle, check for a
dirty or defective lock cylinder.
3. Rotate key throughout all positions and
monitor for a resistance change. This
would indicate a change of over 5 ohms
indicating a problem with the lock cylinder
or key contacts.
Intermittent relay checks:
• If the "SECURITY" Indicator comes on for 5
seconds and then goes off, the relay is most
likely the problem. Check connections to
relay, if OK, install a new relay.
• If the "SECURITY" Indicator remains "ON"
past the 5 second bulb check when the vehicle
will not crank, the relay is not the problem.
• If it is necessary to turn the key to crank
several times before the Engine will crank, the
relay is probably intermittent. Check
connections to relay, if OK, install a new relay
• If the vehicle cannot be started immediately
after a fault, the relay is not the problem.
Some other areas to check include the following:
• Check that the connector to the Theft
Deterrent Module is tight and terminals are
clean.
• Check for History Diagnostic Trouble Code 46
in PCM, intermittent fuel enable CKT 229.
See SECTION 6E3.
• Check power and ground to the module while
manipulating the harness.
• During an Ignition Cycle the "SECURITY"
Indicator will illuminate and remain "ON"
while a problem is detected in the key
resistance circuits (for at least 1 minute) and
will turn "OFF" if the fault goes away.
• Lightly tapping the Theft Deterrent Module
will determine if the module is intermittent.
Intermittents are typically not the Theft
Deterrent Module.
• Thermal cycle Theft Deterrent Relay and
Theft Deterrent Module and reinstall in
vehicle to induce fault.
 THEFT DETERRENT SYSTEMS 90-9

rn
•
Important:
Perform the On-Board Diagnostic System Check
described in SECTION 6E3 to be certain no
trouble codes are stored in PCM memory which
may lead to misdiagnosis, specifically Code 46,
indicating a problem in the PASS-Key®II Fuel
Enable circuit.

SYSTEM CHECK
ACTION NORMAL RESULTS

[ 1]
• Observe "SECURITY" Indicator. "SECURITY" Indicator illuminates for approximately 5
• Ignition Switch to "RUN." seconds then goes "OFF."
[2]
• (Automatic Transmission)
Position Switch in "PARK."
• (Manual Transmission)
Clutch Start Switch closed (depress Clutch Pedal).
• Ignition switch to "START." Engine starts.
[3]
• Ignition Switch to "OFF." Engine stops.
[4]
• Disconnect Ignition Key Lock Cylinder Connector
at base of Steering Column.
• Connect the male and female parts to the mating
connectors on the pigtails from the J 35628-A
Interrogator or equivalent.
• Insert the customer's Ignition Key into the Key
Code Reader on the J 35628-A Interrogator.
• Press the On-Off Rocker Switch to the "ON"
position.
• A number from 1 to 15 will appear on the display
of the Interrogator indicating the electrical code
of the key ("E" indicates error).
• Set the Key Code Selector on the J 35628-A
Interrogator to a code which is different from the
code read on the Key Code Reader display. Vehicle will not crank. "SECURITY" Indicator is
• Turn Ignition Switch to "START." illuminated.
[5]
(Perform this step within the 3 minute shut-down
period).
• Ignition Switch to "OFF."
• Disconnect and remove the J 35628-A
Interrogator. Vehicle will not crank. "SECURITY" Indicator is
• Reconnect connectors at base of Steering Column. illuminated.
• Turn Ignition Switch to "START."
[6]
• Turn Ignition Switch to "OFF."
• Wait 3 to 4 minutes.
• Observe the Indicator.
• When Indicator goes "OFF," turn Ignition Switch
to"START." Engine starts.
90-10 THEfT DETERRENT SYSTEMS

ELECTRICAL DIAGNOSIS: PASS-Key®II

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM}

SYMPTOM TABLE
(Always note condition of "SECURITY" Indicator when fault occurred.}
SYMPTOM I
PROCEDURE PAGE NUMBER
Engine does not crank; "SECURITY" Indicator Chart #1 90-11
illuminates for approximately 5 seconds (bulb check)
then goes out.

Engine cranks but won't start; "SECURITY" Indicator Chart #2 90-12

illuminates for approximately 5 seconds (bulb check)
then goes out.
"SECURITY" Indicator "ON" steady (not flashing); Chart #3 90-12
Engine starts.

"SECURITY" Indicator never illuminates; Engine starts. Chart #4 90-13

Engine does not crank; "SECURITY" Indicator "ON" • Perform Lock Cylinder and Harness Test on
steady (not flashing). page 90-13 (Chart #5).

Engine does not crank; "SECURITY" Indicator • Perform Lock Cylinder and Harness Test on
"FLASHING." page 90-13 (Chart #5).
Engine does not crank; "SECURITY" Indicator does not • Check for battery voltage at Theft Deterrent
illuminate at Ignition "ON.,,, Module Connector terminal "A 1".
• Ignition Switch to "RUN."
• Check for battery voltage at Theft Deterrent
Module Connector terminal "A2".
• Check for ground at Theft Deterrent Module
Connector terminal "BS".
If power and ground wires toTheft Deterrent Module
are OK, replace Theft Deterrent Module.

"SECURITY" Indicator "FLASHING"; Engine starts.
This symptom is present when an unprogrammed
module is put in a vehicle that has an open or short to
B + or short to ground in the Lock Cylinder Contacts or
CKTs 1073 or 1074, or with a damaged key.
• Perform Lock Cylinder and Harness Test on
page 90-13 (Chart #5).
 THEFT DETERRENT SYSTEMS 90-11

CHART #1
ENGINE DOES NOT "CRANK"; "SECURITY" INDICATOR ILLUMINATES

m
•
IMPORTANT:
FOR APPROXIMATEL V 5 SECONDS (BULB CHECK) THEN GOES OUT

TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.

• DISCONNECT THEFT DETERRENT RELAY .

•• ATTACH A TEST LIGHT BETWEEN THEFT DETERRENT RELAY CONN TERM" A 1" AND B + .
WHILE OBSERVING TEST LIGHT, TURN IGNITION SWITCH TO "START."
DOES TEST LIGHT ILLUMINATE?
•
G;J ~
• CONNECT A TEST LIGHT BETWEEN THEFT
DETERRENT RELAY CONN TERM "C2" AND GROUND.
• CHECK FOR POOR CONNECTION, OPEN OR
SHORT TO B + IN CKT 625.
• CLUTCH PEDAL DEPRESSED (MANUAL TRANS) OR IF OK, REPLACE THEFT DETERRENT MODULE.
TRANSMISSION IN THE "PARK" OR "NEUTRAL"
POSITION (AUTOMATIC TRANS).
• WHILE OBSERVING TEST LIGHT, TURN IGNITION
SWITCH TO "START."
DOES TEST LIGHT ILLUMINATE?

G:J ~
• CONNECT A TEST LIGHT BETWEEN THEFT MANUAL TRANSMISSION I AUTOMATIC I
DETERRENT RELAY CONN TERM "C1" AND GROUND. • •
• WHILE OBSERVING TEST LIGHT, TURN IGNITION
SWITCH TO "START."
• CHECK FOR OPEN IN CKT 269
FROM THEFT DETERRENT
• CHECK FOR OPEN IN CKT 269
FROM THEFT DETERRENT
DOES TEST LIGHT ILLUMINATE? RELAY TERM "C2" TO RELAY TERM "C2" TO
CLUTCH START SWITCH TRANSMISSION POSITION
TERM "A". SWITCH TERM "F".
• CHECK FOR POOR
CONNECTIONS AT OR FOR
• CHECK FOR POOR
CONNECTIONS AT OR FOR AN
AN OPEN IN THE CLUTCH OPEN IN THE TRANSMISSION
START SWITCH. POSITION SWITCH.
• CHECK FOR OPEN IN CKT 5
FROM CLUTCH START
• CHECK FOR OPEN IN CKT 5
FROM TRANSMISSION
SWITCH TERM "B" TO 5223. POSITION SWITCH TERM ''E''
105223.

~ ~
• ATTACH A 30 AMP FUSED JUMPER BETWEEN THEFT CHECK FOR OPEN IN CKT 5
DETERRENT RELAY CONN TERM "C1" AND TERM" A2". BETWEEN THEFT DETERRENT RELAY
• IGNITION SWITCH TO "START."
DOES ENGINE CRANK?
CONN TERM "C1" AND 5223.

.
~ ~
r .. ---------------------,
I
• CHECK FOR POOR CONNECTION TO RELAY. : REFER TO "STARTER AND CHARGING," I
IF OK, REPLACE THEFT DETERRENT RELAY. I SECTION SA-30.
• ALSO CHECK CKT 6 TO THE STARTER SOLENOID FOR A L-------------------------~ 1

POSSIBLE SHORT. A SHORT MAY HAVE CAUSED THE

RELAY TO FAIL.
 90-12 THEFT DETERRENT SYSTEMS

ELECTRICAL DIAGNOSIS: PASS-Key®II

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
CHART #2
ENGINE CRANKS BUT WON'T START; "SECURITY" INDICATOR ILLUMINATES
FOR APPROX 5 SECONDS (BULB CHECK) THEN GOES OUT

rn •
IMPORTANT:
TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.

• DISCONNECT THEFT DETERRENT MODULE.

• IGNITION SWITCH TO "RUN."
• WITH A DVM MEASURE VOLTAGE BETWEEN THEFT
DETERRENT MODULE CONN TERM" A3" AND GROUND.
IS MEASURED DC VOLTAGE APPROX + SV?

r- -------------------------,
'•
I
I
CHECK CKT 229 FOR AN OPEN OR SHORT :
BETWEEN THEFT DETERRENT MODULE
• IGNITION SWITCH "OFF."
• RECONNECT MODULE.
I
I CONN TERM" A3" AND POWERTRAIN • IGNITION SWITCH TO "RUN."
I
I CONTROL MODULE (PCM). ALSO CHECK I • MEASURE VOLTAGE AGAIN AT TERM "A3".
I FOR POOR CONNECTIONS TO MODULES. 1 IS MEASURED DC VOLTAGE APPROX + 2.SV?
I
••
I
IF OK, REFER TO SECTION 6E3. FOLLOW :
"ENGINE CRANKS BUT WILL NOT RUN," :
I
I CHART A-3. 1
L---------------------------~
,- --- --- -- --- _,,.... ---,--,
• CHECK FOR POOR CONNECTION: : REFER TO SECTION 6E3; FOLLOW:
IF OK.REPLACE THEFT I "ENGINE CRANKS BUT WILL NOT I
DETERRENT MODULE. : RUN," CHART A-3. :
•---------------------'

CHART #3
"SECURITY" INDICATOR "ON" STEADY (NOT FLASHING); ENGINE STARTS

rn •
IMPORTANT:
TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.

• DISCONNECT THEFT DETERRENT MODULE.

• IGNITION SWITCH TO "RUN."
IS "SECURITY" INDICATOR ILLUMINATED?

• CHECK FOR SHORT TO GROUND ON CKT 728
BETWEEN THEFT DETERRENT MODULE
CONN TERM "AS" AND INSTRUMENT
CLUSTER CONN TERM" A3".
• CHECK INSTRUMENT CLUSTER PRINTED
CIRCUIT FOR SHORTS AND REPAIR/REPLACE
AS NECESSARY.
• PERFORM LOCK CYLINDER AND HARNESS TEST ON PAGE 9D-13 (CHART #5).
• IF KEYS, LOCK CYLINDER AND LOCK CYLINDER HARNESS ARE OK, REPLACE
THEFT DETERRENT MODULE. (THE THEFT DETERRENT MODULE IS
PROGRAMMED WITH A FAULT ENABLE MODE. IN THIS MODE THE "SECURITY"
INDICATOR WILL STAY "ON" STEADY IF A FAILURE OCCURRED, IN THE LOCK
CYLINDER OR CKTS 1073 OR 1074, DURING THE PREVIOUS IGNITION CYCLE.
THE INDICATOR WILL STAY ON APPROXIMATELY ONE MINUTE AFTER REPAIR
IS COMPLETED.)
 THEFT DETERRENT SYSTEMS 90-13

CHART #4
"SECURITY" INDICATOR NEVER ILLUMINATES; ENGINE STARTS

rn •
IMPORTANT:
TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.

• DISCONNECT THEFT DETERRENT MODULE.

• ATTACH A 10 AMP FUSED JUMPER BETWEEN THEFT DETERRENT
MODULE CONN TERM" AS" (HARNESS SIDE) AND GROUND.
• IGNITION SWITCH TO "RUN."
DOES "SECURITY" INDICATOR ILLUMINATE?

--------------------------------------------------------~
CHECK FOR POOR CONNECTION OR OPEN IN CKT 728 BETWEEN THEFT DETERRENT • CHECK FOR POOR CONNECTION
MODULE CONN TERM "AS" AND INSTRUMENT CLUSTER CONN (CHEVY)TERM "C13" OR AT THEFT DETERRENT MODULE.
I
1 (PONT)TERM "A3". IF OK, REPLACE THEFT
:• CHECK FOR OPEN IN CKT 340 BETWEEN INSTRUMENT CLUSTER CONN TERM" A 13" AND DETERRENT MODULE.
: 5209.
1• INSPECT INSTRUMENT CLUSTER PRINTED CIRCUIT AND INDICATOR LAMP, REPAIR/REPLACE
: AS NECESSARY.
: SEE "INSTRUMENT CLUSTER," SECTION SA-81 FOR BACK VIEW AND PINOUT OF CLUSTER.
~----------------------------------------------------------~

CHART#S
LOCK CYLINDER AND HARNESS TEST

rn •
IMPORTANT:
TO AVOID MISDIAGNOSIS, DO NOT PERFORM THIS TEST UNLESS DIRECTED BY SYMPTOM TABLE OR CHART.
• AFTER A REPAIR TO THE LOCK CYLINDER HARNESS, THE "SECURITY" INDICATOR WILL REMAIN "ON" FOR
APPROXIMATELY ONE MINUTE.

• INSERT IGNITION KEY INTO INTERROGATOR J 35628-A.

• TURN THE INTERROGATOR "ON."
• READ THE "KEY CODE" SHOWN ON THE DISPLAY OF THE INTERROGATOR.
IS THE DISPLAYED "KEY CODE" A VALUE OF "1" THROUGH "15"?

• WRITE DOWN THE DISPLAYED "KEY CODE." • CLEAN AND RETEST THE KEY.
• TURN THE INTERROGATOR "OFF." IF THE "KEY CODE" IS
• CONNECT THE INTERROGATOR TO THE 2-WA Y IGNITION SWITCH LOCK CYLINDER INVALID, REPLACE THE KEY.
HARNESS CONNECTOR AT THE BASE OF THE STEERING COLUMN. SEE "KEY REPLACEMENT,"
• INSERT THE IGNITION KEY INTO THE IGNITION SWITCH LOCK CYLINDER. PAGE 90-15.
• TURN THE INTERROGATOR "ON."
• WHILE OBSERVING THE DISPLAY ON THE INTERROGATOR, TURN THE IGNITION SWITCH
SLOWLY TO THE "START" POSITION.
DOES THE DISPLAYED "KEY CODE" VALUE MATCH THE VALUE OBSERVED IN STEP 1?

(CONTINUED ON NEXT PAGE)

90-14 THEFT DETERRENT SYSTEMS
ELECTRICAL DIAGNOSIS: PASS-Key®II
(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
(CONTINUED FROM PREVIOUS PAGE)
• FRONTPROBE WITH A TEST LIGHT THE 2-WAV CONNECTOR
AT THE BASE OF THE STEERING COLUMN BETWEEN TERM
"B" (THEFT DETERRENT MODULE SIDE) AND B +.
DOES THE TEST LIGHT ILLUMINATE?
• CHECK CKT 1073 FOR AN OPEN, SHORT TO
B + OR SHORT TO GROUND.
IF OK, REPLACE THEFT DETERRENT MODULE.
Cg]
KEY CODE READER
(})
Interrogator J 35628-A
: •
----------------------------------1
CHECK FOR POOR CONNECTION. :
IF OK, REPLACE IGNITION SWITCH LOCK CYLINDER AND I
HARNESS (REFER TO SECTION 3F5.) :
~------------------------------------~
• DISCONNECT THEFT DETERRENT MODULE.
• PROBE WITH A TEST LIGHT THEFT DETERRENT MODULE
CONNECTOR BETWEEN TERM "85" AND B +.
DOES TEST LIGHT ILLUMINATE?
• CHECK FOR POOR CONNECTION AT
TERMINALS "85" OR "87" TO
MODULE, OR OPEN IN CKT 1074.
IF OK, REPLACE THEFT DETERRENT
MODULE.
DUPLICATION OF KEYS
KEY REPLACEMENJ(SPARE KEY AVAILABLE)
The J 35628-A Interrogator or equivalent must be
used to determine the proper electrical code of the key.
1. Insert the customer's spare Ignition Key into the
Key Code Reader on the J 35628-A Interrogator.
2. Press the On-Off rocker switch to the "ON"
position.
3. A number from 1 to 15 will appear in the window
designating the electrical code of the key.
4. Cut a new key having the electrical code
determined from the J 35628-A Interrogator.
5. Start the Engine using the new key to insure that
the key is correct both mechanically and
electrically.
SEE PAGE 8A·3·0
FOR PROPER
HANDLING
PROCEDURES
 THEFT DETERRENT SYSTEMS 90-15

KEY CODE AND RESISTANCE CHART J 35628-A Interrogator to indicate the 4-

min ute interval. Start the Timer by
PELLET CODE KEY RESISTANCE IN OHMS depressing the "Start" rocker switch. The red
Nominal Low High
indicator will turn off at the end of a four
minute interval. This procedure must be
1 402 386 438 repeated until the Engine can be started. Cut
2 523 502 564 a new key having the electrical code which
3 681 654 728 allowed the vehicle to start.
4 887 852 942
5 1130 1085 1195 PROGRAMMING A NEW THEFT DETERRENT
6 1470 1411 1549
7 1870 1795 1965 MODULE
8
9
10
2370
3010
3740
2275
2890
3590
2485
3150
3910
m•
Important:
Any new Theft Deterrent Module will
11 4750 4560 4960
12 6040 5798 6302 automatically program to the resistance of the
13 7500 7200 7820 key (or interrogator setting) being used at the
14 9530 9149 9931 first Ignition "ON" cycle. This can only be done
15 11800 11328 12292 once for the life of the module.

KEY REPLACEMENT
(NO SPARE KEY AVAILABLE)
1. If the Ignition Key is lost and there is no spare key,
determine the mechanical code from the code on
the Ignition Key Lock Cylinder. The code may also
be determined from the dealer invoice for the
vehicle, or from the Key Code Bureau (1-800-243-
8957) for Chevy or from Dealer Assistance (1-800-
447-2287) for Pontiac.
2. Cut a new key to this mechanical code. Use a
blank PASS-Key®II test key which has no
resistance pellet. This key will be used to operate
the Ignition Switch for the remaining steps.
3. Remove the hush panel under the Steering
Column and disconnect the two-cavity connector
leading into the Steering Column.
4. Close the LH door.
5. Insert the male half of the connector (I!P Harness)
into the female pigtail connector from the
J 35628-A Interrogator.
6. Set the Key Code Selector on the Interrogator
(J 35628-A or equivalent) to "1".
7. Attempt to start Engine using the key made in
New Theft Deterrent modules are unprogrammed.
Before the system will function properly after a new
module has been installed, it must be programmed to
the code that matches the customer's keys.
Programming a new module is very simple:
1. Install the new, unprogrammed Theft Deterrent
module.
2. Insert one of the customer's keys in the ignition
lock cylinder and turn it to the "ON" position. It's
a good idea to start the Engine at this time to
verify system operation.
3. Observe the "SECURITY" Indicator Lamp:
• The indicator lamp should light for about five
seconds and then go out. If the wiring or
contacts to the Key Resistance Pellet or the
key is defective or intermittent and a new
module is installed, the Engine will start but
the "SECURITY" Indicator will flash at a rate
of one flash per second until the Ignition
Switch is turned off. This indicates that the
module did not program and that the system
components, wiring and contacts should be

m
step 2. checked for a fault.
• If Engine starts, the Key Code Selector is set to
the correct electrical code. Cut a new key with Important:
a resistor pellet having this electrical code. • Before connecting the Interrogator to the
The new key will be the customer's ignition lock cylinder circuit, always verify
replacement key. vehicle key code and set the code into the
• If Engine does not start, turn Ignition Switch Interrogator using "key code" knob. This
to "OFF," then turn the Key Code Selector to will prevent programming an
the next higher position. Wait four minutes unprogrammed Theft Deterrent module with
and attempt to start the Engine using the new an undesired key code.
electrical code. Use the 4-minute Timer on the
90-16 THEFT DETERRENT SYSTEMS
ELECTRICAL DIAGNOSIS: PASS-Key®II
(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
CIRCUIT OPERATION
PASS-Key®II is a theft deterrent system which
prevents the vehicle from starting if the Ignition Key
"Resistance Code" is not recognized by the
Theft Deterrent Module. If the Resistance Code is not
recognized, the Engine is prevented from starting in
two ways: battery voltage from the lgnition Switch to
the starter is disabled by a Theft Deterrent Relay and
fuel to the fuel injectors is stopped without the
presence of a fuel enable signal.
Resistor sensing contacts are located in the
Ignition Key Lock Cylinder. These contact the Key
Resistor Pellet on the key when it is inserted. When
the lock is rotated, Ignition voltage is applied to the
Theft Deterrent Module and pellet resistance is read at
this time. The Pellet resistance is read across
terminals "B7" and ''88" which is then compared
against the resistance value stored in the Module.
If the Key Resistance Pellet is the proper
resistance, terminal "A4" is grounded, energizing the
Theft Deterrent Relay. At the same time, a signal is
applied at terminal "A3" to enable the Powertrain
Control Module (PCM). When this signal is received
by the PCM, it allows fuel injector pulses to begin.
If the Key Resistor Pellet is the wrong value, the
Theft Deterrent Module will shut down for 3 minutes
+ or - 18 seconds. During this interval, there will be
no output at terminals "A3" or "A4" and the
"SECURITY" Indicator will illuminate. The Ignition
Switch input is ignored during this shut down period.
For this reason, the timer will run and the
"SECURITY" Indicator will remain illuminated with
Ignition on or off.
Once the timer has completed its 3 minute + or -
18 second shut down, the next time Ignition is cycled
from off to on, the Theft Deterrent Module timer is
reset. A key having the correct code can then be used
to start the Engine.
"SECURITY" INDICATOR OPERATION
The "SECURITY" Indicator is controlled directly
by the Theft Deterrent Module. The following
describes the modes of indicator operation:
1. When the Ignition is put in "RUN," "BULB
TEST," or "START," the "SECURITY" Indicator
illuminates for about 5 seconds as a bulb check.
2. If the Theft Deterrent Module is actively in the
shut down mode and thus preventing the vehicle
from starting, the indicator will be illuminated
(grounded) by the Theft Deterrent Module for 3
minutes + or - 18 seconds after Ignition is turned
on.
3. If the resistor sensing contacts or CKTs 1073 or
1074 are open or shorted, or if a defective key is
being used at the time Ignition is turned on, the
"SECURITY" Indicator will flash at a rate of once
per second and the Engine will not start; however,
the 3 minute + or - 18 second lockout will not be
activated. Additionally, if an unprogrammed
module is present and there is an open or short, or
if a defective key is being used the Theft Deterrent
Module will not program a key code, the
"SECURITY" Indicator will flash at a rate of once
per second, and the Engine will start.
4. Lock Cylinder CKTs 1073 and 1074 are
continuously monitored and if a fault is detected in
these circuits for 1 minute, the indicator will turn
"ON." If the fault condition goes away for
1 minute, the indicator will turn "OFF" and the
system will function as normal. If a lock cylinder
circuit fault (lock cylinder contacts or wiring
becomes open or shorted, or if a defective key is
detected) while the Engine is "RUNNING", the
vehicle can be restarted. The "SECURITY"
Indicator will illuminate during this Ignition cycle
while the fault is present. When a fault condition
is present at the time Ignition is cycled off, the
vehicle will not be protected by the PASS-Key®II
System and the indicator will be illuminated
whenever the Ignition is on, until the fault is
corrected. This is called the Fault Enable Mode.
After the fault has been corrected, the
"SECURITY" Indicator will remain "ON" for
approximately one minute then go "OFF."
 THEFT DETERRENT SYSTEMS 90·17

ON-VEHICLE SERVICE THEFT DETERRENT MODULE ASSEMBLY

IGNITION KEY ASSEMBLY Figure 3
Copying Ignition Key Assemblies
Tool Required:
l++I Remove or Disconnect
1. Instrument panel assembly. Refer to SECTION 8C.
J 35628-A VATS/PASS Interrogator
2. Bolts/screws (6).
To copy an ignition key assembly, it is necessary to
first determine which PASS-Key 11® key code (resistance 3. Theft deterrent module assembly (1) from inflatable
value) is needed. The ignition key assembly being copied restraint bracket assembly (7).
must be tested to determine the key code. The ignition key 4. Electrical connector.
assembly may be tested using J 35628-A. To use
J 35628-A, turn the tool on, make sure the tool wiring
connectors are disconnected and insert the ignition key l++I Install or Connect
assembly into the tool lock cylinder. The "Key Code NOTICE: See "Notice" on page 9D-1 of this sec-
Reader" will display the key code of the ignition key tion.
assembly. Obtain an ignition key blank matching this
key code and cut it to match the original ignition key 1. Electrical connector.
assembly. 2. Theft deterrent module assembly (1) to inflatable
restraint bracket assembly (7).
Replacing Lost Ignition Key Assemblies 3. Bolts/screws (6) by first securing lower right bolt/
Tool Required: screw (6) and then securing upper left bolt/screw
J 35628-A VATS/PASS Interrogator (6).
To replace lost ignition key assemblies it is neces-
sary to determine the mechanical cut and the electrical key
code.
l~I Tighten
• Bolts/screws (6) to 1.9 N•m (17 lb. in.).
The mechanical and electrical key codes are
recorded on the vehicle invoice. If these codes are avail- 4. Instrument panel assembly. Refer to SECTION 8C.
able, use them to create a new ignition key assembly. If
they are not, follow the procedure below.
The mechanical cut must be determined first. The
mechanical cut can be determined from the key code on
the ignition cylinder assembly or from the original key
"knock outs." If the mechanical cut cannot be deter-
mined, the ignition cylinder assembly should be replaced.
Make an ignition key blank with the correct mechanical
cut to use while determining the proper electrical key
code.
To determine the proper electrical key code, use
J 35628-A and the following procedure:

rn Important
• Do not disconnect yellow two-way SIR con-
nector.
1. Connect J 35628-A wiring to PASS-Key 11® dash
connector at base of steering column assembly. Do
not connect to steering column wiring.
2. Turn J 35628-A on and place key code switch to "1"
and attempt to start engine with proper mechanically
cut key. If engine starts, key code is " 1."
3. If engine does not start, turn ignition off and press
A CONNECTOR, ELECTRICAL
4-minute timer on J 35628-A. 1 MODULE ASSEMBLY, THEFT DETERRENT
4. When timer light goes out, place key code switch to 6 BOLT/SCREW, THEFT DETERRENT MODULE, 1.9 N•m
(17 LB. IN.)
"2" and attempt to start engine. If engine starts, key 7 BRACKET ASSEMBLY, INFLATABLE RESTRAINT
code is "2." INSTRUMENT PANEL MODULE
5. Continue trying different key codes until proper key
code is found. PC0003·9D-F.flP

6. Make new ignition key assembly with proper key Figure 3 - Theft Deterrent Module Assembly
code and mechanical cut.
90-18 THEFT DETERRENT SYSTEMS

THEFT DETERRENT RELAY ASSEMBLY

Figure 4
If the relay assembly is determined to be inopera-
tive, it should be replaced. a

l++I Remove or Disconnect A--..--,"""l)la;..:;>.!.e:~~11

CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
1. Battery negative cable assembly.
2. Instrument panel assembly. Refer to SECTION 8C.
3. Relay assembly (8) from inflatable restraint bracket
assembly (7).
4. Electrical connector from relay assembly (8).

l++I Install or Connect A CONNECTOR, ELECTRICAL

7 BRACKET ASSEMBLY, INFLATABLE RESTRAINT
1. Electrical connector to relay assembly (8). INSTRUMENT PANEL MODULE
8 RELAY ASSEMBLY, THEFT DETERRENT
2. Relay assembly (8) to inflatable restraint bracket
assembly (7).
3. Instrument panel assembly. Refer to SECTION 8C.
Figure 4 - Theft Deterrent Relay Assembly
4. Battery negative cable assembly.

SPECIFICATIONS

FASTENER TIGHTENING SPECIFICATIONS

Theft Deterrent Module Bolt/Screw .................................... 1.9 N•m (17 lb. in.)

SPECIAL TOOLS

J 35628-A

1. VATS/PASS INTERROGATOR

PC0005-9D·F-RP

SECTION 9E
ENGINE COOLANT HEATER
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
Engine Coolant Heater Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
GENERAL DESCRIPTION
The engine coolant heater assembly is used to heat
engine coolant, making it easier to start the engine in cold
climates. It is installed into the engine block assembly at a
water jacket plug location. An engine coolant heater cord
assembly is routed inside the engine compartment. The
heater assembly is rated at 600 watts and uses a 110-volt
ac power supply. For electrical diagram of engine coolant
heater assembly, refer to ELECTRICAL DIAGNOSIS
8A-32.
ON-VEHICLE SERVICE
ENGINE COOLANT HEATER ASSEMBLY
REPLACEMENT
Figures 1 and 2
l++I Remove or Disconnect
CAUTION: Perform this operation when
the engine is cool or personal injury
may result.
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Drain engine coolant from engine block assembly
into an approved container. Refer to SECTION 6B.
3. Cord assembly from heater assembly (1).
4. Loosen bolt/screw (2).
NOTICE: When removing the engine coolant heater
assembly from the engine block assembly, be careful
not to score the machined surface of the plug hole.
5. Heater assembly (1) carefully from plug hole.
• If removing heater assembly (1) permanently,
install water jacket plug into plug hole and
replace engine coolant. For engine coolant re-
placement procedures, refer to SECTION 6B.
ENGINE COOLANT HEATER 9E-1
Engine Coolant Heater Cord Assembly
Replacement .......................... 9E-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-3
Fastener Tightening Specifications . . . . . . . . . . 9E-3
1.,1 Clean
• Plug hole.
- Remove burrs, sealer, paint and other rough
spots.
!++I Install or Connect
NOTICE: The element must not touch the engine
block assembly inner wall in the installed position or
damage to the engine block assembly and heater
assembly could result.
NOTICE: See "Notice" on page 9E-1 of this
section.
1. Apply coat of engine coolant heater lubricant, GM
PIN 9985164 or equivalent, to 0-ring and walls of
plug holes.
2. Engine coolant heater assembly (1) into plug hole.
A. Insert heating element end of heater assembly
( 1) into plug hole.
B. Line up heater assembly (1) with plug hole and
push it straight into place.
C. Rotate heater assembly (1) so that center elec-
trical contact and bolt/screw (2) are in line.hor-
izontally.
D. '(um bolt/screw (2) so that yQke presses
against engine block assembly inner wall.
!~I Tighten
• Bolt/screw (2) to 1.9 N•m (17 lb. in.).
CAUTION: Engine coolant heater cord
assembly must not touch the engine,
hot pipes, manifold or any moving
parts or damage to the vehicle and pos-
sible personal injury may result.
3. Cord assembly to heater assembly (1).
4. Lower vehicle.
 9E·2 ENGINE COOLANT HEATER

1
SECTIONA·A

A 0-RING A 0-RING
B WALL, ENGINE BLOCK B WALL, ENGINE BLOCK
C PLUG HOLE C PLUG HOLE
1 HEATER ASSEMBLY, ENGINE COOLANT D ELEMENT, HEATING
2 BOLT/SCREW, ENGINE COOLANT HEATER, 1 HEATER ASSEMBLY, ENGINE COOLANT
1.9 N•m (17 LB. IN.) 2 BOLT/SCREW, ENGINE COOLA.NT HEATER,
1.9 N•m (17 LB. IN.)

PC0001-9E-F-RP PC0002-9E-F-RP

Figure 1 - Engine Coolant Heater Assembly (5.7L LT1 Figure 2 - Engine Coolant Heater Assembly (3.4L L32
Engine) Engine)

5. Replace engine coolant. Refer to SECTION 6B. 1++1 Install or Connect

CAUTION: Engine coolant heater cord
ENGINE COOLANT HEATER CORD assembly must not touch the engine,
ASSEMBLY REPLACEMENT hot pipes, manifold or any moving
Figures 3 and 4 parts, or damage to the vehicle and
possible personal injury may result.
l++I Remove or Disconnect NOTICE: See "Notice" on page 9E-l of this sec-
1. Note position and routing of cord assembly (3) for tion.
proper placement during installation.. 1. Cord assembly (3) to vehicle routing as noted during
2. Cord assembly (3) from heater assembly (1). removal.
3. Cord straps (4). 2. Cord straps (4).
4. Cord assembly (3) from vehicle routing. 3. Cord assembly (3) to heater assembly (1).
 ENGINE COOLANT HEATER 9E·3

1 HEATER ASSEMBLY, ENGINE COOLANT

3 CORD ASSEMBLY, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
1 HEATER ASSEMBLY, ENGINE COOLANT
3
3 CORD ASSEMBLY, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
~
£~~'
PC0003·9E·f·RP PC0004-9E·f..RP

Figure 3 - Engine Coolant Heater Cord Assembly (5.7L LT1 Figure 4 - Engine Coolant Heater Cord Assembly (3.4L L32
Engine) Engine)

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Engine Coolant Heater Bolt/Screw ..................................... 1.9 N•m (17 lb. in.)
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-1

SECTION 9J
SUPPLEMENTAL INFLATABLE RESTRAINT
(SIR) SYSTEM
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer
to CAUTIONS in this section under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in this section before performing service on or around SIR
components or wiring. Failure to follow CAUTIONS could result in possible air bag
deployment, personal injury, or otherwise unneeded SIR system repairs.

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

CONTENTS
General Description 9J-2 DTC 15 9J-26
Restraint Devices 9J-2 DTC 16 9J-28

.. ...... .................. .. .. .. .. ..........

System Description •••••••••••••• 9J-2 DTC 17 9J-30
Component Description ••••••••••• 9J-3 DTC 18 9J-32
DERM •••••••••••••••••••• 9J-3 DTC 19 9J-34
SIR Component and Wiring Location DTC 21 9J-40
View ••••••••••••••••••• 9J-4 DTC 22 9J-42
"AIR BAG" Warning Lamp ••••••• 9J-5 DTC 23 9J-44
Dual Pole Arming Sensor •••••••• 9J-5 DTC 24 9J-46
Di scrim i nati ng Sensors •••••••••• 9J-5 DTC 25 9J-52
SIR Coil Assembly ••••••••••••• 9J-6 DTC 26 9J-56
lnflator Modules •••••••••• , ••• 9J-6 DTC 28 9J-58
Steering Column ••••••••••••• 9J-6 DTC 31 9J-60
-- Knee Bolster •••••••••••••••• 9J-7 DTC 34 9J-62
Definitions •••••••••••••••••••
Diagnosis •••••••••••••••••••••
9J-7
9J-9
DTC 35
DTC 36
....................
. . . . . . . . . . . . . . . . . ... .
•'•.
9J-64
9J-68
Diagnostic Trouble Codes •••••••••• 9J-9 DTC 42 9J-70
Scan Tool Diagnostics ••••••••••
Use of Special Tools •••••••••••••
9J-9
9J-9
DTC 43
DTC 44
............ .......... .... ...... .. .......... 9J-72
9J-74
SIR Connector Body Face Views •••••••• 9J-10 DTC 51 9J-76
SIR Diagnostic System Check •••••••••• 9J-12 DTC 52 9J-78
Circuit Description ••••••••••••••
Notes on System Check Chart •••••••
9J-12
9J-12
DTC 53
DTC 54
.. .... .... ........ ........ ........ .... .. .... 9J-80
9J-82
Diagnostic Aids •••••••••••••••• 9J-12 DTC 55 9J-84
Chart A - DERM Integrity Check ••••••••
Chart B - "AIR BAG" Warning Lamp Comes
9J-14 DTC 61 . .. . . . . .. . . ... ....... . 9J-86
DTC 62 9J-88
"ON" Steady •••••••••••••••••• 9J-16 DTC 71 and/or 75 •••••••••••••••• 9J-90
Chart C- "AIR BAG" Warning Lamp Does DTC 81 •••••••••••••••••••••• 9J-92
Not Come "ON" (1 of 2) •••••••••• 9J-18 DTC 82 •••••••••••••••••••••• 9J-94
Chart D- "AIR BAG" Warning Lamp Does Not
Come "ON" Steady During Crank ••••• 9J-22
History DTC 83 . . . . . . . . . . . . . .. . . . 9J-96
History DTC 84 9J-98
DTC 14 •••••••••••••••••••••• 9J-24 On-Vehicle Service •••••••••••••••• 9J-100
9J-2 SUPPLEMENTAL INFLATABLE RESTRAINT {SIR) SYSTEM

Service Precautions • • • • • • • • • • • • • • 9J-100 lnflator Module Scrapping

Disabling the SIR System • • • • • • • • • 9J-100 Procedure • • • • • • • • • • • • • • • • 9J-107
Enabling the SIR System ••••••••• 9J-100 Deployment Outside Vehicle
Handling/Installation/Diagnosis • • • • 9J-100 (Driver Inflater Module) ••••• 9J-107
Repairs and Inspections Required After Deployment Outside Vehicle
an Accident • • • • • • • • • • • • • • • • • 9J-101 (Passenger lnflator Module) 9J-112
Accident With Deployment - Deployment Inside Vehicle (Vehicle
Component Replacement and Scrapping Procedure) • • • • • • • 9J-112
Inspections • • • • • • • • • • • • • • 9J-101 Deployed Inflater Module Handling • 9J-117
Accidemt With or Without Deployment- Wiring Repair • • • • • • • • • • • • • • • • • 9J-118
Component Inspections ••••••• 9J-101 Terminal Repair KitJ 38125-A • • • • • • • 9J-118
Sensor Replacement Guidelines 9J-101 SIR Connector (Plastic Body and Terminal
Diagnostic Energy Reserve Module •••• 9J-102 Metal Pin) Repair ••••••••••••• 9J-119
Discriminating Sensors ••••••••••• 9J-102 SIR Wire Pigtail Repair •••••••••••• 9J-119
Forward Discriminating Sensor ••••• 9J-102 SIR Wire Repair •••••••••••••••• 9J-119
Passenger Compartment SIR System Wire Splice Repair ••••••• 9J-120
Discriminating Sensor • • • • • • • • • • 9J-103 Alternative Repair Methods •••••••• 9J-120
DualPoleArmingSensor •••••••••• 9J-104 Connector Position Assurance (CPA) 9J-120
Passenger Inflater Module • • • • • • • • • 9J-105 Terminal Position Assurance (TPA) 9J-120
Live (Undeployed) Inflater Module 9J-105 Special Tools ••••••••••••••••••• 9J-120
Deployed Inflater Module • • • • • • • 9J-105 SIR Driver/Passenger Load Tool •••••• 9J-120
"AIR BAG" Warning Lamp • • • • • • Section 8C J 39200 DVM •••••••••••••••••• 9J-121
Driver Inflater Module • •••• ••• Section 3F Scan Tool •••••••••••••••••••• 9J-121
SIR Coil Assembly • • • • • • • • • • • Section 3FSB J35616-A Connector Test Adapter Kit 9J-121
Inflater Module Handling/Shipping/ Specifications ••••••••••••••••••• 9J-121
Scrapping •••••••••••••••••• 9J-106 Fastener Tightening Specifications •••• 9J-121
Live (Undeployed) Inflater Module 9J-106 Service Parts Information ••••••••••• 9J-121
Shipping Procedures for Live SIR Special Tools ••••••••••••••••• 9J-122
(Undeployed) lnflator Modules • • • 9J-106

GENERAL DESCRIPTION
RESTRAINT DEVICES
Figures 1 and 2

The Supplemental Inflatable Restraint (SIR)

system helps supplement the protection offered by the 3
driver and front passenger seat belts by deploying an
air bag from the center of the steering wheel and from
the top of the right side of the instrument panel
(Figure 1).
The air bag deploys when the vehicle is involved
in a frontal crash of sufficient force up to 30 degrees off
the centerline of the vehicle (Figure 2). To further 1 DEPLOYED AIR BAG
absorb the crash energy there is a knee bolster located 2 KNE.E BOLSTER
beneath the instrument panel for both the driver and 3 SEAT BELT
95 6227-9J
passenger and the steering column is collapsible.
Figure 1 - Restraint Devices
SYSTEM DESCRIPTION The main function of the deployment loops is to supply
Figure 3 current through the inflator modules, which will cause
deployment of the air bags in the event of a frontal
The main portions of the SIR system are the crash of sufficient force, up to 30 degrees off the
deployment loops and the Diagnostic Energy Reserve centerline of the vehicle.
Module (DERM).
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-3

. - - - - ~ TO PASSENGER
36VLR

DUAL POLE
ARMING
SENSOR

PASS.
INFLATOR PASS. INFLATOR
MODULE MODULE JUMPER

NS 11315 PASSENGER
COMPARTMENT
_
C200B: 02 ...:
~

Figure 2 - SIR System "Deployment Window" DISCRIMINATING

SENSOR
The dual pole arming sensor, SIR coil assembly
(driver side only), inflator modules, passenger
compartment discriminating sensor and forward
discriminating sensor make up the deployment loops.
The dual pole arming sensor switches power to the
C200B
inflator modules on the high side (power side) of the 6-21-93
NS11427
deployment loops. Either of the discriminating
sensors can supply ground to the inflator modules on Figure 3 - Deployment Loops
the low side (ground side) of the loops. The inflator If the monitored voltages fall outside of expected
modules are only supplied sufficient current to deploy limits the DERM will indicate a malfunction through
when the dual pole arming sensor and at least one of the storage of a diagnostic trouble code and the
the discriminating sensors are closed simultaneously. illumin:ationof the "AIR BAG" warning lamp.
A function of the DERM is to supply the
deployment loops with a 36 Volt Loop Reserve (36 COMPONENT DESCRIPTION
VLR) to ensure sufficient energy to deploy the air bags Figure4
if the ignition feed to the dual pole arming sensor is
lost during a frontal crash. DERM
Another function of the DERM is electrical system
diagnostics. The DERM monitors the deployment NOTICE: Do not open the DERM case for any
loops in conjunction with the resistors in the dual pole reason. Touching the connector pins or soldered
arming sensor, passenger com part men t components may cause electrostatic discharge
discriminating sensor and forward discriminating damage. Repair of a malfunctioning DERM is by
sensor. These resistors make it possible for the DERM replacement only.
to detect circuit and component malfunctions within
the deployment loops. The DERM monitors the
voltage drop across each component within the loops
during normal non-deployment operation.
9J-4 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

1 PASSENGER COMPARTMENT DISCRIMINATING SENSOR 8 PASSENGER INFLATOR MODULE

2 STEERING COLUMN SUPPORT BRACKET 9 1/P COMPARTMEN,T DOOR ASSEMBLY
3 FRONT END TIE BAR 10 DUA'- POLE ARMING SENSOR
4 FORWARD DISCRIMINATING SENSOR 11 FLOOR TUNNEL
5 HVACDUCT 12 SIR COIL ASSEMBLY
6 DERM 13 DRIVER INFLATOR MODULE
7 SIR WIRING HARNESS 14 DRIVER INFLATOR MODULE HARNESS CONNECTOR
7-7-92
NS 11453

Figure 4 - SIR Component and Wiring Location View

 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-5
The DERM is designed to perform the following
functions in the SIR system:
1. Energy Reserve - The DERM maintains two 36
Volt Loop Reserve (36 VLR) energy supplies to
provide deployment energy when the vehicle
voltage is low or lost in a frontal crash.
2. Malfunction Detection - The DERM performs
diagnostic monitoring of SIR system electrical
components.
3. Malfunction Recording - The DERM provides
SIR system diagnostic trouble code
information through a scan tool.
4. Driver Notification - The DERM warns the
vehicle driver of SIR system malfunctions by
controlling the "AIR BAG" warning lamp.
5. Frontal Crash Recording - The DERM records
the SIR system status during a frontal crash.
The DERM is connected to the SIR wiring harness
by a 24-way connector. This harness connector uses a
shorting bar across certain terminals in the contact
area. This shorting bar connects the "AIR BAG"
warning lamp to ground when the DERM harness
connector is disconnected. This will cause the "AIR
BAG" warning lamp to come "ON" steady whenever
the ignition switch is at the RUN, BULB TEST or
START positions with the DERM disconnected.
"AIR BAG" Warning Lamp
Ignition voltage is applied to the "AIR BAG"
warning lamp when the ignition switch is at the RUN;
BULB TEST or START positions. The DERM controls
the lamp by providing ground with a lamp driver. The
"AIR BAG" warning lamp is used in the SIR system to
qo the following:
1. Verify lamp and DERM operation by flashing
seven times when the ignition switch is first
turned "ON."
2. Warn the vehicle driver of SIR electrical
system malfunctions which could potentially
affect the operation of the SIR system. These
malfunctions could result in non-deployment
in case of a frontal crash or deployment for
conditions less severe than intended.
The "AIR BAG" warning lamp is the key to driver
notification of SIR system malfunctions. For proper
lamp operation, refer to the "SIR Diagnostic System
Check" in this section.
Dual Pole Arming Sensor
The dual pole arming sensor is a protective switch
located in the high side (power side) of the deployment
loops. The dual pole arming sensor is calibrated to
close at low level velocity changes (lower than the
discriminating sensors).
This ensures that the inflator modules are connected
directly to the "36 VLR" outputs of the DERM or
"Ignition 1" voltage when any discriminating sensor
closes.
The dual pole arming sensor consists of: a sensing
element, two sets of normally open switch contacts,
diagnostic resistors and diodes. The .sensing element
closes both sets of switch contacts when the velocity of
the vehicle changes at a rate indicating a potential
need for deployment.
Two of the diagnostic resistors are connected in
parallel with the switch contacts. This allows a small
amount of current to flow through each of the
deployment loops during normal, non-deployment
operation. This current flow results in voltage drops
across each component in the deployment loops. The
DERM monitors these voltage drops to detect circuit or
component malfunctions. There are two additional
diagnostic resistors within the dual pole arming sensor
which allow the DERM to monitor the voltage supplied
to the high side of the deployment loops. These
monitored voltages are used by the diagnostic logic of
the DERM to make a more precise determination of
the actual deployment loop malfunction.
The diodes within the dual pole arming sensor
provide isolation between the "36 VLR" outputs of the
DERM and the vehicle electrical system "Ignition l"
voltage. The presence of the diodes prevents a direct
continuity measurement through the dual pole arming
sensor resistors to terminals "A", "B" or "C".
Discriminating Sensors
The discriminating sensors are protective switches
wired in parallel on the low side (ground side) of the
deployment loops. These sensors are calibrated to
close with velocity changes which are severe enough to
warrant deployment.
The discriminating sensors consist of a sensing
element and normally open switch contacts. The
sensing element closes the switch contacts when the
vehicle velocity changes are severe enough to warrant
deployment.
A diagnostic resistor is connected in parallel with
the switch contacts within the passenger compartment
discriminating sensor and forward discriminating
sensor. These parallel resistors supply the ground
path for the current passing through the deployment
loops during normal, non-deployment operation. This
current flow results in voltage drops across each
component within the deployment loops. The DERM
monitors these voltage drops to detect circuit or
component malfunctions.
 9J-6 SUPPLEMENTAL INFLATABLE.RESTRAINT (SIR) SYSTEM

SIR Coil Assembly

Figure 5

The SIR coil assembly consists of two current

carrying coils. They are attached to the steering
column and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver inflator module.
There is a shorting bar on the yellow 2-way
connector near the base of the steering column which
connects the SIR coil to the SIR wiring harness. The
'shorting bar shorts the circuits to the SIR coil and
driver inflator module when the yellow 2-way
connector is disconnected. The circuit to the driver
inflator module is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SIR system components.

lnflator Modules
Figures 6 and 7
SIR COIL ASSEMBLY
The inflator modules consist of an inflatable bag
and an inflator (a canister of gas-generating material 2 !NFL.ATOR MODULE CONNECTOR
and an initiating device). When the vehicle is in a
frontal crash of sufficient force to close the dual pole 3 STEERING COLUMN CONNECTOR
arming sensor and at least one of the discriminating NS 15297
sensors simultaneous.ly, current flows through the
deployment loops. Current passing through the Figure 5 - SIR Coil Assembly
initiator ignites the material in the inflator module.
The gas produced from this reaction rapidly inflates
the air bag.
There is a shorting bar on the driver inflator
module side of the upper steering column connector
4
which connects the SIR coil assembly to the driver
inflator module. The shorting bar shorts across the
driver inflator module circuits when the upper
steering column connector is disconnected. The circuit
to the driver inflator module is shorted in this way to
help prevent unwanted deployment of the air bag
when servicing the driver inflator module, the steering
column or other SIR system components.
There is a shorting bar on the passenger inflator
module connector which connects to the passenger
inflator module jumper. The shorting bar shorts
across the passenger inflator module circuit when the
passenger inflator module connector is disconnected.
The circuit to the passenger inflator module is shorted
in this way to help prevent unwanted deployment of
SIR COIL ASSEMBLY
the air bag when: servicing the passenger inflator
module, the instrument panel or other SIR system 2 INFLATOR MODULE
components.
3 CONNECTOR POSITION ASSURANCE (CPA)
Steering Column 4 INFLATOR MODULE HARNESS CONNECTOR
NS11318
The steering column is energy absorbing and is
designed to compress in a frontal crash to decrease the Figure 6A - Driver lnflator Module (Camara)
chance of injury to the driver. A steering column
reinforcement is also used for additional support.
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-7
2
6
!VIEWA!
5
6 B+ - Battery voltage, the voltage available at the
SIR COIL ASSEMBLY
2 REDUNDANT STEERING WHEEL CONTROLS
3 DRIVER INFLATOR MODULE
4 CONNECTOR POSITION ASSURANCE {CPA)
5 INFLATOR MODULE HARNESS CONNECTOR
6 HORN LEAD
Figure 68 -.Driver Inflater Module (Firebird)
1/PTRIM PAD
2 SIR BRACKET ASSEMBLY
3 PASSENGER INFLATOR MODULE
4 1/P COMPARTMENT DOOR ASSEMBLY
Figure 7 - Passenger Inflater Module
Knee Bolster
The knee bolsters are used to absorb energy and
control the forward movement of the vehicle's front
seat occupants during a frontal crash, by limiting leg
4 movement.
DEFINITIONS:
AIR BAG. - An inflatable cloth cushio.n designed to
deploy in certain frontal crashes. It supplements the
protection offered by the seat belts by distributing the
impact load more evenly over the vehicle occupant's
head and torso.
ASYNCHRONOUS - Performed in a non~periodic
3
fashion, i.e. no defined time or interval.
battery at the time of the indicated measurement.
With the key "ON" and the engine not running, the
system voltage wiU likely be between 12 and 12.5
volts. At idle the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
NS11319
BULB CHECK - The DERM will cause the "AIR BAG"
warning lamp to flash seven. times and then go "OFF"
whenever the ignition switch transitions to the RUN
position from any other ignition switch position and no
malfunctions are detected.
"CONTINUOUS MONITORING" - Tests performed by
the DERM on the SIR system every 100 .milliseconds
while "Ignition l" voltage is in the normal operating
voltage range at the DERM.
DATA LINK CONNECTOR (DLC) - Formerly
"ALDL", a connector which is connected by wires to
multiple on-board computers allowing communication
with an off-board computer, such as a scan tool.
DATUM LINE - A base line parallel to the plane of the
underbody or frame from which all vertiea,l
measurements originate.
DEPLOY - To inflate the air bag.
DEPLOYMENT LOOPS - The circuits which supply
current to the inflator modules to deploy the air bags.
DERM - Diagnostic energy reserve module which
provides reserve energy to the deployment loops and
performs diagnostic monitoring of all SIR system
NS 11320
components.
9J-8 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM
DIAGNOSTIC TROUBLE CODE (OTC) - Formerly
"Code," a numerical designator used by the DERM to
indicate specific SIR system malfunctions.
DRIVER CURRENT SOURCE - An output of the
DERM which injects current into the driver inflator
module circuit during the "Initiator Assembly
Resistance Test."
DRIVER INFLATOR MODULE - An assembly located
in the steering wheel hub consisting of an inflatable
bag, an inflator and an initiator.
DUAL POLE ARMING SENSOR - A sensor on the
high side (power side) of the deployment loops that is
calibrated to supply voltage to the inflator modules
when the vehicle velocity changes are severe enough
to warrant arming of the air bags in preparation for
deployment.
EEPROM - Electrically Erasable Programmable Read
Only Memory. Memory which retains its contents
when power is removed from the DERM.
FORWARD DISCRIMINATING SENSOR - A sensor
on the low side (ground side) of the deployment loops
which is calibrated to ground the inflator modules
when the vehicle velocity changes are severe enough
to warrant deployment of the air bags.
HIGHER PRIORITY FAULT - Each diagnostic trouble
code is assigned a priority based on the detectability
with other DTCs present. The priority corresponds to
the detectability of the malfunction ONLY, and does
NOT relate to the criticality of the malfunction with
respect to deployment or non-deployment under any
given condition.
IGNITION CYCLE - The voltage at the DERM
"Ignition l" inputs, with ignition switch "ON," is
within the normal operating voltage range for at least
ten seconds before turning ignition switch "OFF."
IGNITION 1 - A battery voltage (B +) circuit which is
only powered with the ignition switch in the RUN,
BULB TEST, or START positions.
INITIATOR - The electrical component inside the
inflator module which, when sufficient current flows,
sets off the chemical reaction that inflates the air bag.
"INITIATOR ASSEMBLY RESISTANCE TEST" -
Tests performed once each ignition cycle when no
malfunctions are detected during "Turn-ON" or
"Continuous Monitoring." This test checks for the
correct DERM configuration for the vehicle, shorts to
"Ignition l" in the deployment loops, high resistance
or opens in the "Driver Side High," "Driver Side Low,"
"Passenger Side High" and "Passenger Side Low"
circuits and measures the resistance of the inflator
assembly consisting• of: 1) Initiators, 2) SIR coil
assembly (driver side only), 3) Connectors and
associated wiring.
NORMAL OPERATING VOLTAGE RANGE - The
voltage measured between the DERM "Ignition 1;'
terminals and "Ground" terminals is between 7.25 and
16 volts.
PASSENGER COMPARTMENT DISCRIMINATING
SENSOR - A sensor on the low side (ground side) of the
deployment loops which is calibrated to ground the
inflator modules when the vehicle velocity changes are
severe enough to warrant deployment of the air bags.
PASSENGER CURRENT SOURCE - An output of the
DERM which injects current into the passenget
inflator module circuit during the "Initiator Assembly
Resistance Test."
PASSENGER INFLATOR MODULE - An assembly
located in the right side of the I/P consisting of an
inflatable bag, an inflator and an initiator.
PASSENGER INFLATOR MODULE JUMPER - An
assembly of two current carrying wires which connects
the passenger inflator module to the deployment loop.
SCAN TOOL - An off-board computer used to read
diagnostic information from on-board computers via
the data link connector.
SERIAL DATA - Information representing tlie status
of the SIR system. ·
SIR - Supplemental inflatable restraint.
SIR COIL ASSEMBLY - An assembly of two current-
carrying coils in the driver deployment loop that
allows the rotation of the steering wheel while
maintaining the continuous contact of the driver
deployment loop to the driver inflator module.
SIR WIRING HARNESS The wires and connectors
O
that electrically connect the components in the SIR
system.
"10 MINUTE LOOP TEST" - Portions of the "Initiator
Assembly Resistance Test" are repeated every teri
minutes during an ignition cycle. These are the check
for shorts to "Ignition l" in the deployment loops and
the check for an open discriminating sensor
interconnect circuit.
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-9

"TURN-ON" - Test which the DERM performs on the
SIR system once during each ignition cycle
immediately after "Ignition I" voltage is applied to the
DERM and before "Continuous Monitoring."
36 VLR - The 36 volt loop reserve energy supplies from
the DERM which provide deployment power when
vehicle voltage is low or lost in a frontal crash.
36 VLR DELAY - Charging of the 36 VLR power
supplies is inhibited briefly during "Turn-ON." This
allows detection of certain malfunctions related to
"Ignition l" voltage which cannot be tested with 36
volts present.
DIAGNOSIS
CAUTION: To avoid deployment when
troubleshooting the SIR system, do not
use electrical test equipment such as a
battery powered or ac powered
voltmeter, ohmmeter, etc., or any type of
electrical equipment other than that
specified in this manual. Do not use a
non-powered probe type tester.
Instructions in this manual must be
followed carefully, otherwise personal
injury may result.
DIAGNOSTIC TROUBLE CODES
USE OF SPECIAL TOOLS
CAUTION: To avoid deployment when
troubleshooting the SIR system, do not
use electrical test equipment such as a
battery powered or ac powered
voltmeter, ohmmeter, etc., or any type of
electrical equipment other than that
specified in this manual. Do not use a
non-powered probe type tester.
Instructions in this manual must be
followed carefully, otherwise personal
injury may result.
You should be familiar with the tools listed in this
section under the heading "SIR SPECIAL TOOLS."
You should be able to measure voltage and resistance.
You should be familiar with proper use of a scan tool
such as the Tech 1 Diagnostic Computer TK-0, SIR
Driver/Passenger Load Tool J 38715, Connector Test
Adapter Kit J 35616-A, and the DVM (Digital
Multimeter) J 39200.

The "SIR Diagnostic System Check" must always

be the starting point of any SIR system diagnosis. The
"SIR Diagnostic System Check" checks for proper" AIR
BAG" warning lamp operation and checks for SIR
diagnostic trouble codes using the scan tool.
I. Current diagnostic trouble codes - Malfunctions
that are presently being detected. Current
diagnostic trouble codes are stored in RAM
(Random Access Memory).
2. History diagnostic trouble codes - All malfunctions
detected since the last time the history memory
was cleared. History diagnostic trouble codes are
stored in EEPROM.

Scan Tool Diagnostics

A scan tool is used to read current and history

diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan tool
must be updated to communicate with the SIR system
through a replaceable cartridge before it can be used
for SIR diagnostics. To use the scan tool, connect it to
the data link connector and turn the ignition switch
"ON." The scan tool reads serial data from the DERM
"Serial Data" line terminal "Bll" to the data link
connector terminal "M".
9J-10 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

DERM

Passenger Jumper Harness and

lnflator Connectors (Male)

Passenger Jumper Harness and

lnflator Connectors (Female)

Dual Pole Arming Sensor Harness Steering Column Harness Connector

Connector

Passenger Compartment Discriminating Forward Discriminating Sensor

Sensor Harness Connector Harness Connector

10-28-92
ALL SIR SYSTEM CONNECTORS ARE YELLOW NS 15413

Figure 8 - SIR Connector Body Face Views

SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-11

BLANK
9J-12 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

CAUTION: To avoid deployment when troubleshooting the SIR system, do not use
electrical test equipment such as a battery powered or ac powered voltmeter,
ohmmeter, etc., or any type of electrical equipment other than that specified in this
manual. Do not use a non-powered probe type tester. Instructions in this manual must
be followed carefully, otherwise personal injury may result.

SIR DIAGNOSTIC SYSTEM CHECK

The diagnostic procedures used in this section are
designed to find and repair SIR system malfunctions.
To get the best results, it is important to use the
diagnostic charts and follow the sequence listed below.
A. PERFORM THE "SIR DIAGNOSTIC SYSTEM
CHECK."
The "SIR Diagnostic System Check" must be the
starting point of any SIR diagnostics. The "SIR
Diagnostic System Check" checks for proper "AIR
BAG" warning lamp operation, the ability of the
DERM to communicate through the "Serial Data"
line and whether SIR diagnostic trouble codes
exist.
B. REFER TO THE PROPER DIAGNOSTIC CHART
AS DIRECTED BY THE "SIR DIAGNOSTIC
SYSTEM CHECK."
The "SIR Diagnostic System Check" will lead you
to the correct chart to diagnose any SIR system
malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis and incorrect parts replacement.
C. REPEAT THE "SIR DIAGNOSTIC SYSTEM
CHECK" AFTER ANY REPAIR OR
DIAGNOSTIC PROCEDURES HAVE BEEN
PERFORMED.
Performing the "SIR Diagnostic System Check"
after all repair or diagnostic procedures will
ensure that the repair has been made correctly and
that no other malfunctions exist.
CIRCUIT DESCRIPTION
The DERM responds by grounding the "SIR Indicator"
output terminal "Bl" until "Ignition l" voltage is
removed from the "Crank" input. This results in the
"AIR BAG" warning lamp being "ON" steady during
cranking.
After cranking the DERM will flash the "AIR
BAG" warning lamp six times and perform tests on the
SIR system.
NOTES ON SYSTEM CHECK CHART:
1. The "AIR BAG" warning lamp should flash seven
times after ignition is first turned "ON."
2. The "AIR BAG" warning lamp should remain
"ON" steady during cranking.
3. After cranking, the "AIR BAG" warning lamp
should flash six times then go "OFF."
4. This test checks for the proper operation of the
"Serial Data" line. This test will also determine
whether history diagnostic trouble codes are stored
and, if so, identify them.
5. When the "AIR BAG" warning lamp flashes four
times during "Bulb Check" this indicates a
malfunction in the redundant lamp driver
circuitry. These malfunctions are diagnosed by
DTC 62 chart.
6. Improper operation of the "AIR BAG" warning
lamp is indicated. This test differentiates a
warning lamp stays "ON" condition from a
warning lamp does not come "ON" condition.
7. This test checks for proper operation of the "Serial
Data" line. This test will also identify the stored
diagnostic trouble codes and whether they are
current or history.

When the ignition switch is first turned "ON," DIAGNOSTIC AIDS:

"Ignition l" voltage is applied from the "SIR" fuse to
the DERM at the "Ignition l" input terminals "A9" The order in which diagnostic trouble codes are
and "AlO" and from the "IGN" fuse to the DERM at diagnosed is very important. Failure to diagnose the
the "Redundant Indicator Ignition 1" input terminal diagnostic trouble codes in the order specified may
"B2". The DERM responds by flashing the "AIR BAG" result in extended diagnostic time, incorrect diagnosis
warning lamp seven times while performing tests on and incorrect parts replacement.
the SIR system.
When the engine is being cranked, "Ignition 1"
voltage is applied from the "CRANK" fuse to the
DERM at the "Crank" input terminal "BlO".
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-13

SIR DIAGNOSTIC SYSTEM CHECK

CD • NOTE "INFL REST'' WARNING LAMP AS IGNITION SWITCH
IS TURNED "ON."
DOES WARNING LAMP FLASH 7 TIMES?

0 • NOTE "INFL REST" WARNING LAMP AS

ENGINE IS STARTED.
DOES WARNING LAMP COME "ON" STEADY
DURING CRANKING?

r- ---------,
© : GOTO OTC 62. :

I GO TO CHART D. 1
L-----------J
NOTE "INFL REST" WARNING LAMP
AFTER STARTING.
DOES WARNING LAMP FLASH 6 TIMES
r'" --------..,

: GO TO CHART C. :
---------
: GO TO CHART B. :
THEN GO "OFF"?
'-----------...J

©• •
IGNITION SWITCH "OFF."
CONNECT SCAN TOOL TO DATA LINK
(j) •
•
IGNITION SWITCH "OFF."
CONNECT SCAN TOOL TO DATA LINK CONNECTOR,
CONNECTOR, FOLLOW DIRECTIONS AS GIVEN FOLLOW DIRECTIONS AS GIVEN IN THE SCAN TOOL
IN THE SCAN TOOL INSTRUCTION MANUAL. INSTRUCTION MANUAL.
• IGNITION SWITCH "ON." • IGNITION SWITCH "ON."
• REQUEST SIR DIAGNOSTIC TROUBLE CODE • REQUEST SIR DIAGNOSTIC TROUBLE CODE DISPLAY,
DISPLAY, RECORD ALL HISTORY DIAGNOSTIC RECORD ALL DIAGNOSTIC TROUBLE CODES SPECIFYING
TROUBLE CODES, SPECIFYING AS SUCH, ON AS CURRENT OR HISTORY ON REPAIR ORDER.
REPAIR ORDER.

NO SIR DIAGNOSTIC HISTORY DIAGNOSTIC

TROUBLE CODES TROUBLE CODES ARE
ARE DISPLAYED. DISPLAYED.
SIR SYSTEM IS
• IGNITION SWITCH "OFF."
FUNCTIONAL AND FREE • WHEN OTC 8315 SET, GO
OF MALFUNCTIONS. NO TO OTC 83 CHART.
FURTHER DIAGNOSIS IS • WHEN OTC 84.15 SET, GO
REQUIRED. TO OTC 84 CHART.
• FOR ALL OTHER HISTORY
DIAGNOSTIC TROUBLE
CODES, REFER TO
"DIAGNOSTIC AIDS" FOR
THAT SPECIFIC
DIAGNOSTIC TROUBLE
CODE. A HISTORY OTC
INDICATES THE
MALFUNCTION HAS
BEEN REPAIRED OR IS
INTERMITTENT.
SCAN TOOL DIAGNOSTIC TROUBLE
INDICATES "NO DATA CODES ARE DISPLAYED.
RECEIVED."
r---- -----,
I REFERTO I • IGNITION SWITCH "OFF."
I I
I SECTION 8A-50. 1 • WHEN DTC 51 IS SET, GO TO DTC 51
L----------J •
CHART.
DIAGNOSE REMAINING CURRENT
DIAGNOSTIC TROUBLE CODES
FROM LOWEST TO HIGHEST.
• WHEN ONLY HISTORY DIAGNOSTIC
TROUBLE CODES EXIST, REFER TO
"DIAGNOSTIC AIDS" FOR THAT
SPECIFIC DIAGNOSTIC TROUBLE
CODE. A HISTORY DTC INDICATES
THE MALFUNCTION HAS BEEN
REPAIRED OR IS INTERMITTENT.

6-24-93
NS 13277
9J-14 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

DERM
TO IGNITION AIR BAG 15A 5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 8 YEL IGNITION 1
r---------1139EYEL__/ \ 1139CYEL IGNITION 1
.----------------------------236YEUBLK DRIVER 36 VLR
.---------------------------1400LTGRN DRIVER
SOURCE SENSE
.-----------------------~1401PNK PASS. 36 VLR
.---------------------1837LTGRNl'vVHT PASS. SOURCE
SENSE
.------14038 WHT/BLK----~ REFER TO SECTION 8A·14
REDUNDANT
PASS. 1650 8LK--L650 BLK INDICATOR
INFLA TOR PASS. INFLA TOR GROUND
MODULE MODULE JUMPER
~1403CWHT/BLK -----1403AWHT/BLK PASS, SIDE HIGH
~348HDKGRN { - - - - - - 3 4 8 8 DK GRN PASS. SIDELOW
~SHORTING BARS _j
348 E DKGRN
CRANK
TO •
IGNITION
~---------- CRANK

SWITCH REFER TO 238 BLKl'vVHT DRIVER SEAT

SECTION 8A-76 BELT
REFER TO -...---800 TAN SERIAL DATA
SECTION 8A-50
l~----------"--------'---347AWHT DRIVER SIDE
HIGH
'--T-O--~G~A~G=E~S~10~A=-----S2_0_6------348ADKGRN DRIVER SIDE
LOW
348C IGNITION ~ 3 9 A P N K - - - - - - - - - 3 9 8 PNK REDUNDANT
DK GRN SWITCH INDICATOR
PASSENGER 39CPNK IGNITION,1
COMPARTMENT c200DI
r- ,
DISCRIMINATING INST,.R!J~-E~J f!:.IJ,STER
I 02 I
SENSOR L--..J I I
348F - .}fc200B
DK GRN - L348G DK GRN CA MARO 358 SIR INDICATOR
"AIRBAG" BRN
FIREBIRD AS WARNING A7 SHORTING.BAR
8:45k0 LAMP
17518 BLKl'vVHT --y-1751A BLKl'vVHTos;.· r--, ,._ --- '"'."
1751C BLKl'vVHT GROUND
-=- C200B ,._ ~~ k:'
.J
2
C 00D 1751 E BLKl'vVHT GROUND
1751 F BLKl'vVHT ·
6-19-93
NS11608

CHART A
DERM INTEGRITY CH ECK
Circuit Description:
When the DERM recognizes "Ignition l" voltage, applied to terminals "A9" and "AlO", is in the normal
operating voltage range, the "AIR BAG" warning lamp is flashed 7 times to verify operation. At this time the
DERM performs "Turn-ON" tests followed by "Continuous Monitoring" tests. When no malfunctions are detected
the DERM proceeds to the "Initiator Assembly Resistance Test." When a malfunction is detected the DERM sets
a current diagnostic trouble code and illuminates the "AIR BAG" warning lamp. The DERM will clear current
diagnostic trouble codes and move them to a history file when the malfunction is no longer detected and/or the
ignition switch is cycled, except for DTC 51. DTC 51 can only be cleared using a scan tool "Clear Codes"
command.
Chart Test Description: Number(s) below refer to 2. This test checks for a malfunction introduced int9
circled number(s) on the diagnostic chart. the SIR system during the diagnostic process. It is
1. This test confirms a current malfunction. If no extremely unlikely that a malfunctioning DERM
current malfunction is occurring (history DTC set) would cause a new malfunction to occur during the
the "Diagnostic Aids" for the appropriate diagnostic process.
diagnostic trouble code should be referenced. The 3. When all circuitry outside the DERM has been
DERM should not be replaced for a history found to operate properly, as indicated by the
diagnostic trouble code. appropriate diagnostic chart, then and only then
should the DERM be replaced.
 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 91-15

CHART A
DERM INTEGRITY CHECK·

THIS CHART ASSUMES THAT THE "SIR DIAGNOSTIC SYSTEM CHECK"

AND EITHER A SYMPTOM CHART OR A DIAGNOSTIC TROUBLE CODE
~HART DIAGNOSIS HAVE BEEN PERFORMED. WHEN ALL CIRCUITRY
OUTSIDE THE DERM HAS BEEN FOUND TO OPERATE PROPERLY, AS
INDICATED BY THE APPROPRIATE DIAGNOSTIC CHART, AND THE
SYMPTOM OR DTC REMAINS CURRENT, THE FOLLOWING
DIAGNOSTIC PROCEDURES MUST BE PERFORMED TO VERIFY THE
NEED FOR DERM REPLACEMENT.

0 •
•
IGNITION SWITCH "OFF."
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE
PROPERLY MOUNTED.
• ENSURE THE IGNITION SWITCH HAS BEEN "OFF" FOR AT LEAST TWO MINUTES.
• NOTE" AIR BAG" WARNING LAMP AS IGNITION SWITCH IS TURNED "ON."
DOES WARNING LAMP FLASH 7 TIMES THEN GO "OFF"?

0 • USING A SCAN TOOL REQUEST DIAGNOSTIC TROUBLE CODE

DISPLAY.
IS THE SAME SYMPTOM OR OTC OCCURRING AS WAS WHEN
THE "SIR DIAGNOSTIC SYSTEM CHECK" WAS FIRST PERFORMED?
• THE SYMPTOM OR DTC IS NO LONGER
OCCURRING.
• CLEAR SIR DIAGNOSTIC TROUBLE CODES.
• REPEAT "SIR DIAGNOSTIC SYSTEM CHECK."

0 •
•
CLEAR "SIR DIAGNOSTIC TROUBLE CODES."
IGNITION SWITCH "OFF" FOR AT LEAST TWO MINUTES.
•
•
IGNITION SWITCH "OFF."
GO TO THE APPROPRIATE CHART FOR
• NOTE "AIR BAG" WARNING LAMP AS IGNITION SWITCH THE INDICATED MALFUNCTION.
IS TURNED "ON."
DOES WARNING LAMP FLASH 7 TIMES THEN GO "OFF"?

SIR SYSTEM IS FUNCTIONAL AND FREE OF MALFUNCTIONS. • IGNITION SWITCH "OFF."

NO FURTHER DIAGNOSIS IS REQUIRED. • REPLACE DERM.
• RECONNECT ALL SIR SYSTEM COMPONENTS,
ENSURE ALL COMPONENTS ARE PROPERLY
MOUNTED.
• REPEAT "SIR DIAGNOSTIC SYSTEM CHECK."

4-6-93
NS 15420
9J-16 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

DERM
TO IGNITION AIR BAG 15A 5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - 1 1 3 9 B Y E L IGNITION 1
.---------1139EYEL__/ \ 1139CYEL IGNITION 1
.---------------------------~236YELJBLK DRIVER 36 VLR
.---------------------------1400LTGRN DRIVER
SOURCE SENSE
.------------------------1401PNK PASS. 36 VLR
,---------------------1837LTGRN/WHT PASS. SOURCE
SENSE
..------14038 WHT/BLK-----, REFER TO SECTION 8A-14
REDUNDANT
PAS~ · 1650BLK~650BLK INDICATOR
INFLATOR PASS. INFLATOR GROUND
MODULE MODULE JUMPER
~1403CWHT/BLK ...-----1403A WHT/BLK PASS. SIDE HIGH
~348HDKGRN { - - - - - - 3 4 8 8 DK GRN PASS. SIDE LOW
~SHORTING BARS
348 E DKGRN
CRANK
TO • '°"'•-----------806PPL
*3A'-'
CRANK
IGNITION
SWITCH REFER TO 238 BLK/WHT DRIVER SEAT
SECTION 8A-76 BELT
REFER TO - - - - 8 0 0 TAN SERIAL DATA
SECTION 8A-50
l ' - - - - - - - - - - - - - - - - - - - 3 4 7 A WHT DRIVER SIDE
HIGH
B ..__T_O
_ _ _G_A_G_E~S-10_A_ _ _ _S_20-6------348ADKGRN DRIVER SIDE
LOW
348C IGNITION ~ 3 9 A P N K - - - - - - - - - 3 9 8 PNK REDUNDANT
DK GRN SWITCH INDICATOR
PASSENGER 39CPNK IGNITION 1
COMPARTMENT C200D
DISCRIMINATING r--,
INSTRUMENT CLUSTER
SENSOR
I 02 I
L..--..J